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Becker
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AN ENGINEER’S VIEW
Mechanical Genes This week I have been invited to talk to the first year mechanical engineering students at UCT about nothing in particular, but everything in general. The challenge, of course, is to refrain from being overly authoritative and persuasive, and in the short time available, to identify what it is that students want to know. That is clearly an undertaking with some 140 students from a variety of backgrounds and pre-university experiences.
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he faculty is fully if not over subscribed for the year as all the tertiary institutions have to select from an over-supply of applicants. Chris Reay I will be interested in due course to know Chairman of the Working what percentage pass into second year Committee: Communications (SA Institution of Mechanical and even more so, the profile of both Engineering) the successful and unsuccessful ones, premising this eventuality on the rolling average pass rate over decades of first year classes. Inevitably one is inclined to reflect on what attracts students to take up engineering and mechanical in particular, and I cast my mind back to my own spell at Wits University in the 60s. Oddly enough, we had a class size of mechanical students after first year that was well over the average class size for that era, 26 in all. We came from all sorts of backgrounds and locations but quickly became a congenial class of friends who participated in many of the typical student activities.
This environment was paradise to the genetically hardwired mechanical student
I mention all this as I believe that this environment was paradise to the genetically hard-wired mechanical student. We learned how things worked, how they should be disassembled and reassembled, how bearings should be treated, engine designs and modifications, gearboxes, differentials, combustion, fuel and air mixtures, heat transfer, power and torque curves, pre-stressing of bolts, brake designs, clutch modifications, balancing, timing and even early electronic ignition systems. I did a formula one engine design as a final year project which bore a remarkable resemblance to a later Cosworth design, and in the laboratory we did early research on free-flow absorption type silencers. We formed the Wits Branch of the Sports Car club and ran frequent rallies and gymkhanas.
Credit is due
“Hotting-up”
Aside from the usual parties, rag events, stunts, raids on girls’ residences etc, a significant majority of the students, not only in the mechanical faculty, used old and very used cars as transport. Some did not have the luxury. These vehicles were either hand-me-downs from the family or acquired from older students selling them off as they progressed to better things. It was quite normal for us to fix and maintain our own vehicles and in most cases this involved the emerging tradition of “hotting-up” to improve performance. Many hours, which perhaps we can say should have been used for studying, were spent in our various garages at home carrying out these activities. The mechanical excellence of even the simplest of vehicles was a hot topic of discussion and focus. Some of us developed an active interest in rallying and racing and those were the days when you could take your own road car to the track or on a rally route, removing only the hubcaps and sometimes the silencers.
Pit crew
accept same, racing brake linings before the advent of disc brakes. Dynamometer tuning was done via the connections we had in the tune-up industry. Some of us progressed to pit crew for our local production car and formula one drivers and the 9 hour endurance event was a huge crowd attraction with our group.
I wonder these days what real, mechanical handson activities the modern mechanical engineering student has at his or her disposal? With modern motor vehicle technology having been besieged by the electronics industry and any form of competition now only possible with major sponsorship, there seems very little opportunity for such mechanical dedication. Reflecting back to those days, we have Rory Byrne who was one of our “playing with engines and cars” community at the time, and as we know progressed to become Chief Design Engineer for Ferrari’s formula one team. Then there is Gordon Murray who was a mechanical student from Natal University of Technology who became Chief Designer for McLaren. Keith Helfet was a mechanical engineering student at UCT and did the designs for Jaguar’s XJ-220, XK-180 and the F-Type. I believe credit should be given to that era when mechanical hands-on experience was almost normal for the student of the day and contributed significantly to the need for basic training.
The engines had in the meanwhile been homemodified: skimmed heads, polished ports, high-lift camshafts, dual choke carburetors, straight through exhaust systems, bigger choke carbs, wide wheels, balanced flywheels, additional gears if the box would THE SOUTH AFRICAN MECHANICAL ENGINEER
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May 2012 VOLUME 62 NUMBER 5
Contents
On the cover: Sprag Components cc Tel: (011) 742-9600 Email: wayne@spragcomponents.co.za
HVAC 8 Harmful to Humans?
POWER GENERATION TODAY
Cover Story
21 New Endorsement 24 Power Generation News
9 One-way Rotation Control
Monthly Column 10 Prominent Professionals
29 New Boiler Design 33 New Burner Guarantees Savings
Opinion
Regulars
12 Soapbox
Power Transmission 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.
Steam, Turbines & Boilers
15 Caring for Bearings 18 Adapting to Market Needs
3 An Engineer’s View 6 Institution News 37 SAIT 39 Market Forum
The monthly circulation is 4 242
Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123, Republic of South Africa Tel: (011) 781-1401, Fax: (011) 781-1403 Email: samecheng@promech.co.za, www.promech.co.za Managing Editor Susan Custers Editor Kowie Hamman Circulation Catherine Macdiva Advertising Mark Bennett DTP Zinobia Docrat / Donovan Vadivalu Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R405,00 (incl postage and VAT) per year; R1 020,00 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.
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Official Publication of THE SA INSTITUTION OF MECHANICAL ENGINEERING and endorsed by:
CORROSION INSTITUTE OF SA SA PUMP MANUFACTURERS ASSOCIATION SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION THE SA INSTITUTE OF TRIBOLOGY NUCLEAR INSTITUTE SA INSTITUTE FOR NON-DESTRUCTIVE TESTING NATIONAL SOCIETY OF BLACK ENGINEERS INSTITUTE FOR CERTIFICATED MECHANICAL AND ELECTRICAL ENGINEERS SOUTH AFRICAN ASSOCIATION OF CONSULTING ENGINEERS ASSOCIATION OF SOCIETIES FOR OCCUPATIONAL SAFETY AND HEALTH THE SOUTHERN AFRICAN ASSOCIATION FOR ENERGY EFFICIENCY (SAEE)
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THE SA INSTITUTION OF MECHANICAL ENGINEERING
Council 2011/2012 Office Bearers
President .................................................. G Barbic (George) Vice President .............................................. D Findeis (Dirk) National Treasurer ............................... KK Nyangoni (Kudzai)
Branch Chairpersons
Central ...................................................... M Cramer (Mike) Eastern Cape ................................................ W Rall (William) KwaZulu/Natal ................................................. J Moto (John) Mpumalanga Highveld.............................. L Odendaal (Louis) Western Cape ........................................... Dr D Blaine (Debbie)
Portfolios:
Communications/Strategic Planning/ Specialist Group..................................................CD Reay (Chris) Young Engineers Forum................Prof B Collier-Reed (Brandon) Education: Universities of Technology............... E Zawilska (Ewa) Membership .................................................... E Zawilska (Ewa) Professional Development Programme..........M Black (Malcolm) Technology Programme ................................. SZ Hrabar (Steve) To be confirmed....................................................A Roos (Andre) To be confirmed.........................................G Bartholomew (Bart)
Chief Executive Officer: Vaughan Rimbault
Postgrad Research SAIMechE Western Cape Branch Presents a Conference on “Mechanical, Manufacturing and Materials Engineering” - showcasing postgraduate research at local universities. 20 - 21 June 2012 Auditorium, CPUT, Bellville Campus
This conference, organised in association with the Cape Peninsula University of Technology, University of Cape Town and the University of Stellenbosch, and showcasing postgraduate research at local universities, is the first regional postgraduate student conference organised by the Western Cape Branch of the SAIMechE. It is aimed at providing an opportunity for the presentation of current research and interesting technological developments in topics related to the broad field of mechanical engineering. This two-day event will include formal oral presentations as well as opportunities for exhibiting appropriate research achievements.
Scope of conference
Email: info@saimeche.org.za
The Conference Organisers will accept papers that address the broad field of mechanical engineering and related disciplines. Recent research, research in progress and topics of current technological importance are invited.
Website: www.saimeche.org.za
General topics include:
Membership: Central, Eastern Cape, Mpumalanga & KZN:
• Mechanical engineering design.
membership@saimeche.org.za
• Solid and fluid mechanics.
Membership: Western Cape: saimeche.wc@vodamail.co.za
• Aeronautical engineering.
National Office Manager: Anisa Nanabhay PO Box 511, Bruma, 2026 Tel: (011) 615-5660, Fax: (011) 388-5356
• Robotics and control in engineering systems. • Materials design and optimisation.
Company Affiliates Alstom Power Service SA
Rotek Engineering
• Engineering management and lean manufacturing.
Babcock Africa Limited
RSD a division of DCD-Dorbyl S.A.M.E Water
• Non-destructive testing and evaluation.
Bateman Engineered Technologies Bosch Projects
Sasol Technologies
Fluor SA
SEW Eurodrive
GEA Air-cooled Systems
Siemens
Hansen Transmissions SA
SNC-Lavalin SA
• Education research.
Hatch Africa
Spicer Axle SA
Registration
Howden Power
Spirax Sarco SA
Howden Projects
Technical Systems
Please contact Julie Medhurst (medhurstj@cput. ac.za) to register for the conference.
Industrial Water Cooling
Thyssenkrupp Engineering
Cost per delegate: R500*
• Energy conversion and utilisation. • Advanced manufacturing processes. • Engine and fuel technology.
MBE Minerals (SA) (Pty) Ltd Transvaal Pressed Nuts & Bolts (previously KHD Humboldt Ultra-Flow Engineering Services Wedag SA) Vital Engineering Megchem Eng & Drafting Services Weir Minerals Africa Mod-U-Flow Winder Controls Osborn Engineered Products SA
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*Should student financial assistance be required, please submit a motivation with your preliminary registration form.
Sponsorship
We are looking for sponsors for the conference. If you are interested, please contact Julie Medhurst (medhurstj@cput.ac.za, 021-953 8669) May 2012
THE SA INSTITUTION OF MECHANICAL ENGINEERING
Training: Who You Know? In the February 2012 issue, several reasons were given for why SAIMechE should become your preferred short course technical training provider; namely tried and tested training methods and standards are deployed, as well as competitive pricing and member discounts are given. However, engineers who wish to attend specific training events sometimes are unable to do so because insufficient bookings are received for the events in question. This leads to disappointment and lack of opportunity to gain CPD points.
High standards
Having been assured by many sources that our workshops cover both essential fundamental and advanced material and that our training standard is high, we believe that we need to widely cast our advertising net to include all industries where engineers are employed. The National Events Department strives to increase its industrial businesses database but needs your help to do so. Therefore, if you know of others who would be interested in 1-3 days technical training, please kindly phone me or send me a mail. I require your referral’s first and last name and either his/her phone number or email address. Similarly, if you know of a company that should be on our mailing list, please send me its name and location, as well as any other information on it, so that I can contact it to learn who would like to receive our mail. By recruiting other engineers and technologists to join our mailing list, the chances of assuring that all SAIMechE workshops take place will increase.
Joining forces
forces with another company to book a minimum of 10 delegates for a workshop held at your premises, your company will benefit from our reduced In-house workshop discount for every attending staff member. This In-house discount rate applies to SAIMechE members, as well as non-members on your staff. Furthermore, customized in-house training can be developed and given for large groups.
10 delegates for a workshop held at your premises Together with your assistance, let’s make SAIMechE the proud provider of all your external technical short course training needs. I look forward to receiving your mailing list referrals and suggestions. Linda Robinson, SAIMechE National Events Manager, Tel: 031 764 7136, Email: linda@saimeche.org.za
It should be noted too that if your company joins
Forthcoming SAIMechE Training Events Event fee : R2,920.00 per person per day (excl.VAT). SAIMechE Members in good standing may claim a 20% discount on their event fee. An early payment discount of 5% of invoice value may be claimed for event payments received no less than 7 calendar days before the event start date. A registration form and full terms and conditions may b e obtained from Carey Evans on E-mail carey@saimeche.org.za or Tel. 031-764-7136. Also, detailed individual event programmes are available from Carey. For information on In-House events, as well as event planning, kindly contact Linda Robinson on linda@saimeche.org.za or Tel: 031 764 7136. Code
Abbreviated Title
Date - Start
Date - End
Region
C2412
Predictive & Preventive Maintenance Best Practice Workshop
5 Jun 12
5 Jun 12
Cape Town
B2412
Predictive & Preventive Maintenance Best Practice Workshop
12 Jun 12
12 Jun 12
Port Elizabeth
E2512
Effective Management Roles Workshop
13 Jun 12
12 Jun 12
East Rand
K2412
Predictive & Preventive Maintenance Best Practice Workshop
19 Jun 12
19 Jun 12
Bloemfontein
E2412
Predictive & Preventive Maintenance Best Practice Workshop
21 Jun 12
21 Jun 12
East Rand
A2512
Effective Management Roles Workshop
4 Jul 12
4 Jul 12
Durban
B2512
Effective Management Roles Workshop
1 Aug 2012
1 Aug 2012
Port Elizabeth
F2512
Effective Management Roles Workshop
15 Aug 2012
15 Aug 2012 Secunda
C2512
Effective Management Roles Workshop
12 Sep 2012
12 Sep 2012 Cape Town
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HVAC
Harmful to Humans? The Hot Dip Galvanizers Association Southern Africa (HDGASA) would like to correct a few misconceptions with regard to the supply of zinc and its possible health risks.
W
hen the hot dip galvanizing industry was notified of the intended closure of Zincor Ltd, alternative plans were put into place in order to ensure a continued, reliable supply of zinc into the country. The importation of zinc is not a new phenomenon and as such, the industry was capable of sourcing alternative supplies of zinc in order to continue to meet the demand of our customers. Furthermore, there are alternative suppliers of zinc who are already operating and ably assisting the industry. Therefore, the hot dip galvanizing industry is well placed in order to continue supplying this valuable service to its customers.
Innuendo
It appears that some innuendo is being leveled in that zinc is harmful to humans. Interestingly enough, zinc is a recyclable material and is recovered from process materials such as galvanizing residues. Hot Dip Galvanizing consists of a coating of zinc
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alloyed to the surface of the steel. Zinc melts at about 420ºC (the temperature of the galvanizing bath) and boils at 907ºC. When zinc boils the vapour reacts quickly with the air to form zinc oxide, which is the dense white fume easily visible. Although zinc oxide is an important component of some medicines and creams (particularly for nappy rash), one should avoid breathing zinc oxide; or any other fume for that matter. If one does breathe in zinc fumes, the zinc will be absorbed into the bloodstream, with excess zinc excreted quickly through the kidneys and then in the urine. One may have an acute case of “Zinc fever”, displaying flu-like symptoms for 24 hours. As far as the International Zinc Association (IZA) is aware, “zinc fever” is almost unknown in modern industrial countries which observe basic health and safety precautions. Saskia Salvatori, Hot Dip Galvanizers Association SA, Tel: (011) 456-7960, Fax: (011) 454-6304
May 2012
COVER STORY
One-way Rotation Control A sprag clutch is a one-way freewheel clutch which resembles a roller bearing, but instead of cylindrical rollers, nonrevolving asymmetric figure-of-eight shaped sprags are used. When the unit rotates in one direction the rollers slip or freewheel, but when torque is applied in the opposite direction, the rollers tilt slightly, producing a wedging action and binding as a result of the induced friction.
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lso known as an over-running clutch, a freewheeler, a backstop clutch or a camclutch, this is a highly specialised unique power transmission component made of specially hardened materials machined to very fine tolerances. Whatever you call it, the function of this high precision piece of mechanical equipment is to ensure that a shaft turns freely in one direction only. Wayne Swaffield of Sprag Components
The only company in South Africa which specialises in making a wide range of one-way clutches As unique as the component, so is local company Sprag Components, the only company in South Africa which specialises in making a wide range of one-way clutches for an equally wide range of
power transmission applications, the most generally known being the conveyor backstop application. “SA Mechanical Engineer” speaks to Wayne Swaffield, owner of Sprag Components at the company’s assembly facility in Benoni.
Local player
“Apart from our own in-house designed large conveyor back-stop, manufactured locally entirely, we have been the official agents for the full range of Stieber clutches from Germany since 2008,” he says. “Since establishing the company in 1991, we’ve specifically specialised purely in one-way solutions and today cover all the OEM brand transmission systems with equivalent products made locally. So much so that some OEMs are no longer importing their one-way components, they simply order from us.” The range of clutches, sprags and free wheel elements and one-directional bearings designed, manufactured, repaired and serviced cover most of the well-known brand names in industrial gearboxes. In terms of applications this includes electric motors, gearboxes, conveyors, printing machines, bucket elevators, kilns, tube mills, crushers, winches, drive pulleys and fans.
All sizes
A typical sprag clutch
‘Off-the-shelf’ stock ranges from units as small as a roller-type freewheel of 4mm bore for a fishing rod, right through to large roller ramp units of a 300 mm bore used in accurate indexing of large machinery. “We stock all types of shaft mounted units such as small needle cam bearings as well as the large shaft mounted units used with most THE SOUTH AFRICAN MECHANICAL ENGINEER
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COVER STORY
include overrunning clutches, compressor drive clutches, one-way bearings for small applications and a whole range of free-wheel elements.
Walk-through
Wayne takes us on a tour of the facility which at first sight makes a great impression because of the well-arranged tidiness not normally found in a mechanical workshop. Here we see clutches of all sizes in various stages of assembly with technicians working on lathes and boring machines carrying out final finishing on clutch components manufactured to Sprag’s design parameters. On the dispatch side Wayne opens a neatly-made wooden box, specially fumigated for export purposes to show us a packaged backstop, complete with all its quality control papers with full traceability and a comprehensive installation manual of how this unit should be fitted. “Many failures come from installing the clutch unit incorrectly,” says Wayne. “We do not do installations ourselves because it requires heavy lifting equipment, for example, to fit a 1.5 tonne backstop, most plants have this equipment and the technicians to do it. Nonetheless, each unit that goes out of our workshop has a detailed instruction manual of how the unit should be installed, and we will certainly offer to supervise an installation if requested to do so, especially when it’s a first time installation of any of our products.”
High precision
The mechanical nature and operating principle of a sprag clutch clearly dictates absolute precise engineering within high tolerances, otherwise it will fail or worse, it won’t work in the first place. “Being a specialist company dedicated to one-way components we have gathered the right professional expertise in the company over the years to produce a product which can compete with the best in the world,” Wayne rightly says in conclusion. “We have the experience and the knowledge in-house not only to advise clients on new applications and designs, but also to manufacture, repair and refurbish all types of one-way components.”
A conveyor backstop on the assembly line at Sprag Components
Each unit that goes out of our workshop has a detailed instruction manual of how the unit should be installed, and we will certainly offer to supervise an installation
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of the industrial gearbox brands,” says Wayne. “All our local manufacturing is outsourced to reputable engineering companies with whom we have longstanding relationships. The units are then assembled at our premises after going through a strict in-house quality control procedure.”
Wayne Swaffield, Sprag Components cc, Tel: (011) 742-9600, (011) 965-0394, Email: wayne@spragcomponents.co.za
The range of one directional clutches is huge mainly due to the direct relation between speed and torque which dictates the type of clutch used for a specific application. The types available from Sprag include units functioning as load-sharing back stops on gearboxes plus new releasable loadsharing backstops which are designed for extra safety. There are also centrifugal lift-off clutches for high speed applications, roller-ramp clutches specifically effective in indexing and large conveyor backstops with torque arms. Other types available
Are you looking for engineering resources?
THE SOUTH AFRICAN MECHANICAL ENGINEER
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Engineer Placements Consider the following: • A specialist service • Operated by Professional Engineers • That speak engineering language • Has a large, live local skills database • A network with access to scarce skills • Advanced searching for future needs
May 2012
Contact us for a win-win deal admin@engineerplacements.com
MONTHLY COLUMN
Prominent Professionals A project
Stephen Meijers (Dr.), Chief Executive, ELB Engineering Services
Two stand out; One was a unique ash classification system in Hong Kong with everything supplied out of South Africa. The second is a rapid train loading system we’ve just completed for Asmang. It is the most sophisticated and accurate train loading system in existence.
Academic School:
St John’s College, Houghton
Graduate studies:
Wits University, Johannesburg; BSc Mechanical Engineering
Any awards
The ash classification system for Hong Kong won a mechanical engineering award in South Africa.
Post-Graduate:
Masters in PhD at Wits; Wits Business School; Harvard Business School.
Future – a concept, a dream or a wish
Professional Bodies
To bring about a greater integration of the high technology typical of the medical and medicine field into the diagnostic monitoring of equipment. Also, we need far more integration of robotics into the bulk materials handling engineering field.
Member of the South African Institute of Materials Handling; The Conveyor Manu- Stephen Meijers, CE of ELB Engineering facturers Association; Institute of Directors. Services
Career Path First employer
Myself when I was 14 years old, running a glazing business, building cabinets and making demobilisers for vehicles. My first professional job after army service was with the University of Pretoria as an associate professor in materials handling.
Growth path
After the university job I joined Bateman to start the pneumatic conveying department. In the nineties, I took over Bateman Materials Handling to merge Iron Steel Technologies with Brunt Contracting and Bateman Materials Handling to form Bateman Engineered Technologies. In the late 90s I moved to the Bateman main board till 2004 as the group’s chief operating officer. When ELB sold Bateman I moved over to ELB to re-grow the engineering, materials handling business within ELB.
Present employer and position
Chief Executive of ELB Engineering Service in the ELB Group.
Achievements A design
Our innovation makes us different from other engineering companies, leading to winning the Technology Top 100 award several times over the years. One of the designs is the Pneumo Dryer, a whole new concept we developed for the pneumatic conveying of coarse material while drying the material at the same time. Over 60 of these systems have since been installed across the world to make it the standard method of drying diamond ore.
Projects Most challenging
The loading station at Assmang. The conditions of loading were challenging necessitating building the whole plant based on Finite Element Analysis using a completely different design technology in order to meet the accuracy the client required.
Most rewarding
The Hong Kong project where we made the best profit ever on any project. But, all our projects have been very rewarding.
Commentary Are there shortcomings in the Mechanical Engineering Industry in South Africa?
First of all, there’s a definite massive lack of mechanical engineering skills for the next management age group coming through. In terms of training, the world has changed from what it was in the 90s and you can no longer rely purely on an academic engineering discipline, we have to bring in the entrepreneurial spirit. Thirdly, the world has become borderless and we need more training in logistics as well as commercial contractual law in order to do contracts more efficiently, be it under-graduate or on the job training.
Message to young engineers
Young engineers are entering the most exciting twenty years of development in Africa that any profession could ever want. They’ve got to be bold, brave and entrepreneurial.
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OPINION
Soapbox On his rounds, Kowie Hamman, our Editor, is conducting an informal survey on the lighter side of engineering. We follow up from last month with two pertinent questions.
Do you see the Chinese as a threat? Brian Volk of PHC Projects - In the short term they are a threat to the manufacturing industries of the rest of the world, however they will lose their competitive edge over time and will also force the Western Countries to re-think their manufacturing policies and competitiveness. Phildy Schlotz of DRA - whether you see them as a threat or not, it won’t make them go away, we just have to be more innovative in order to participate and compete to become better than them. We have to learn how to do business with them. This
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is a challenge rather than a threat and something which also applies to India. Tom Esterhuizen of Tom Esterhuizen & Associates - Many years ago we were warned against people coming in to take over our work, but it hasn’t happened and I don’t think it will. If you do a good job, and provide good service, then there is nothing to fear. Thalefang Mtombeni of Schaeffler - Yes and no. Yes: because the Chinese market produces things very cheaply without regard for quality and the
May 2012
OPINION
effect this will have on the market. No: because most of the big corporates have joined hands with the Chinese companies to make sure better quality is produced. The answer is to take an active role to make sure they produce good quality products to international standards. If you can’t beat them, join them. Izak van Niekerk of Bell Equipment - I’m a chronic optimist, but without getting too philosophical about the future and the economists’ predictions about wars for food, it is clear that China is and will be hungry, growing and rich, let’s be smart and work together, without compromising our own. Konnie de Boom of Megchem – Yes!
Do you agree with the term – battle of the sexes? Brian Volk of PHC Projects - Not really, people have different aptitudes and strengths so if we use the strengths of each sex properly there should be no battle, but we need to appreciate worth in what people do.
Phildy Schlotz of DRA - If a person can do the work, then I don’t have a problem. We have such a critical skills shortage that anyone who wants to take part, and is capable, should do so. Tom Esterhuizen of Tom Esterhuizen & Associates - I don’t have problem. Today you see a lot of woman going places especially in the architectural industry where we, as a company, do a lot of work.
Thalefang Mtombeni of Schaeffler - To some extent I do, yes. It’s just that sometimes the female species seems to want it all… they want their bread buttered on both sides. However, I’m not undermining them in any way, but I do think their role should be clearly defined.
Izak van Niekerk of Bell Equipment - Those days are long gone! Konnie de Boom of Megchem – no comment.
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SAMHYDRAULIK, which is one of the leaders in the field of hydraulic transmission, has been operating for over 25 years in the international market, offering a complete range of orbital hydraulic motors and power steering units, axial pumps and motors for medium and high pressure ranges, all characterised by excellent performances. SAMHYDRAULIK employs 120 people who operate inside a very modern and efficient plant that spans over 6 000 square metres to assure a high standard and flexible production capacity. The latest computer technology is used for both design and production, combined with strict quality control procedures during all production phases, which translates into innovative, reliable and functional products that meet the various needs of the market. Its ISO 9001 certification, held since 1994, is the result of a qualityorientated philosophy on which SAMHYDRAULIK has always based its operation.
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AXIOM HYDRAULICS (PTY) LTD Tel: (011) 334-3068 / 334-3086 Fax: (011) 334-4543 E-mail: axiomjhb@mweb.co.za
THE SOUTH AFRICAN MECHANICAL ENGINEER
17 Heidelberg Road, Village Main, Johannesburg, 2000 P O Box 260248, Excom, South Africa, 2023
VOL 62
May 2012
POWER TRANSMISSION
Caring for Bearings If just one bearing in an automobile fails, the whole vehicle is rendered defunct, be it a wheel bearing, an engine bearing or even the small bearing in the alternator. The same applies to industrial plant machinery where plant performance literally pivots around the condition of the bearings in the machinery.
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lthough bearing manufacturers go to great lengths to manufacture a wide range of high precision bearings for all applications, the most crucial factors in getting optimum performance from a bearing are largely dependent on correct selection, proper fitment, the right lubrication and regular maintenance.
Mechanical faults
To address issues around bearing care “SA Mechanical Engineer” speaks to Tlhalefang Mtombeni, the applications engineer at Schaeffler Industrial, manufacturers of the INA/FAG range of bearings and bearing related accessories. “According to global statistics, around 80% of bearing failures are due to lubrication related problems but here in South Africa, we’re finding that a large percentage of the problems are mechanical due to incorrect mounting, alignment and balancing of the bearing or adjacent machinery/equipment,” he says.
Tlhalefang Mtombeni, the applications engineer at Schaeffler Industrial
“To address both the mechanical and lubrication issues, we’re presenting training courses to customer technicians, both on site and at our training facility in Johannesburg.”
We’re finding that a large percentage of the problems are mechanical due to incorrect mounting, alignment and balancing of the bearing or adjacent machinery/equipment First step
Through tests carried out by Schaeffler’s engineering department, the reasons for bearing failures can today be pin-pointed accurately in order to address each unique cause of failure in a specific application. “As an example, we’ve just solved a problem on a mine where the pinion bearings on a mill kept on failing,” explains Tlhalefang. “In a case like this the first step is to collect the lubricant used in the application to carry out an in depth analysis in order to ascertain what contaminants are present. From this analysis we can tell whether the right grade of lubricant is used, or whether the grease or oil is aged and hasn’t been changed often enough and so on.”
Inspections
Fitting a bearing right is crucially important
“In addition we physically inspect the bearing for mechanical defects due to premature wear,” adds Tlhalefang. “Once we have all the ‘evidence’ of what has caused the failure, we make recommendations to the client, not only in terms of the type of bearing for a particular application, but also the correct lubrication for it, including a specific maintenance schedule. THE SOUTH AFRICAN MECHANICAL ENGINEER
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“It is very rare, but we’ve had a couple of cases where the type of bearing clients have been using simply isn’t suitable, be it due to a high temperature environment, high impact forces or the speed of the application,” explains Tlhalefang. “For example, it may very well be the right type of bearing, but the cage type of that bearing may not be suitable for that specific application because the operating temperatures are too high.”
Aside from our service teams identifying and fixing all these problems, we offer to train the technicians responsible for the maintenance on the plant
In addition to the training and the field service teams, the company has a wide range of equipment aimed specifically at taking care of bearings
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It becomes a bit trickier though if the problem is not down to lubricant alone. “In many cases, especially in South Africa, it turns out to be a mechanical problem where the drive motor, for example, hasn’t been aligned properly,” Tlhalefang says. “Aside from our service teams identifying and fixing all these problems, we offer to train the technicians responsible for the maintenance on the plant. We virtually hold the technician’s hand over a period of time until he’s confident and able to do everything properly on his own.”
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Training the technicians responsible for the maintenance on a plant
Tools
In addition to the training and the field service teams, the company has a wide range of equipment aimed specifically at taking care of bearings. “Our product range comprises tools for the mechanical, hydraulic and thermal mounting and dismounting of rolling bearings,” says Tlhalefang. “Mechanical tools are used predominantly for smaller bearings while medium-sized and large rolling bearings are mainly mounted and dismounted using hydraulic or thermal tools. “Our range of alignment tools assists in the alignment of shafts and belt pulleys as well as the checking of belt tension,” he adds. “This reduces wear of bearings and seals, misalignment problems resulting in reduced heat development as well as higher economic efficiency through reduced energy consumption.”
Condition monitoring
In today’s highly sophisticated plants, condition monitoring is crucial in achieving high availability and long life of machinery. “Our monitoring
The SmartCheck system
products help in planning maintenance work and reducing costs,” says Tlhalefang. “Temperature measuring and sonar devices make it possible not only to constantly check the operating conditions of machinery, but also to keep tabs on vibration, torque and the state of lubricants. “Our latest addition to this range of equipment is the SmartCheck system which we’ve just started introducing into the South African market,” says Tlhalefang. “It is an on-line measuring system for real time monitoring of machines, but it costs about 60% less than most condition monitoring systems with the same functionality.
Keep tabs on vibration, torque and the state of lubricants At first glance
“Due to its very attractive price, the online monitoring of small, redundant or non-redundant units becomes cost efficient for the first time,” adds Tlhalefang. “Application-wise it can be installed for electric motors, pumps, compressors, ventilators, fans and gearboxes.” At first glance, the FAG SmartCheck unit resembles a classic vibration sensor. “However, it can do much more than conventional measuring devices,” Tlhalefang says in conclusion. “In spite of its small size of about 44 x 57 x 45 millimetres, the intelligent system not only records the standard parameters such as vibration and temperature, but also other operating parameters such as pressure or flow rate. This provides a broad basis of information which permits our experts to make a very accurate assessment of a machine’s condition, thereby contributing to optimising processes in order to reduce lifecycle costs. The FAG SmartCheck App permits you to access data via an iPhone or iPad and can be downloaded from the iTunes Store free of charge.”
Automated lubrication systems
Tlhalefang Mtombeni, Schaeffler Industrial, Tel: (011) 225-3000, Email: tlhalefang.mtombeni@schaeffler.com
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Adapting to Market Needs You stand still, you die! Timken, the name synonymous with premium bearings, has certainly not stood still. To bearings, they added a full range of special lubricants, then came ancillary products such as condition monitoring and test equipment through a series of acquisitions. Now the company is entering the power transmission market in full force with a range of power transmission equipment such as drives, chain and couplings.
Barry Crawford, manager of industrial sales at Timken South Africa
The well-proven steel coupling is ideal for tough applications where strength and affordability are important
Housed bearings
S
A Mechanical Engineer” speaks to Barry Crawford, the manager of industrial sales at Timken South Africa. “In pursuit of a more diverse product range in power transmission, we’ve purchased a couple of companies over the past year to add steel-housed bearings, couplings, chain and industrial geared drives to our range,” he says. “We’re now marketing the company as a power transmission solutions specialist rather than just a bearing company.
As the market transforms, so customers requirements change, and expanding our product offering has met both our customer’s and Timken’s objectives of keeping up with market trends
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One of these is a steel housed-bearing unit, wellknown in the South African market through a local distributor. “QM bearing’s housed unit, known as the Blue Brute, is widely used locally, but will eventually become a Timken brand,” explains Barry. “For the local distributor it simply means they’ll be getting stock from us directly rather than having to import.” The Blue Brute is a rugged and innovative design in a wide range of four-locking styles, six housing types and 15 primary and secondary seals. The rugged steel housings are standard and include a lifetime housing breakage guarantee while it has external covers for extra sealing protection.
Fixed to floating
“As the market transforms, so customers requirements change, and expanding our product offering has met both our customer’s and Timken’s objectives of keeping up with market trends,” Barry adds. “Although the geared drive products are
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highly specialised transmission systems for marine and aerospace applications, mainly aimed at the American markets, the chain, coupling and new bearing products are known in South Africa and will in future be branded under the Timken name.”
These steel units are easily converted from fixed to floating mounts with the eccentric lock (EC) series guaranteed to remain fixed on a properly-prepared shaft. It’s fitted with a standard pressure relief valve to prevent over-lubrication and dimensionally interchanges with virtually all other mounted roller bearing units on the market.
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“Commonly, bearing blocks are made in cast iron housing, but QM developed a rugged steel housing, originally for the rough conditions at timber saw mills,” adds Barry. “Today they’re widely used across all industries, especially mining, where dirt and harsh environments are the order of the day. The special sealing arrangement ensures proper protection for the bearing, the part you want to protect against premature failure.”
These couplings require no lubrication and are easy to install and maintain. “Once the two coupling hubs, insert and cover are installed for the first time, the coupling hubs do not need to be moved again for the life of the equipment,” says Barry. “The straight-forward design means there is no possible interference between the coupling hubs if the insert fails. Plus, the urethane insert can be easily changed without moving the hubs or shafts. There’s a choice of four insert elements for varying torque needs
Once the two coupling hubs, insert and cover are installed for the first time, the coupling hubs do not need to be moved again for the life of the equipment Couplings
“We’ll also bring the Quick-Flex coupling from QM to the South African market,” Barry says. “It is a simplistic design consisting of two coupling hubs with an elastomeric insert and cover to offer advantages not offered by other coupling designs such as jaw, grid, gear, chain, tire or disc couplings. The interlocking elastomer element comes in a wide range of variants for different torque requirements for different applications.”
The Blue Brute, is widely used locally, but will eventually become a Timken brand
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The Blue Brute bearing
and they can by used at temperatures up to 177ºC. We even have a stainless steel version for harsh conditions or for food processing environments.”
Fit for life
From the same manufacturer, a range of rigid couplings is available in South Africa. “The rigid compression coupling design is guaranteed for life against breakage,” says Barry. “The well-proven steel coupling is ideal for tough applications where strength and affordability are important. The cast steel couplings are for joining two shafts of the same size. Also known as a ‘rigid clamp style’ coupling, they’re made from weldable cast steel. The castings are first roughly machined with a 1/16 inch spacer placed between the coupling halves before they’re bolted together for final boring. The spacer is removed and the result is a compression clamp on the shaft.” Of course, no offering is complete without the technical expertise to back it up. The acquisitions have not only brought over new product to Timken, but also a host of specialist experience to assist customers in terms of complete drive train problems. “Although our bearings range from small dentist drills to the large bearings found in wind turbines for example, we’re no longer just a bearing company,” Barry says in conclusion. “We pride ourselves on focussing on customers who have specific requirements and difficult applications. We like to get involved in assisting customers to overcome the problems they’re facing.” Barry Crawford Timken South Africa Tel: (011) 741-3820, Email: barry.crawford@timken.com
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PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: samecheng@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial: Kowie Hamman Advertising: Mark Bennett Circulation: Catherine Macdiva DTP: Zinobia Docrat/ Donovan Vadivalu Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.
Copyright
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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.
New Endorsement The “SA Mechanical Engineer” is delighted to announce that the SAEE has officially endorsed the publication. We kick off this issue with an overview of the SAEE and we look forward to further news and information on this invaluable topic in the months and years ahead. Welcome aboard! Susan Custers Managing Editor
The Southern African Association for Energy Efficiency (SAEE)
The SAEE is a non-profit energy efficiency co-ordinating body and a driver of networking, information dissemination, and awareness creation, in addition to becoming a body of authority, in all matters relating to energy efficiency and its associated industries. As a chapter of the US-based Association of Energy Engineers (AEE), the SAEE is in its 10th year of existence and has access to a source of information within the dynamic field of energy efficiency, energy engineering and energy management, renewable and alternative energy, power generation, energy services, sustainability, and all other related areas of engineering. As a growing professional association, the AEE’s overall strength is augmented by its strong membership base of over 16 000 professionals in 89 countries and its widely-recognised energy certification programmes. Its network
South Africa cannot begin to talk about the specifications of its proposed nuclear build programme before a tariff trajectory is forged by the Department of Energy for a 20-year period and the relevant authority is established. The deputy director-general responsible for nuclear, clean energy and electricity, Ompi Aphane, says the department will produce its first draft of the pricing cycle in June. A company set up by German investors - Isivunguvungu Wind Energy Converter – has produced the
of 70 local chapters located throughout the US, and abroad, meets regularly to discuss issues of regional importance. The SAEE sees its purpose as providing networking opportunities to all energy stakeholders in South and Southern Africa. With a full array of information outreach programmmes to create awareness from technical seminars, conferences, books to critical buyer-seller networking tradeshows, job listings, certification programs and accreditation of training, and even its own radio programme called The Green Hour, the SAEE and AEE offers a variety of information resource tools to live up to its purpose. The foresight and guidance provided is made possible by the Board of the SAEE, whom collaboratively can boast 100 years’ experience within the energy engineering and energy efficiency industry. Clear management and direction has equipped industry experts
first gigantic, 52m–long wind turbine rotor blade in Africa, for use by ArcelorMittal South Africa in a wind farm at Saldanha on the West Coast.
Manufacturing turbines for wind farms is a sustainable market using mostly local content including resin and fibre-glass. At present certain components are not yet available in this country but there are potential South African suppliers.
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Best Overall Chapter ter that provides various platforms for education and awareness creation in energy engineering and all its related industries at a time when our country is experiencing exceptional energy supply constraints coupled with excessive generation cost increases that could potential hinder economic development.” The numerous activities in the region have opened the market to national and international energy experts to share Prof LJ Grobler, President of the SAEE (right), receives the Best Overall Chapter Performance knowledge, disseminate information Award of the AEE for 2012 from Dr Eric Wood, 2011 President of the AEE in America and facilitate networking to active individuals within the energy efficiency industry SAEE has done the country proud by scooping the through the Southern African Energy Efficiency International Best Overall Chapter Performance Convention (SAEEC) and the Mining and Industrial Award presented by the US-based Association Energy Optimisation (MIEO) chapter. These initiaof Energy Engineers (AEE), of which the SAEE is tives serve as a direct conduit between, normally one of 70 chapters. President of the SAEE, Prof inaccessible, experts and the delegates, whom LJ Grobler was elated at the news and said, “After are ultimately responsible for bringing energy efalmost 10 years of serving the Southern African ficiency initiatives to fruition. market through the SAEE’s activities we feel proud to have achieved this Award and thereby fly the South African flag high in America. It cements the speculation by experts in the industry that our country has the potential to become a leader in the global energy efficiency sector.”
A scholarship outreach programme creates opportunities for upcoming and developing energy engineering individuals and enables the development of this young market on the continent. SAEE, Danielle Badenhorst, Tel: (018) 293-1499, Email: info@saee.org.za, www.saee.org.za
“The SAEE has established itself as an AEE chap-
to utilize the available networking and information dissemination platforms successfully.
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Annual Energy Awards are presented by the SAEE to persons and organisations that excel in the field of energy efficiency, and have gone the extra mile for the good of the cause.
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African International Energy has announced its acquisition of 76 percent control of gas production and exploration rights in the Ibhubesi gas fields along South Africa’s west coast. The announcement followed the $270 million (R2.1 billion) purchase of both Forest Exploration and Anschutz, companies that shared the rights with state-owned PetroSA, which still holds 24 percent. Eskom plans to start pressure testing on one of the
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ETF
Capacity building and training is also a purpose the SAEE fulfills through facilitating and overseeing the Energy Training Foundation’s (ETF) activities. International and national accreditation is awarded to the training offered by the ETF and this initiative
boilers at the Medupi power plant, at the end of May. Applications for the Southern African Association for Energy Efficiency (SAEE) annual three bursaries is open.
A consultant will soon be selected to conduct a full feasibility study into a planned solar park in the Northern Cape
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has delivered in excess of 400 certified professionals who now service the Southern African market and assist organisations in reaching energy efficiency targets. Various courses are offered for Certified Energy Management, Certified Energy Auditing and Certified Measurement and Verification– professional status is certified by the AEE and is internationally recognised. www.energytrainingfoundation.co.za
SAEEC
The Energy Efficiency @ Work convention and exhibition, the Southern African Energy Efficiency Convention (SAEEC) is the flagship event of the SAEE and annually draws over 60 knowledgeable speakers from across the world to address a niche audience of delegates. This year the SAEEC2012 will be held on 14–15 November 2012 at Emperors Palace in Gauteng. Great opportunities are created for exhibitors to display their products, solutions and services to delegates that attend from across the continent. Opportunities exist for persons to present case studies, share knowledge on new solutions and discuss matters surrounding the energy efficiency and related industries by presenting a paper. Sponsorship opportunities also exist. www.saeec2012.org.za.
CMVPSA
With the imminent introduction of tax incentives for companies that can prove energy efficiency savings, the SAEE established the Council of Measurement and Verification Professionals of South Africa (CMVPSA) which is an independent Measurement & Verification (M&V) body that represents the M&V industry and ensures that the quality of M&V services and service providers are credible, trustworthy and transparent. A primary requirement for companies to benefit from this tax incentive is that they need to make use of independent M&V professionals, certified by an independent M&V professional body, which is a need the SAEE now fills. www.cmvpsa.org.za
efficiency. Dubbed The Green Hour, this energy efficiency radio programme is hosted by Gareth on Mondays between 1 and 2pm. While this is a pilot project based in the Eastern Cape, the programme material will be made available weekly to a web pod of 25 other national radio stations to use at their own discretion, as well as being made available on various social networks, blogs and websites. Online broadcasting is available from www.kingfisherfm.co.za and news feeds can be found by joining the Facebook group The Green Hour – Kingfisher FM and GreenHourSA on Twitter. Recordings on www.saee.greenhour.co.za
All stakeholders
Green Hour
The SAEE has joined forces with Gareth Burley, a radio presenter on Kingfisher FM in Nelson Mandela Bay, in starting a national conversation about energy
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Gareth Burley, radio presenter on Kingfisher FM
Botswana’s electricity industry is expected to grow significantly over the next five years - millions of dollars have been invested in it and additional power generation capacities commissioned. German renewable energy developer Juwi Holding is talking to companies about partnerships to develop solar and wind power projects in SA.
By becoming an SAEE member you will help us create awareness so that your business can grow too! Become part of a distinguished group of energy efficiency professionals that attends to specific needs of the industry. We invite you to keep up to date with the latest developments around the SAEE and matters concerning the energy efficiency sector, build up new business relationships and strengthen existing ones through participating in the many initiatives offered by the SAEE. Membership is open to all energy stakeholders as individuals, institutions or corporate organisation in South and Southern Africa. Already the association has seen participation from members in countries such as Botswana, Lesotho, Swaziland, Namibia, Zimbabwe, Malawi, Zambia and Mozambique. Danielle Badenhorst, SAEE, Tel: 018 293-1499, Email: info@saee.org.za
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Evaluating Battery Energy Storage ABB, the power and automation technology group, 4R Energy, Nissan North America, Inc (NNA) and Sumitomo Corporation of America have formed a partnership to evaluate the reuse of lithium-ion battery packs that power the Nissan Leaf, the world’s first and only all-electric car designed for the mass market. The purpose is to evaluate and test the residential and commercial applications of energy storage systems or back-up power sources using lithium-ion battery packs reclaimed from electric vehicles after use. Energy storage systems can store power from the grid during times of low usage and feed that electricity back into the grid during periods of peak demand, increasing grid performance and providing back-up power during outages. The team plans to develop a Leaf battery storage prototype with a
capacity of at least 50 kWh, enough to supply 15 average homes with electricity for two hours. “The agreement will allow us to evaluate the commercial viability of a grid storage solution and develop a prototype to effectively reuse Nissan Leaf batteries,” said Bruno Melles, head of ABB’s Medium Voltage power products business, a part of the company’s Power Products division. “We look forward to working with our partners to take electric vehicle battery energy storage technology a step further.” Electric vehicle batteries have longer lives than those of personal computers or cell phones, with up to 70% capacity remaining after 10 years of use in an automotive application. This longevity allows them to be used beyond the lifetime of the vehicle for applications such as a smart-grid community energy
management system or battery energy storage. Innovative energy storage solutions are expected to become a key component of the smart grid, contributing to greater efficiency, reliability and performance. They will facilitate further integration of renewable energy sources, such as wind and solar, into the grid. The evaluation of Nissan batteries, through the partnership, will help determine their suitability for the power industry as a cost-effective ABB Group Media Relations, Thomas Schmidt; Antonio Ligi, Email: media.relations@ch.abb. com, www.abb.com Nissan North America, Katherine Zachary, Email: Katherine.Zachary@Nissan-Usa.com, www.nissanusa.com 4R Energy Corporation, Koichiro Furukawa, Email: koichiro.furukawa@4r-energy.com, www.4r-energy.com
New Fuel Cell Industry South Africa has the potential to be a leader in the fuel cell industry through a technology partnership between government and the private sector. “Prioritising the development of a local fuel cell industry will create many thousands of jobs, provide clean, reliable power for South Africa, and will support the government’s drive for more effective in-country beneficiation. Momentum is building in the global fuel cell market to accelerate the application of this proven and versatile technology. To make South
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Africa a truly global player, the focus now must be to promote a strong, viable local manufacturing industry that supports the everyday use of fuel cell technology,” Cynthia Carroll, CEO of Anglo American PLC, said,“South Africa is in a unique position to reap significant benefits from a local fuel cell market. There is strong political support for local beneficiation and clean energy programmes. Fuel cell demonstration projects are underway around the country and it has the necessary manufacturing and engineering
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expertise. The window of opportunity to make this happen is now,” Cynthia Carroll said. Fuel cells are a proven technology, providing clean, reliable and cost-effective power. Platinum-based fuel cells that use hydrogen are versatile, scalable and convert stored hydrogen into electricity with great efficiency.
Pranill Ramchander, Anglo American, Tel: (011) 638-2592, Email: pranill.ramchander@angloamerican.com, www.angloamerican.com
POWER GENERATION NEWS
Hydrogen Technology “Air Products is leading the way in developing innovative hydrogen technologies, which can reduce dependence on other heavy fossil-burning fuels and drive economic growth,” says Seelan Gounden, general manager supply chain at Air Products. “Air Products is the largest producer of hydrogen to oil refineries globally which use the gas to produce cleaner burning fuels. Hydrogen enables refiners to increase the amount of fuel that can be produced from every barrel of crude oil while assisting to remove pollutants from crude oil” says Seelan. Hydrogen has applications in many other industries such as chemical, electronics, and foods, where it is used on a daily basis. Its dynamic properties are proven to improve quality output, optimise performance and reduce costs. “Hydrogen is the cleanest burning and
Growing Green Economies
Ross Bruton, Frost & Sullivan Energy & Power Systems industry analyst
Although Africa is endowed with fossil and renewable energy resources, which could more than adequately cover its energy needs, it remains the most poorly electrified continent in the world. The proportion of people without electricity in Africa is higher than anywhere else on the planet, with as little as 5% of
most efficient fuel,” explains Seelan. “It can be used to produce electricity in a fuel cell for the cleanest option, or in an internal combustion engine where emissions are significantly reduced compared to other fuels.” Hydrogen is a great carrier of energy and can be produced from many renewable resources. It is carbon-free, nonhazardous and produces no greenhouse gases when used as a fuel. Because hydrogen is a light, clean-burning, abundant chemical, it is the first choice for fuel cells. Through the process of electrolysis, hydrogen can produce electricity and electricity can produce hydrogen, creating an energy loop that is ongoing and renewable. Dustin Mulder, Air Products South Africa, Tel: (011) 977-6492, Email: mulderd@apsap. co.za, www.airproductsafrica.co.za
the population having direct access to electricity in some countries. This significant challenge does, however, have a massive potential upside. The need to provide electrification to remote communities is one of the key drivers of renewable energy development on the continent. This is one of the findings in Frost & Sullivan’s analysis entitled “Mega Trends in Africa: A bright vision for the growing continent”. The study was released at GIL 2011: Africa – The Global Community of Growth, Innovation and Leadership. “The total investment into renewable power in Africa was $3.6 billion by 2010 and is expected to grow to $57.72 billion by 2020,” asserts Frost & Sullivan Energy & Power Systems industry analyst, Ross Bruton. “The key growth sectors will be wind power, solar power, geothermal power and foreign direct investment (FDI) into energy & power infrastructure.” Development of the renewable energy sector in Africa will lead to a diversification of the generation mix, a decreased dependency on a singular feedstock and greater security of supply.
New investments into the continent’s electricity infrastructure are likely to incorporate new technologies and standards. This requirement for smart technologies will mean that ICT development will also need to take place alongside electrification efforts. “Smart electricity development in Africa will be driven through grid incorporation of renewable power, and technological leapfrogging through investments into greenfield T&D infrastructure projects,” Ross believes. “Smart grids are, however, only expected to play a significant role in key high growth African economies.” Over the next ten years, renewable energy initiatives will be dominated by wind power projects, such as the Ashegoda Wind Farm in Ethiopia and Tanzania’s Singida Wind Farm. Solar power will also show good growth although this will most likely be through South Africa’s Upington solar project and renewed interest in Desertec in North Africa. Mani James, Frost & Sullivan, Tel: (021) 680-3208, Email: mani.james@frost.com, www.frost.com
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POWER GENERATION NEWS Making Inroads in African Hydropower Marelli Motori says the time and energy it has invested in the African market in the last few years is starting to pay off. The global Italian generator giant’s regional manager for Africa, Dean Pratt says there is great potential for hydropower in Africa, particularly in South Africa, Namibia, Malawi, Zambia, Ethiopia, Kenya, Tanzania, DRC, Zimbabwe, Ghana and Uganda. He says some of Marelli Motor’s successes in power projects on the continent include North Mara (Tanzania). Marelli has around 19 x 1300kva, 6600v generators running the mine. They were installed from 2001 onwards running 24/7/365 and are still going strong. The hydroelectric water plant at Kapanga-Musumba (DRC) was supplied with a 225kW, 400v, 8 pole (750rpm) hydropower generator
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Marelli Motori making inroads in Africa’s hydropower industry
during early 2010. This has been successfully installed and running without any hitches. In Marupupele (Botswana), Marelli will be supplying a 1500kva, 11000v generator. This is the first time that the Marelli South African office will be involved in the supply and commissioning of a 11kv generator. A 3000kva, 6600v generator was supplied to Exxaro Grootegeluk (South Africa). This was coupled to a 20 valve MTU engine, about the biggest motivator ever built wordwide. This has been successfully load tested and commissioned.
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Dean says, “Power projects on the continent pose many challenges but there is also huge potential as so much needs to be done.” He continues, “There are massive power shortages but this offers an opportunity for Marelli Motori to do business here. There is always a risk when it comes to financing projects as government or donor money is not always available which puts an extra burden on projects getting delayed or scrapped. The hydroelectric water plant at Kapanga-Musumba is a case in point.” Dean Pratt, Marelli Motori, Tel: (011) 8225566, Email: dpratt@marelli.co.za, www.marellimotori.com
POWER GENERATION NEWS Turning Waste Into Energy Organic waste is one of the untapped sources of natural energy available today. “It’s a simple solution that can be deployed in as quickly as three days but people don’t know too much about it”, says Jonathan de Magalhães, Managing Director of Ubuntu Energy Solutions. While biogas is used all over the world, India for example has more than 4.5 million digesters–harnessing biogas energy in South Africa is practically unknown. Only a small number of digesters have been built successfully and commissioned to date – a loss to the renewable industry sector in the country since biogas fulfils all of the criteria relating to environmental sustainability, requires a relatively low technological input and is cost effective to implement. Biogas provides a clean, easily controlled source of renewable energy from available organic waste for a small labour input, replacing firewood or fossil fuels, which are becoming more expensive as demand outweighs the supply. Additionally, a biogas digester treats the organic waste and prevents it from
taking up precious space in our landfills or over-burdened sewerage plants. In South Africa the waste disposed of in landfills produces unwanted landfill gas (Methane CH4) and leachate emissions. Furthermore, there is pressure on the country’s aging sewerage system. According to Jonathan, generating biogas presents a win-win solution because it offers easy disposal and treatment of organic waste, reduction of associated energy costs, and provides further cost savings or a passive income According to Jonathan, generating biogas offers a better ROI than solar or wind systems. “It’s easy to install and deploy,
and is very low in maintenance, probably only requiring some attention once every 5 to 7 years. For these reasons, biogas digesters would work well in rural villages, farming communities and game lodges,” he concludes. Ubuntu Energy Solutions info@ubuntuenergy.com Facsimile: +27 86 566 6767
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symbiosis
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STEAM, TURBINES & BOILERS
New Boiler Design Usually when you ask a boiler manufacturer what’s new, the answer is, not much. It’s an age old technology which, apart from electronics coming into play in terms of burner technology, in principle still works just fine to this day.
Andries Jacobs of Boiler & Steam Installations
The new design is a two-pass boiler which has a wet-back door in the place of the traditional dry-back wall you’d find on two-pass boilers
I
ndustrial boilers still use coal as they did in the days of steam ships and steam-driven railway locomotives, but today oils and gas have become popular fuels while the use of electricity to run boilers has diminished somewhat because of rising costs.
We can confidently assure customers a 15% saving on fuel with this new design, but so far many of our customers have seen savings of around 25% consistently
Totally new system
It therefore came as a big surprise when we asked Andries Jacobs of Boiler & Steam Installations (BSI) what’s new and he actually had something completely novel to share with “SA Mechanical Engineer’s” readers. “About three years ago we put the first of an entirely new design boiler into the market locally and today have more than 110 units installed with highly satisfied customers, mainly due to the huge savings they achieve in fuel costs” he says. “Conservatively, we can confidently assure customers a 15% saving on fuel with this new design, but so far many of
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A boiler under construction at BSI
our customers have seen savings of around 25% consistently.”
How it works
Basically the new design is a two-pass boiler which
has a wet-back door in the place of the traditional dry-back wall you’d find on two-pass boilers. “We’ve termed it the Therm “O” Steam Boiler, a design which we’ve patented to protect our intellectual
Evaporative water cooling for numerous applications IWC supply the following products and services:
Tel: +27 11 466 0699 • Fax: +27 11 466 8180 Email: mail@iwc.co.za • Web: www.iwc.co.za INDUSTRIAL WATER COOLING (Pty) Ltd
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©CM 101210(c)MF
• Package & modular cooling towers under the Searle Bush brand. • Large field erected mechanical draught cooling towers of all types and materials of construction. • Slurry cooling towers. • Refurbishment of all types of cooling towers. • Turnkey cooling water installations. • Water treatment equipment - filters and dosing equipment. • Testing and evaluation of cooling towers. • Spares and accessories for all makes of cooling towers.
STEAM, TURBINES & BOILERS
Final touches to a boiler near completion
property. At this stage the principle can only be applied to oil and gas burning boilers, but we’re working on a design for coal fired boilers which, so far, looks very promising.” Normally a two-pass boiler has a refractory lined wall in a chamber at the back end of the boiler so that the heat from the burner can be redirected to pass through the boiler tubes in order to heat the surrounding water. “The bricks or cement of the refractory liner absorb a certain amount of heat which is therefore not used to heat any water as such,” explains Andries. “We’ve managed to come up with a wet-back door where this ‘lost’ heat, or waste gas, is absorbed into a water jacket to pre-heat the water flowing into the boiler’s tank.
Conversions
“This increases the temperature of the water going into the boiler to around 130º C,” elaborates Andries. “According to boiler design parameters you need water entering the boiler to be at a temperature of 100ºC in order to get 200 Kg steam. If, for example, this water is only 60ºC, you only get about 170 Kg steam. With our design you’re pumping water in at 130 degrees, preheated with energy which is normally wasted on a brick wall. The wet-back principle is not entirely new as such, but it has never been applied successfully on this type of boiler in the way we’ve designed the system.”
The range of boilers BSI manufactures varies from small units up to 5 tonne two-pass boilers with all the new builds coming out in the wet-back version. “Many of our customers who have our original dry-back version have since opted for a conversion to the new design purely to benefit from a fuel-saving perspective,” says Andries. “In terms of other brands, the wet-back conversion can be done on some of the makes but there are one or two types which cannot be converted at all. New or converted, the wet-back version is the same size and has the same footprint as our original boiler and on the outside looks just like the old one. Only the back-end looks slightly different because of the insulation and extra piping we fit onto it.”
The wet-back principle is not entirely new as such, but it has never been applied successfully on this type of boiler in the way we’ve designed the system Other products
Although BSI does not manufacture coal fired boilers, they do service and rebuild all sizes and makes of coal fired boilers. “Apart from designing and manufacturing autoclaves of all sizes we also do calorifiers, heat exchangers, chimney stacks, hot well tanks and water treatment plants specifically for boiler plant,” Andries elaborates. “A large portion of our work, especially lately, is replacing electric
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boilers with either gas or oil burning systems. We’ve just replaced an electric boiler with an oil burning boiler for a client who extracts avocado oil. His monthly electricity bill of R110 000 a month is now down to R45 000 a month for the oil.”
Water
In Andries’ book, one of the most important aspects of boiler efficiency is water treatment. “We recently re-tubed a boiler which had been in operation since 1963. Its long life can only be ascribed to regular maintenance which includes proper water treatment,” he says. “The heart of a boiler is in the water. Apart from custom building water treatment systems for our customers as a package deal with a boiler, we assist with advice where we can, and if we can’t help, we refer clients to the experts who specialise in water treatment.” Andries Jacobs, Boiler & Steam Installations, Tel: (011) 396-2737, Email: www.boilerandsteam.co.za bsi.aj@mweb.co.za
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A burner test in the workshop
VOL 62
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STEAM, TURBINES & BOILERS
New Burner Guarantees Savings The safe, reliable and efficient generation of steam has challenged boiler design since steam was first harnessed for power. Today, more than ever, energy efficiency in steam generation is critical. In USA, for instance, about 45% of all fuels burnt is used to generate steam.
L
ocal steam users will be delighted to hear that a guaranteed energy saving burner solution for steam boilers is now available in South Africa.
“SA Mechanical Engineer” speaks to John Rundle of Steam Generation Africa in Midrand about the Limpsfield burner. “We’re the official distributors John Rundle, Steam Generation Africa in Gauteng for Combustion Technology in Cape Town, the agents for this range of burners imported from the UK,” John explains. “We’ve just installed a twelve tonne boiler fitted with a Limpsfield burner,
Limpsfield is the only burner manufacturer in the world which actually guarantees a fuel saving of 8 % with their new unique technology which can burn oil or gas, or mixtures of different gases
The Limpsfield burner
generally now regarded as the Rolls Royce of gun-burners on the market.
Growing installed base
“Limpsfield is the only burner manufacturer in the world which actually guarantees a fuel saving of 8% with their new unique technology which can burn oil or gas, or mixtures of different gases, or even a mixture of oil and gas,” says John. “Even if you consider just a 5% fuel saving on some of the fuel bills out there, the return on investment can be as short as 12 months.”
A boiler ready for delivery
Hand in hand with more efficient burning technology goes reduced emission levels, making this a green option in terms of environmental concerns. “In addition to being easy to set up and adjust, the unique forced draft combustion design distributes the combustion air in the THE SOUTH AFRICAN MECHANICAL ENGINEER
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STEAM, TURBINES & BOILERS
The in-house test bench
blower head so that the necessary static pressure is maintained for stable combustion and flame geometry throughout the whole burner range,” says John. “This burner achieves less than 3% O2.”
The split gas head can be used on most applications and provides excellent mixing to maintain good combustion throughout the firing range Combustion
It comes standard with an auto-flame combustion control unit which constantly controls the burner in relation to what’s happening in the boiler in terms of steam demand, creating a very controlled environment. John adds, “As this product is new to the South African market, we’ve employed an expert in gun-burner and auto-flame applications. Our commitment to this technology, which we expect to catch on quickly, reflects that which made our coal fired boilers firmly established in industry.” Limpsfield offers standard burners with an output ranging from 0.9 MW (3.000,000 Btu/ hr) to 31 MW (110,000,000 Btu/hr), firing a wide range of fuels including natural gas, diesel, heavy fuel oil, waste oils, animal fats, fish oil and biogases. Each project is engineered to suit the specific requirements whether it is a single fuel, dual fuel, multi-fuels, change over on the fly between fuels or burning waste stream oils. The burner can also be supplied as a low NOx burner for gas and for oils.
In the mix
“The superior advantage of this system lies in how easy it is to mix fuels within the burner while it’s in operation,” says John. “In addition to two 40-tonne boilers on order for a client which will be equipped with these burners, we’re currently busy with a project where the client produces their own biogas. This supply is supplemented with purchased natural gas. By programming the auto-flame
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Refurbishing an old boiler
to control the burner, we’re setting up the system so that they’ll use as much biogas as is available before the system automatically tops up the consumption with natural gas in order to maintain optimum steam production without any interruptions.
Guarantees
“The cherry on the cake is the written guarantee Limpsfield offers,” says John. “Many suppliers say they can guarantee a fuel saving, but nobody actually puts it in writing as they do.” These burners provide high turndowns, typically between 4:1 and 10:1. This turn down is established by using a split gas head or a spider head. The split gas head can be used on most applications and provides excellent mixing to maintain good combustion throughout the firing range. The unique spider head assembly offers the user high turn down ratios. It was initially designed to be fired when using fuels with high burning velocities such as propane or hydrogen. Unlike the split head, the fuel is introduced after the diffuser plate enabling the flame to establish good retention while maintaining excellent mixing.
Firm footing
Since visiting Steam Generation Africa just two years ago when the company set up shop in Midrand, they have established a firm footing in the steam industry, clearly indicated by a workshop filled with
The valve repair shop
boiler parts, burners and steam valves in various stage of repair or servicing. “We now have an in-house valve repair and servicing section and have also set up our own test bench,” John says in conclusion. “This gives us the flexibility of operating beyond normal office hours when customers have an emergency. From designing, through installing the coal handling operations and gas lines, we’re now geared to handle everything up to and including the final point of use.” John Rundle, Steam Generation Africa Tel: (011) 695-2500 Email: john@steamgeneration.co.za
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All Nkosi Johnson ever wanted was a normal childhood. Fortunately for us, he never enjoyed one.
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THE SOUTH AFRICAN MECHANICAL ENGINEER
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VOL 62
May 2012
SAIT
18th International Colloquium Tribology, TAE, Germany During January, Ostfildern Germany, is a very grey little town, which as the name suggests is outside of any metropolitan area, and is at the very end stop of Stuttgart’s metro system. But from Monday 9 to Friday 12 January this year, the Technische Akademie Esslingen (TAE) campus, on the edge of Ostfildern, again played host to the world-renowned Professor W Bartz and his International Colloquium Tribology, held every second year. As a regular event it attracts the highest level of papers and participants in the tribology world.
A Patrick G Swan
s always Monday afternoon was taken up by a meeting of the World Tribology Council, of which South Africa is a member, under the chairmanship of Professor Peter H Jost. This year most discussion revolved around the 2013 World Tribology Congress, WTC 2013, which will be held from 8 to 13 September 2013 in Turin, Italy.
• Lubricating Greases • Environmentally Acceptable Lubricants
The TAE colloquium was arranged into eight plenary sessions with 22 papers, many of which ran concurrently, and 149 regular papers in nine concurrent sessions. It would take a very dedicated team to even attend most of the papers!
• A new range of additives which has the potential to reduce friction under boundary conditions, to less than 0.03. Under normal fully-lubricated conditions, this represents a reduction of 60%.
The TAE theme was ‘Solving Friction and Wear Problems’, and a common theme was Green Tribology or Ecotribology, since being at the forefront of friction and wear reduction, tribology is inherently ‘green’. The main subjects were:
Basics of Tribology • • • •
Fundamentals of Friction and Wear Hydrodynamic and Elastohydrodynamic Materials and Surface Engineering Machine Elements
Tribotesting and properties of lubricants
• Chemical, Physical and Technological Properties • Classification and Standardization of Lubricants • Condition Monitoring
Automotive lubrication
Highlights were: Global lubes market
• Volumes; trends; and base oil trends
Research
• Additives; base oils; and surfaces
Items of major interest were:
• Surface texturing has long been shown to reduce friction; just consider a golf ball. This technology is being thoroughly researched, and in future gears, piston rings, and many other items can be expected to have laser textured surfaces. Texturing however is not a panacea, it does not work in all applications, and can increase friction if used incorrectly. • Several papers reported on the development of triboconditioning or tribofilms that coat a surface to create a new chemical film, generally only a few nanometres thick, that both smooth the surface and have been shown to reduce friction by between 10 and 60%. Data presented by Peugeot Citroen showed a power increase of 20 horsepower by applying tribofilms to the valve train and pistons in current production engines, with ongoing work on the crankshaft and gear train.
• IC engine fuel economy will rely on both tribofilms and lower lubricant viscosities. A method for rating heavy duty crankcase lubricants has been developed using a Volvo D12D engine, and an SAE 0W-20 viscosity grade has shown excellent race Industrial lubrication • Metal Working and Metal Forming Lubricants track performance. and Lubrication • ZF, who supply most of the world’s gears or • Lubrication of Industrial Gears, Compressors gear technology, went as far as proposing an oil and Hydraulics free gearbox, using a newly developed gear tooth • Engine Oils and Lubrication • Gear Lubrication • For-Life-Lubrication
Lubricants and fluids • • • • • •
profile and tribofilms.
Hydraulic Fluids and Seals Base Oils for High Performance Lubricants Mineral Oils Synthetic Fluids Additive Developments and Technology Solid Lubricants
Patrick G Swan SAIT Committee Member SAIT, Gill Fuller, Tel: (011) 802-5145/6, Fax: 086 719 2261, Email: secretary@sait.org.za www.sait.org.za
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Central/decentral Festo South Africa was sub-contracted by Bateman Engineering Technologies to supply and install a pneumatic system for Meulwater Water Treatment Works (WTW), a newly- constructed purification plant located in the ecologically sensitive Paarl Mountain Nature Reserve, designed by Aurecon. “We supplied and installed automation equipment for the plant filtration and backwash recover y systems. The
components form part of a concept that ensures the plant can use a hybrid centralised and decentralised approach to control, implementing a ’best of both worlds’ approach. This is something we are very proud of,” says Brian Abbott, Festo product manager. The pneumatic equipment boasts quiet operation and uses clean compressed air technology. The valve actuators are simple in construction, with few moving
parts, and have a long life expectancy. The system also features low energy requirements, all of which contribute significantly to the ‘green’ aspect of the system. Tracey Swart Festo (Pty) Ltd Tel: (011) 971-5500 Fax: (011) 974-2157
Largest ever stock order Elquip Solutions, a Third Party Channel for ABB South Africa, signed an agreement to be a distributor for the ABB low voltage motors and placed the largest ever order for stock in South Africa. “We are very proud to be associated with ABB’s world-leading brands, including their high-quality SABS-approved cast iron range of low voltage motors with capacities from 0.18 kW up to 315 kW in 400 and 525 V options,” says Mike Cronin, managing director of Elquip Solutions. Mike explains that Elquip Solutions will carry the largest stockholding of the ABB low voltage motors in South Africa and will offer these motors to other ABB Third Party Channels. Elquip will be selling these motors to their existing
and new customers and will also offer these motors to other ABB Third Party Channels. “From the customer’s point of view, the biggest advantage is having virtually immediate access to a large range of high-quality products at extremely competitive prices. The same accessibility advantages will be afforded to the other ABB Third Party Channels, allowing them to supply their established customer bases with ABB products, without having to undergo the lengthy lead time associated with the traditional ordering and delivery process,” Mike concludes. Mike Cronin, Elquip Solutions Tel: (011) 826-7117 Email: mike@elquip.co.za
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MARKET FORUM mark at operations like Kleinkopje Colliery, Iscor Sishen, Zimbabwe’s Wankie Colliery, Empressa Minera Copper Mine in Chile and Namakwa Sands, reflecting the diverse applications of this range of screens in products ranging from coal and copper to iron ore, heavy mineral sands and diamonds. IFE Screens use finite element analysis to provide optimum performance and structural strength. The Exciter driven unit is designed to handle high amplitude vibrations without decreasing life expectancy.
Screening diamonds
Osborn product manager Emile Oosthuyzen explains that the screens will be employed at Petra Diamonds' Cullinan operation, where a new tailings reclamation plant is being set up. This order comprises six Osborn IFE screens – two 12” x 24” double deck screens
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and four 12” x 24” single decks – as well as one 3” x 16” Osborn Obex single deck screen. Outlining the benefits of Osborn's IFE Screens, he notes that they are designed for heavy-duty to extra-heavy-duty screening, and feature a gearbox drive that is driven via a cardan shaft from an electric motor, in order to generate more G-force for the weight of the machine. Over the years, these tough, hard-wearing screens have made their
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Complementing the large, heavy-duty IFE screens that will be employed at Cullinan as primary screens is an Osborn Obex Screen that will be utilised in the final recovery stage. Emile elaborates, “Driven by out of balance electric motors, the Obex screen is designed for medium to heavy duty applications, and its size and design features make it an ideal final recovery screen. It is much longer than it is wide, to achieve maximum screening efficiency when working with the lower tonnages in the final recovery stage, when the raw ore has been processed down to concentrate.” Neill du Plessis Osborn Engineered Products Tel: (011) 820-7600 Fax: (011) 388-1136 www.osborn.co.za
MARKET FORUM
Free cooling A revolutionary design for Internet Solutions’ 11th African data centre, will slash client power costs, increase data centre productivity, and improve disaster resilience. It will also give clients greater connectivity flexibility by allowing competitor carriers to connect directly into the data centre. Internet Solutions’ fourth to be built in the Gauteng area, the Randview data centre has been designed to operate without conventional air- conditioning for all but the hottest time (9%) of the year. The data centre will boast power utilisation efficiency (PUE) of 1.4 versus the industry average of 2.5. “Cooling is the largest item on a data centre bill, so reducing the need for compressor based air-conditioning has a significant impact on a client’s data centre costs,” says Barry Hatfield, Internet Solutions business development manager for cloud solutions. Randview’s very nearly free cooling has been achieved by the use of three Kyoto
Cooling Cells, mechanical devices made of conductive aluminium and some 6 metres in diameter. Half of the wheel is exposed to outside air, and the other half to the data centre air. The cooler exterior air temperature is transferred into the building as the wheel turns. Because the inside half of the wheel is sealed from the outside, dust and other contaminants in the external atmosphere are not transferred to the interior of the data centre. Heat is extracted from the data centre interior by means of a hot isle contained exhaust system and the wheel-cooled air is delivered at volume to the racks. “Kyoto Cooling has been tested and proven in many different applications in Europe and, most publicly, in Sydney Airport in Australia,” Barry says. “So, there’s no operational risk in using this technology in a data centre. More to the point, because we can use volume instead of temperature differential to cool the servers and we don’t lose efficiency
through a mixture of hot and cool air over the servers, very little of the electricity we bring in to the building is being lost. Most of what we draw from Eskom is going towards powering the servers.” Its cabling runs above the racks, preventing damage to the cables and facilitating maintenance and installation. This has also enabled the use of solid concrete floors, which don’t need reinforcing to be able to carry high density, heavy computing devices. “In other words, Randview is not just about saving electricity - it’s also about being able to do more with the electricity that is available as well as with the floor and building space,” Barry says. “Randview is not simply more energy efficient, it’s more productive overall.” Another Internet Solutions innovation has been to make Randview carrier agnostic, enabling client organisations to use their incumbent connectivity providers to access the data centre. Kate Thompson Headlines Tel : (011) 887-3422 Email: kate@headlinespr.co.za
Replacement screen order Anglo Coal has placed a R2.9-million order with Weir Minerals Africa for the supply of ten horizontal, single and double deck screens for installation at its coal handling processing plant in Mpumalanga. Weir Minerals Africa’s Santosh Gunpath says the screens, in various sizes from 1.8 metres wide to 3.6 metres wide, are being supplied with 3CR12 stainless steel deck frames and stringers for corrosion protection.
example, sizing, desliming, grading and scalping.
In coal production, these screens are suitable for sizing applications, dense media recovery and dewatering in coal handling plants. They also serve the hard rock industry in similar applications, for
“They are widely used in these sectors and are ideal wherever linear motion screens are required,” Santosh says. “The screens are very robust and designed to maximise machine availability.”
René Calitz Weir Minerals Africa (Pty) Ltd Tel: (011) 929-2622 www.weirminerals.com
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Simplicity
Electra Mining
Beijing United Chinese Business International Consulting, CMEC International Exhibitions and the China Council for Promotion of International Trade machinery Sub-Council (CCPIT).
Africa 2012 This year marks the twentieth time that the Electra Mining Exhibition will be staged spanning across forty years and will once again demonstrate the strong growth enjoyed by the event since it was first held in 1972. At the most recent show in 2010, more than 35 000 visitors attended, with 739 exhibitors taking up the over 33 000 square metres of exhibition floor space. Tectra Automation, a subsidiary of the Hytec Group and a distributor of Bosch Rexroth automation equipment in South Africa, has developed an innovative control system suitable for applications where programmable logic controllers (PLCs) are too sophisticated, but conventional systems do not offer enough control. Based on a PIC18F4620 microcontroller, the Tectra Programmable Controller (TPC) allows for in-circuit programming and re-programming using a programmer that is connected to a header on the TPC. “Using the C-programming language makes the system more versatile and easier to program once the TPC is installed,” says Jaco de Beer. The TPC consists of a number of components that are soldered onto a PCB board. This allows damaged components to be isolated and replaced within a couple of hours, saving on downtime and costs. Jaco de Beer, Tectra Automation, Tel: (011) 971-9400, Email: jaco.debeer@tectra.co.za, www.tectra.co.za
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Gary Corin, managing director of Specialised Exhibitions, says that Electra Mining Africa, together with the co-located shows will provide visitors with the “ultimate platform to view a vast array of new innovations, products, services, technologies, trends and industry developments in the mining, industrial, construction and power generation industries. “Visitors can expect to see many leading-edge South African companies in the packed halls and outside precincts, as well as high-profile international exhibitors from countries such as Canada, USA, the United Kingdom, France, Germany, Austria, Italy, Switzerland, Sweden, Russia, Turkey, India China and Botswana,” says Gary. International Pavilions confirmed include the Canadian Association of Mining Equipment and Services for Export (CAMESE); O.T.S.A with involvement from UK, Ireland, Germany and Sweden; a Meridyen International Fair from Turkey; and Chinese support through
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Electra Mining Africa is recognised as a gateway into Africa for local and global investors looking for new business opportunities in the mining, industrial, construction and power generation industries. Together with Elenex Africa, Machine Tools Africa (endorsed by the Machine Tool Merchants Association of South Africa) and Transport Expo Africa, Electra Mining Africa brings coinciding industry sectors together at one location for visitor and exhibitor convenience. “The exhibitor mix has changed over the years to suit market-driven needs and some companies have reduced exhibitor floor space compared with previous years. But this has led to greater creativity in the utilisation of space and also the addition of many new exhibitors eager to be at Electra Mining Africa for the first time,” says Gary. He adds that the Electra Mining event has accreditation from UFI, which is the Global Association of the Exhibition Industry. This means that the event is audited according to strict standards. Electra Mining Africa 2012, Elenex Africa 2012, Machine Tools Africa 2012 and Transport Expo 2012 are being hosted at the Expo Centre, Nasrec, Johannesburg, from 10-14 September. Visitor pre-registration is open at www. electramining.co.za. Electra Mining Africa is organised by Specialised Exhibitions a member of the prestigious Montgomery Group and a member of the Exhibition Association of Southern Africa (EXSA). Tel: (011) 835-1565 Email veda@specialised.com or cwood@specialised.com www.electramining.co.za
MARKET FORUM MARKET FORUM toughest applications, for instance in Dakar racecars, in Terex special trucks for construction and also to manufacture Porsche race cars,” says Ken Steel, general manager of BMG’s seals division. “Typical applications of the Loctite range include threadlocking, thread sealing, gasketing and retaining for bearings, bushes, shafts and cylindrical parts. The range also includes instant adhesives for joining small parts or for fast processing and structural bonding materials for joining large structural parts.
From left, Gari nDenysschen, senior technical sales representative, Loctite and Ken Steel, General Manager, Seals Division, BMG - Bearing Man Group
Toughest applications
BMG has been appointed distributors of the comprehensive range of Loctite branded sealants and adhesives in
Southern Africa, and has extended its range to now include Loctite chemical products and equipment solutions for automotive applications, industrial manufacturing and in electronics, as well as for aerospace and medical technology. “Loctite products are used in the
Metal filled compounds are used for worn and damaged components and special materials are available for cleaning, lubrication and protection. Loctite also has a range of materials for the surface treatment and corrosion protection of components. BMG supports this range with a technical advisory and back up service from its network of over 100 outlets. BMG - Bearing Man Group Tel: (031) 576-6288 Fax: (031) 576-6584 Email: kens@bmgworld.net www.bmgworld.net
Mobile Dewatering Plant A demonstration unit has been built prior to the full commercial roll-out of a Bellmer Winklepress Mobile Dewatering Belt Press, for sewage and effluent treatment in mining, municipal and general industrial applications. Bellmer Winklepress belt presses have been used successfully in southern Africa for many years in municipal wastewater treatment plants and in the paper and fruit juice industries. With this mobile press, however, Bateman Engineered Technologies, aims to significantly extend the technology’s range of applications.
ids loading, polyelectrolyte consumption, cake dry solids concentration, filtrate solids concentration, overall capture rate and the establishment of the cost for dewatering sludge. The mobile dewatering plant is fully automated, complete with PLC and a SCADA system, all mounted on a 12.2m
semi trailer. Operation of the plant is controlled according to variable set-points selected by the operator according to particular process requirements. Marius Botha, Bateman Engineered Technologies, Tel: (011) 201-2300, Email: enquiries@bet.bateman.com
The demonstration plant has been built to demonstrate the performance and efficiency of the mobile dewatering belt press to clients, prior to them committing to building full-scale dewatering plants for their sites. The parameters that can be assessed in such a demonstration include hydraulic loading, dry solTHE SOUTH AFRICAN MECHANICAL ENGINEER
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MARKET FORUM
A Breath of Fresh Air In recent deals, worth approximately R1.6 million, Goscor KLG has installed two Sullair WS1110, two WS0710 compressors, four DMD desiccant air dryers and eight VS10-7.5 vacuum pumps at the Netcare Union and Clinton Hospitals in Alberton and Netcare Rosebank Clinic in Rosebank.
Goscor KLG MD Jayson le Roux says that working in the hospital environment poses critical challenges. “Air or vacuum supply can never be interrupted. Temporary standby connections have to be in place before any work commences to ensure a continuous air supply,� he explains. The Goscor KLG team developed a lead/lag control panel that ensures that the load is evenly distributed and that stopping and starting the compressors and vacuum pumps occurs in sequence. The lead/ lag panel also ensures that the machines sense the standby generator
starting and immediately start all the machines in the event of a power failure, bring all pressures back to the required standard and then initiate the sequencing of the compressors and vacuum pumps. Special medical grade copper tubing is used for inline filtration that has no harmful substances; this tubing meets and exceeds international standards. Jayson le Roux, Goscor KLG Tel: 0861 GOSCOR (467 267) Email: compressedair@goscor.co.za www.goscor.co.za
Netcare Clinton Clinic
YOUR PARTNER IN ENERGY EFFICIENCY AND THE ENVIRONMENT
>>CLEAN ENERGY SOLUTIONS<< Tel: +27 11 704 0580
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email: enquiry@cbz.co.za
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website: www.cbz.co.za
MARKET FORUM
Make-Over In Antarctica The SANAE IV (South African National Antarctic Expedition) research base in Antarctica was originally constructed in 1997, when an SSI group company provided the mechanical services. The Base is now due for refurbishment and modernisation to improve energy efficiency, structural reliability and living conditions for the 10 scientists and technical personnel who over-winter at SANAE IV. They live this lonely existence in perhaps the most desolate place on the planet. Maintenance and repair work as well as re-stocking of the base is done by a Department of Public Works (DPW) team of ± 60 during the summer months – November to end February. SSI Engineers and Environmental Consultants won the tender issued by the Department of Public Works, on behalf of the Department of Environmental Affairs & Tourism who administer the facility. The first step in the refurbishment process is the compilation of a status quo report, then converting this into a procurement and construction contract document
Robert van Putten and right, Johan Scheepers of SSI ‘on site’
which will go out to tender. Thereafter SSI will supervise the refurbishment work which has to be completed within a 40 month time frame set by the client. The first investigation visit to the base has been completed and concentrated on reviewing all mechanical, electrical and structural components of the base. Due to the hostile weather conditions which include severe winter storms, refurbishment work can only be undertaken during the summer months. Where possible, replacement equipment will be packaged in kit form and inspected, prior to shipping from Cape Town. Getting the new equipment to the SANAE base is
a logistical exercise in itself. The ‘normal’ route involves shipping personnel and equipment to an off loading area close to the German’s Neumayer base. From there a helicopter ferries personnel and small equipment some 300km to the SANAE IV base. Heavier equipment however, must be skid-mounted and towed by caterpillar tugs overland through dangerous terrain to reach the base, a journey that takes several days in good weather conditions. Hillary Erasmus Tel: (011) 798-6551 Email: hillarye@ssi.co.za
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On the Move Book NOW for 2012 Book NOW for 2012
July
• Compressors, air motors and vacuum pumps June • Hydraulics and pneumatics • • HVIC Bearings and lubrication • Generation • Power Computers in engineering • Pipes, pumps and valves August Charity Gumede
Christi Bester
• Power Powertransmission Generation • • Computers in engineering • Pipes, pumps and valves • Power Generation • Electra Mining Africa 2012 exhibition issue
Dr Ralph Heath
September • Oils and lubrication • Compressors, air motors and vacuum pumps • Mills Contact Mark Bennett on • Power Generation Joe von Aulock
Bill Scurr
Steve Smithies
BLT SA, newly-established materials handling specialists for the shipping sector, has appointed Charity Gumede as marketing director.
Honeywell is pleased to announce the appointment of Joe von Aulock as their new Business Development Manager.
Christi Bester has been appointed as Finance and Registration Manager of the Southern African Association for Energy Efficiency (SAEE).
Amec, an international engineering and project management company, has announced the appointment of Steve Smithies to the role of technical director, Mining & Geology for Africa.
Global engineering and environmental consulting, design and construction services company, Golder Associates announced the appointment of Dr Ralph Heath as its new Managing Director and Regional Vice-President for Africa.
The Southern Africa Stainless Steel Development Association (Sassda) is proud to announce the appointment of its new executive director, Bill Scurr.
Tel: (011) 781-1401 or October E-mail: samecheng@pro• Power transmission mech.co.za • Computers in engineering for further details • Pipes, pumps and valves • Power Generation • Materials and Machine Tools
Contact Mark Bennett on Tel: (011) 781-1401 or E-mail: samecheng@promech.co.za for further details
Index to Advertisers 19
Compressor Valves
Afzelia 38
Engen 12
PPS 11
Artic Dryers
34
Engineer Placements
Rodecon
Atlas Copco
13
Hansen 26
SEW
Axiom 14
Horne 42
SKF 8
Becker
Inside Front Cover
ILS 4
Sprag
Bonfiglioli
Inside Back Cover
IWC
27, 30
Symbiosis 28
Chemsystems 34
KDP 20
Voith 40
Clyde Bergemann
Nkosi’s Haven
Wearcheck 16
46
44
THE SOUTH AFRICAN MECHANICAL ENGINEER
19
Orange Vibrator Motor Company
AES 32
10
36
VOL 62
May 2012
20 Outside Back Cover Outside Front Cover
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 62
May 2012
47
48
THE SOUTH AFRICAN MECHANICAL ENGINEER
VOL 62
May 2012