SA Mechanical Engineer Nov/Dec 2014

S MECHANICAL A ENGINEER Nov/Dec 2014

Publication of the South African Institution of Mechanical Engineering, incorporating News of Associate Organisations

Tourists Take On Knife-Making Clearing Up Confusion THE SOUTH AFRICAN MECHANICAL ENGINEER Around Welding Standard

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► EIA Process

► Environmental Risk Assessments

► Geographical Information Systems

► Agricultural Assessment and Advise

► Project Managment

► Wetland and Riparian Services

► Natural Resource Services

► Visual Impact Assessments

► Ecological/Biodiversity Services

► Public Participation Process

► Application Assistance

► Game Ranch Management

► Developement Research, Monitoring and Evaluation

N2 Mnini ECO Duties

Plant rescue

Durban Coal Terminal Site Inspection

Ohlanga Pump station ECO Duties

Freightpak Warehouse Site Audit

Public participation Makhabeleni

Ballito Interchange Botanical survey

Site assessment Sundumbili pipeline

l Tel: (031) 303-2835 l Fax: 086 692 2547 l l Email: info@afzelia.co.za l www.afzelia.co.za l

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Nov/Dec 2014Skills on Site

Septmeber 2012

1

Chris Reay

Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)

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John Aspinall

The monthly circulation is 3 947

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Event Code Event Title

Start Date

End Date

Region

E8615

Machinery Failure Analysis & Prevention

20-Jan-15

22-Jan-15

East Rand

A8615

Machinery Failure Analysis & Prevention

27-Jan-15

29-Jan-15

Durban

D6415

Tank Design, Construction & Installation

28-Jan-15

29-Jan-15

Vaal

C8615

Machinery Failure Analysis & Prevention

03-Feb-15

05-Feb-15

Cape Town

F6415

Tank Design, Construction & Installation

04-Feb-15

05-Feb-15

Secunda

B9215

Pressure Safety Valves

10-Feb-15

12-Feb-15

Port Elizabeth

C6515

Fans & Air Handling

11-Feb-15

12-Feb-15

Cape Town

F9215

Pressure Safety Valves

17-Feb-15

19-Feb-15

Secunda

A1815

Materials Selection Specification and Welding Technology

18-Feb-15

18-Feb-15

Durban

A1915

Understanding How Corrosion Protection, Inspection, NDT 19-Feb-15 Technology & In-service Inspection can Improve Asset Integrity Management

19-Feb-15

Durban

D9215

Pressure Safety Valves

24-Feb-15

26-Feb-15

Vaal

B6415

Tank Design, Construction & Installation

25-Feb-15

26-Feb-15

Port Elizabeth

B8615

Machinery Failure Analysis & Prevention

03-Mar-15

05-Mar-15

Port Elizabeth

E6415

Tank Design, Construction & Installation

04-Mar-15

05-Mar-15

East Rand

A7715

Value Engineering in Projects

10-Mar-15

12-Mar-15

Durban

F8615

Machinery Failure Analysis & Prevention

10-Mar-15

12-Mar-15

Secunda

D8615

Machinery Failure Analysis & Prevention

17-Mar-15

19-Mar-15

Vaal

E6515

Fans & Air Handling

18-Mar-15

19-Mar-15

East Rand

A9215

Pressure Safety Valves

24-Mar-15

26-Mar-15

Durban

E9215

Pressure Safety Valves

31-Mar-15

2-Apr-15

East Rand

C9215

Pressure Safety Valves

7-Apr-15

9-Apr-15

Cape Town

B6515

Fans & Air Handling

8-Apr-15

9-Apr-15

Port Elizabeth

A4415

Shutdown & Turnaround Management & Planning

14-Apr-15

16-Apr-15

Durban

H7715

Value Engineering in Projects

14-Apr-15

16-Apr-15

Rivonia

D4415

Shutdown & Turnaround Management & Planning

21-Apr-15

23-Apr-15

Vaal

F6215

Technical Communication & Report Writing

22-Apr-15

23-Apr-15

Secunda

D6015

Finding Inventive Solutions to Engineering & Technical Chal- 05-May-15 lenging Problems

06-May-15

Vaal

B6215

Technical Communication & Report Writing

07-May-15

Port Elizabeth

06-May-15

F7715

Value Engineering in Projects

12-May-15

14-May-15

Secunda

A9015

Pump Design, Operation, Maintenance & Troubleshooting

12-May-15

14-May-15

Durban

C6015

Finding Inventive Solutions to Engineering & Technical Chal- 19-May-15 lenging Problems

20-May-15

Cape Town

D6215

Technical Communication & Report Writing

21-May-15

Vaal

20-May-15

B7714

Value Engineering in Projects

26-May-15

28-May-15

Port Elizabeth

E6215

Technical Communication & Report Writing

27-May-15

28-May-15

East Rand

F6015

Finding Inventive Solutions to Engineering & Technical Chal- 02-Jun-15 lenging Problems

03-Jun-15

Secunda

D7715

Value Engineering in Projects

04-Jun-15

Vaal

02-Jun-15

D2915

Practical Lubrication & Lubricants

17-Jun-15

17-Jun-15

Vaal

A6215

Technical Communication & Report Writing

17-Jun-15

18-Jun-15

Durban

D6915

Practical Lubricants & Oil Monitoring

18-Jun-15

18-Jun-15

Vaal

H6015

Finding Inventive Solutions to Engineering & Technical Chal- 23-Jun-15 lenging Problems

24-Jun-15

Rivonia

C6215

Technical Communication & Report Writing

25-Jun-15

Cape Town

24-Jun-15

F4415

Shutdown & Turnaround Management & Planning

30-Jun-15

02-Jul-15

Secunda

E2915

Practical Lubrication & Lubricants

01-Jul-15

01-Jul-15

East Rand

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Impact of co-generation on coal consumption and electrical power cost Boiler steaming rate

t/h

20

20

20

20

Boiler outlet steam pressure

barg

10

61

61

61

61

Boiler outlet steam temperature

째C

184

455

455

455

455

Coal burnt

t/h

2.21

2.70

2.70

2.70

2.70

Relative coal consumption

%

100

122

122

122

122

Process steam pressure (ex-back pressure turbine)

barg

NA

10

7.5

3

2

Net electrical output available after parasitic load

MWe

NA

1.72

1.95

2.56

2.77

Operational cost reduction

R/h

NA

783

976

1 489

1 672

Potential annual cost reduction

R million

NA

6.86

8.55

13.04

14.64

Basis: Comparative electrical power cost (typical averaged annual industrial rate) R0.85/kWh Coal cost R1400/t

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THE GRASSO V-SERIES COMPRESSORS Reduced Total Cost of Ownership •

Reduced power consumption due to improved COP

•

Increased service intervals

•

Minimum maintenance costs due to onboard Grasso Maintenance Monitor

•

Extremely low oil carry over

•

Improved cost per kW ratio

•

Simple installation of packages, no water cooling required

Maximum Reliability & Ease of Maintenance •

Proven composite material valves for increased maximum operating hours

•

O-ring seals, no scraping or polishing required

•

50% less fixing bolts all over compressor housing

•

Supplied standard with heavy duty thrust bearing

•

Continuous monitoring of discharge temperature per cylinder via Thermo Master option

GEA Refrigeration Africa (Pty) Ltd

19 Chain Avenue, Montague Gardens, 7441, RSA P.O.Box 36815, Chempet, 7442, RSA Phone: +27 21 555 9000, Fax: +27 21 551 4036 industrial@gea.com, www.gearefrigeration.co.za

GEA Refrigeration Technologies engineering for a better world

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Academic

Career Path

John Aspinall

Projects

Commentary

Achievements

IT PAYS TO KEEP THE RIGHT COMPANY Find out if you qualify to #JOINOURTABLE at www.pps.co.za

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Universal Storage Systems (SA) (Pty) Ltd www.universal-storage.co.za generalsales@universal-storage.co.za Nov/Dec 2014

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Logistics Insurance Solutions that gives you peace of mind Aon has the expertise and extensive knowledge in logistic insurance solutions to make sure your cargo has the right cover. We’ll partner with you throughout the full logistics cycle with decades of experience in freight insurance solutions.

Extensive regional Network and the Largest African Footprint.

Call 0860 453 672, or SMS* “Freight” to 31762, alternatively visit aon.co.za National office: Cheryl Beurel +27 11 944 7214 | cheryl.beurel@aon.co.za Jeffry Butt +27 11 944 7792 | jeffry.butt@aon.co.za Risk. Reinsurance. Human Resources.

#AskAon * Standard rates apply.

Aon South Africa (Pty) Ltd is an Authorised Financial Services Provider (FSP #20555).

Aon is a Principal Sponsor of Manchester United.

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Requirement

ISO 3834

EN 15085

Technical Review

Required

Required

Sub-contracting

Permitted

Permitted but welding to be contracted to an appropriately certified company according to EN 15085

Welding Personnel

Welders: to be qualified appropriately to Welders: only qualified to ISO 9606 a manufacturing code (ie, ASME IX, AWS D1.1, ISO 9606, etc.)

Coordination Team: education levels are not Coordination Team: to be qualified as IWE, specified, competence is required IWT or IWS depending on certification level or as defined by EN 15085

Inspection & Test Personnel

Welding Inspection: specific qualifications Welding Inspection: minimum qualification is are not required, competence is required IWIP/EWI Level 1 NDT: to be qualified appropriately to an NDT: to be qualified to EN 473 / ISO 9712 appropriate standard (eg, ASNT - TC-1A, ISO 9712, etc.)

Technical Requirements

To have appropriate equipment

Stipulates additional equipment on top of the bare essentials of ISO 3834

Welding Procedure Qualifications

To be qualified appropriately to a relevant code To be qualified according to ISO 15607 (ie, ASME IX, AWS D1.1, ISO 15607, etc.)

Production Planning

Required

Required

Welding Consumables

Required

Required

Inspection & Testing

Required

Required

Non-conformance & Corrective Actions Required

Required

Quality Record s

Required

Required

*The above information is a brief overview of the similarities between the two standards but is not all-encompassing

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Paste Type

% Solid Lubricants

Application

Black Pastes

60% MoS 2 and other Solid Lubricants

Assembly Thin Film Threaded Connections

White Pastes

60% White Solid Lubricants

Assembly Thin Film Threaded Connections

Metal Pastes

60% Metal Powders and other Solid Lubricants

Threaded Connections

Grease Pastes

25% Solid Lubricants

Thick Film Lubrication Life Time Lubrication

Oil Pastes

10 – 20% Solid Lubricants

Life Time Lubrication Corrosion Protection Adhesion

Metal Free Pastes 60% Black and White Solid Assembly Lubricants Threaded Connections

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MoS 2

Graphite

PTFE

Very wide temperature High thermal stability Max service temperature range -180 °C up to 450°C up to 600°C of 260°C Under vacuum up to 1100°C

Good lubrication in presence of humidity

Limited load carrying capacity

Very high load carrying Poor adhesion on metal surfaces capacity Up to 3000 N/mm²

Low µ at low loads

Very good adhesion on High conductivity metal surfaces

Low conductivity

Good against fretting

Poor efficiency at vacuum Translucent/ white

Needs running-in (high Good chemical stability loads)

Non-coatable

Humidity sensitive (µ increase)

Black

Good lubrication at vacuum

Very low conductivity

Works synergistically with MoS 2

White / whitish

Good resistant against Black radiation and chemicals Good lubrication in the presence of oxygen Black

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25 Âľm

Advantage

Disadvantage

Spraying

good appearance even film overspray exhaust cabinet thickness

Dipping

good appearance even film bath control stiring equipment thickness

Dip-spinning

bulk goods economic

poor appearance two layers, bath control

Printing

exact design economic

special coatings (viscosity, evaporation)

Coil coating

outside treatment economic big quantities (m 2)

expensive equipment lot of space needed

Figure 6. Several typical anti friction coating applications

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Conference & Exhibition 15–17 July 2015 Cape Town International Convention Centre, Cape Town, Republic of South Africa www.powergenafrica.com | www.distributechafrica.com

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Host Utility:

Presented by:

THE SOUTH AFRICAN MECHANICAL ENGINEER

Supported by:

VOL 64

Nov/Dec 2014

Supporting Association:

POWER

GENERATION

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T O D A Y

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On a larger scale this means that a water treatment plant can now not only generate electricity for its own consumption, but even feed the surplus into the grid or to the grid of a small community in the area

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Solar is used for converting the digester’s energy into a renewable fuel like biogas

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Tim Abbott

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Abrie Schutte

The pumps produce a fixed flow through the system because variable flow was not possible during the design of these systems. Excess water is back-passed and temperature is used as a safety barrier

Figure 1: Typical system layout

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Figure 2: Temperature safety barrier

Figure 3: Energy saving strategy

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Figure 4: Pre-cooling tower dam level

Figure 5: BAC water supply

The specialist also noted that the reduced flow would increase the amount of fouling as a high flow helped deter fouling

Boundary condition

Before

After

Units

Ambient enthalpy

38.7

37.0

kJ/kg

Outlet water temperature

3.0

3.0

o

Flow to underground

230

230

â„“/s

Ventilation air outlet temperature* (WB)

5.0

7.0

o

C C

*The temperature with control is still within mine specifications.

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Figure 6: Condenser tubes showing scaling and fouling

An average demand saving of 1.8 MW was achieved with a case study

Figure 7: Project implementation layout

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Figure 8: Baseline vs. case study power usage

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MEET THE FAMILY

The combination and interaction of the four strategies with installation of new equipment such as VSDs and other instrumentation resulted in an energy efficiency project Strategy

Pumping power saving [kW]

Refrigeration machine power saving [kW]

Total power saving [kW]

Pre-cooling

119

169

288

BAC

122

556

679

Evaporator

347

104

450

Condenser

266

154

420

Total

1837

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Table 2: Summary of case study results

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THE SOUTH AFRICAN MECHANICAL ENGINEER 22364 Linde Supply Chain (267mm x 90mm).indd 1

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2014/05/15 12:24 PM

MARKET FORUM

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MARKET FORUM

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MARKET FORUM

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MARKET FORUM

Eamonn Parker

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Increased Strength - reduced cost.

It doesn’t get any better.

Contact details: Cape Town tel: 021 701 4814 Johannesburg tel: 011 708 0222 www.racklock.co.za THE SOUTH AFRICAN MECHANICAL ENGINEER

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