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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THE SOUTH AFRICAN MECHANICAL ENGINEER
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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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Nov/Dec 2014
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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.
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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:
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Supported by:
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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
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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