SA Mechanical Engineer Nov/Dec 2018 by Promech Publishing

S MECHANICAL A ENGINEER Nov/Dec 2018

Publication of the SA Institution of Mechanical Engineering, incorporating News of Associate Organisations

Piecing together your success.

12415/E

We understand that youâ&#x20AC;&#x2122;ve been building your career piece by piece, and that all those hours, projects and plans allow you to live the lifestyle you deserve. Partner with PPS, and let us help you ensure your success is more than the sum of its parts. Proud sponsor of the SAICE Young Engineer of the Year. Visit pps.co.za to find out more about our financial solutions for graduate professionals. PPS is an authorised Financial Services Provider.

AN ENGINEERâ&#x20AC;&#x2122;S VIEW

Understanding Mediation, Adjudication, Arbitration and Litigation

any of you have watched the TV broadcasts of the Zondo Commission into state capture. The terms of reference of this inquisitorial inquiry are to determine the facts regarding accountability for what had occurred and probable reasons why. The rules of procedure adopted by this Commission relate more closely to Conciliation, Mediation, and certain Adjudication dispute resolution processes. Arbitration and Litigation procedures follow a different legal process ending with an imposed enforceable finding to settle the matter. Civil litigation is a function of our Courts in resolving disputes and enforcement of a binding solution regarding the substantive rights and duties of the parties. Court decisions and procedures are subject to considerable legal constraints, rights and precedents. The private nature of an arbitration agreement is essentially contractual, therefore failure on the part of one party to comply with this particular contract provision carries the same penalty as any other major breach of contract. The circumstances for appealing an arbitration agreement are highly restricted. The successful party can easily obtain a court order for enforcement.

Significant advantage

12415/E

The settlement of engineering and construction disputes by means of arbitration confers a significant advantage over litigation proceedings, as the choice of arbitrator can be based on technical knowledge of the type of work associated with the dispute. Obviously this of particular importance and interest to all engineers involved in projects and design contracts. If the court appointed presiding officer cannot comprehend the engineering complexity then a just and equitable decision is unlikely. An additional advantage of arbitration over litigation is that the process is private and away from adverse publicity. The participants also have the mutual convenience of arranging the dates, venue and times for submissions and hearings that suit themselves. The other remedies for resolving disputes are nonstatutory, which means their form and procedure

is not prescribed by law, and the Graeme Lloyd outcome is also not legally enforceable, unless agreed in the rules of conduct. Because these processes rely on both parties negotiating in good faith, there is always the possibility that they could be a preliminary dress rehearsal for arbitration proceedings.

Willingness

Mediation can only succeed if both participants are genuinely willing to agree upon the terms of settlement. Their joint objective must be to strive to reach a win-win rather than lose-lose scenario. The chosen mediator is not expected or mandated to recommend or propose a settlement solution. The mediatorâ&#x20AC;&#x2122;s core responsibility is to act as an intermediary, seeking to narrow the field of controversy by facilitating dialogue and understanding between the parties. In our country, in the context of CCMA decisions, a conciliator is expected to propose a solution to the dispute.

Because these processes rely on both parties negotiating in good faith, there is always the possibility that they could be a preliminary dress rehearsal for arbitration proceedings

Successful adjudication depends upon selecting an adjudicator who is fluent in the language of the contract. It is also essential that the participants agree on the adjudication rules of procedure and binding outcome. Legal representation is normally excluded. The format and content of the documentation submitted to the adjudicator is a vital ingredient for discussion at the preliminary meeting of the parties. An adjudicator plays a more active and interventionist role in the proceedings compared with an arbitrator. Graeme Lloyd Email: Graeme.Lloyd@blast.co.za Fellow SAIMechE. FAArb (SA)

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

The future of mining

Quality. Innovation. Efficiency. Gear units and motors from SEW-EURODRIVE have always set the trend and established new standards in drive technology. For this reason, the quality label â&#x20AC;&#x153;made by SEWâ&#x20AC;? has become a hallmark of quality in the drive industry. Market-orientated products developed and manufactured in-house, as well as uncompromising quality, are the cornerstones of our success. SEW-EURODRIVE - Driving the world Tel: +27 11 248 7000 Email: info@sew.co.za Web: www.sew-eurodrive.co.za

S MECHANICAL A ENGINEER Nov/Dec 2018

Publication of the SA Institution of Mechanical Engineering, incorporating News of Associate Organisations

S MECHANICAL A ENGINEER VOLUME 68

November/December 2018

Contents On the Cover Combustion Technology Tel: 021 715 3171 info@combustiontechnology.co.za www.combustiontechnology.co.za

Cover Story

Solar Challenge

26 Eight-day Road Trip

Boiler Energy Efficiency

Power Transmission

Power Generation

10 We Will Be Hungry Tomorrow

29 Integrated Solutions

SA Institute of Tribology

Telematics

13 Standard and Safety Data Sheet Requirements

33 Filling Stations and Forecourts

Sustainable Solar Energy

35 Focus: Maintaining HVAC Systems

SARACCA

16 Film Over Reservoir

Compressed Air

Regulars

19 To Customers Needs

Pumps 20 Reduces Energy Consumption by 50 Percent 22 Forward Thinking Municipality Pumps

3 7 38 46

An Engineer’s View Institution News Market Forum On the Move

All rights reserved. No editorial matter published in “SA Mechanical Engineer” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields. Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 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 Editorial Contributors Liesl Venter/Patricia Holburn Advertising Sales: Louise Cresswell Cell: 071 886 1263 DTP: Anne Rotteglia Circulation: Belinda Siegruhn Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/ Overseas. Disclaimer

Ofﬁcial Publication of THE SA INSTITUTION OF MECHANICAL ENGINEERING and endorsed by:   

      

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

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

 



CONSULTING ENGINEERS OF SA CORROSION INSTITUTE OF SA INSTITUTE FOR CERTIFICATED MECHANICAL AND ELECTRICAL ENGINEERS NATIONAL SOCIETY OF BLACK ENGINEERS NUCLEAR INSTITUTE SA ASSOCIATION FOR ENERGY EFFICIENCY SA CAPITAL EQUIPMENT EXPORT COUNCIL SA INSTITUTE FOR NON-DESTRUCTIVE TESTING SA INSTITUTE OF TRIBOLOGY SA PLASTIC PIPE MANUFACTURERS ASSOCIATION SA PUMP MANUFACTURERS ASSOCIATION SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION VALVE & ACTUATOR MANUFACTURERS CLUSTER OF South Africa

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

Your boutique business destination Surrounded by lush gardens in the hub of Johannesburgâ&#x20AC;&#x2122;s northern suburbs, The Peartree in Craighall Park caters for groups of two through to 100 guests in nine well-appointed and equipped business suites. Breakfast meetings, working lunches, indoor or outdoor dining, half-day and full-day packages including all welcome refreshments, teas and lunches are offered in Standard, Gold and Platinum packages. Secure parking, business centre, fibre optic broadband AV, lockable space, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.

www.thepeartree.co.za e-mail: info@thepeartree.co.za Tel: 011 781 1401 41 St. Albans Ave, Craighall Park

SA INSTITUTION OF MECHANICAL ENGINEERING

Council 2016 - 2018

Company Affiliates

Office Bearers President.....................................................Prof D Blaine (Debby) Vice President ...................................... H Makwarela (Hangwani) National Treasurer............................Prof JL van Niekerk (Wikus)

Branch Chairpersons

Central .............................................................. A Celliers (Alicia) Eastern Cape .......................................... G van den Berg (Gideon) KwaZulu-Natal ....................................... Dr J Padayachee (Jared) Mpumalanga Highveld ....................................N Lecordier (Noel) Vaal ............................................................. N Swanepoel (Niekie) Western Cape .............................................. Dr M Venter (Martin)

Portfolios:

Communications and Marketing .................G Bartholomew (Bart) Technology Programme and Procedures........... SZ Hrabar (Steve) TBC...........................................................MAE Black (Malcolm) TBC.............................................................G Bartholomew (Bart) Chief Executive Officer..................... Vaughan Rimbault National Office Manager................ Anisa Nanabhay PO Box 511, Bruma, 2026 Tel: (011) 615-5660 Email: info@saimeche.org.za Website: www.saimeche.org.za Membership Email: membership@saimeche.org.za

Amoricom

MBE Minerals (SA) (Pty) Ltd

Autodesk as represented by Worldsview Technologies

Megchem

Ainsworth Engineering (Pty) Ltd

Osborn Engineered Products SA (Pty) Ltd

Mod-U-Flow CC

Alstom Power Service SA (Pty) Ltd

Plant Design & Project Services (Pty) Limited (PDPS)

Babcock Ntuthuko Engineering Pty Ltd

PPS Insurance Co Limited Proconics (Pty Ltd)

Bosch Projects Pty Ltd

Redheads Engineering Services (Pty Ltd)

Eskom Rotek Industries SOC Ltd

S.A.M.E Water (Pty) Ltd

Esteq Group (Pty) Ltd

SA Power Services (Pty) Ltd

Exxaro Resources (Pty) Ltd

Sasol Technology (Pty) Ltd

Festo (Pty) Ltd

Siemens (Pty) Ltd

Fluor SA (Pty) Ltd

Simera Technology (Pty) Ltd

Kelvion Systems (Pty) Ltd

Spirax Sarco (Pty) Ltd

Green Plan Consultants (Pty) Ltd

Tenova Mining and Minerals SA

Hatch Africa (Pty) Ltd

Thyssenkrupp Engineering (Pty) Ltd

Howden Power (a div of Howden Africa)

Vital Engineering (Pty) Ltd

Howden Projects (a div of James Howden)

Weir Minerals Africa

Message from the CEO - IDoEW Status The long outstanding issue of the Identification of Engineering Work (IDoEW) was raised in an article of the October 2018 bulletin from the Council for the Built Environment (CBE).

he article summarised progress on this issue to date and also identified the major stumbling blocks in the process. The article also highlighted the urgency of properly identifying the work reserved for registered professionals and invited submissions on the topic in an effort to restart the process. While SAIMechE has not received a formal invitation to engage on the IDoEW, we should certainly bring this issue once again to the fore and revisit our position. We have posted a summary of the article on the News section of our website. Comments from interested members would be welcome there.

ECSA Engineering Awards

The Engineering Council of South Africa (ECSA) hosted their inaugural Engineering Awards banquet on 1 November 2018. This glittering gala event recognised the contribution of the engineering profession in the accreditation of qualifications and registration of professionals. The awards highlighted the significant contribution of individual engineering professionals to the achievement of ECSA’s statutory mandates, and reinforced the strong connection between the engineering profession and its regulator.

SAIMechE Student Chapters

2018 has been a year of phenomenal growth in our Student membership grade, driven by the activities of student chapters, many of which were only formed this year, under the stewardship of Marietjie Jansen van Rensburg. Students are realising that their objectives are much easier to achieve if they work together in a group, and the Student Chapter is an ideal

platform for this. Students are realising that they can organise their own site visits, technical presentations, mentoring evenings and social events and are seeing the value of doing so within a Student Chapter.

Vaughan Rimbault, CEO, SaiMechE

SAIMechE Training Events

SAIMechE’s National Events Department will cease to exist in its current format at the end of November 2018, in line with the Council decision made earlier in this year. The Council decision aims to shift traditional training activities to our branches and encourage increased participation by local members and industry. At the same time, Council have recognised the need for SAIMechE to develop training activities for online and distance learning and will be focusing resources on the creation of relevant and valuable content. We would especially like to invite members to share their knowledge, experience and insight into creating online content.

Conclusion

As 2018 draws to a close, I hope that many SAIMechE members reflect positively on all those areas where they benefited as a result of their membership, and look forward to increasing that in the new year. Here’s wishing us all a safe and happy holiday season! Vaughan Rimbault, SAIMechE CEO

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

Boiler Energy Efficiency Considering the strict design codes that all boiler makers around the world have to adhere to, what really differentiates boiler manufacturers? In reality, quality, solid after-sales service, integrity and experience are a given, no matter whose door one knocks on. “SA Mechanical Engineer” caught up with Grant Renecle, managing director of Combustion Technology, to find out more.

Grant Renecle, Combustion Technology

ape-based Combustion Technology, like most of its competitors, prides itself on its modern and highly efficient solutions. Specialising in oil and gas burners and boiler installations, conversions from coal firing to natural gas firing, the company has offices in Cape Town and Johannesburg as well as an extensive dealer network servicing the rest of the country. It is the exclusive boiler distributor for Bono Energia, IVAR and Unical Boilers, Limpsfield & Riello Burners and Autoflame Combustion Management Systems. Undoubtedly, a solid choice when choosing a boiler expert, but then again so are many other companies. Combustion Technology, however, have the proverbial Ace up their sleeve. Their partner Limpsfield Engineering is the only company in the world to guarantee oxygen levels of sub 3% throughout the complete burner firing range. Grant solidly believes in this capability to such an extent that he puts his money where his mouth is. “We give a written guarantee on a whole project that if we do not meet these very specific emissions standards, we reimburse,” he says.

Carbon tax impact

While the environmental discussion has had a slower offtake in Africa than in the rest of the world, where reducing carbon emissions is a definite business imperative, the pending carbon tax is going to hit South Africa hard.

Energy efficiency has become the distinguishing factor but considering that manufacturers are only required to prove that their products conform to the maximum continuous rating (MCR), it begs the question, how many actually offer efficiency?

VOL 68

Dramatic increase

Making a good quality boiler is no longer the differentiating factor. Paging through any given brochure will show that the world’s manufacturers are all meeting the EN12953 and other codes promising efficiency of 90% plus which can be moved up a THE SOUTH AFRICAN MECHANICAL ENGINEER

notch or two with an economizer.

“This all sounds well and good but what is actually happening when you shift off that point?” Grant states. “No boiler in the world runs at MCR for any serious length of time. Delivering an efficiency of 90% plus is often just not the case.”

The premise of this move by the government is simple – to tax direct emissions associated with business activities. Practically it means any company emitting greenhouse gas will have to pay up and secondly, the cost of electricity will be higher.

Limpsfield burner

Cost is a factor and natural gas not only delivers the efficiency, but it is also cheaper overall. Grant and his team have proven this time and time again. When ABInBev embarked on an aggressive programme to reduce its carbon emissions and subsequent carbon footprint by installing two new gas fired boilers and converting two existing coal fired boilers to natural gas fired, they called on the team at Combustion Technology. The reduction in energy usage was extraordinary

November 2018

COVER STORY

while the coal boiler efficiency increased dramatically from around 70% to consistently running between 80 to 83% on natural gas. Production energy usage improved from between 175-154MJ/HI to 105-99MJ/HI on natural gas. “Coal is often chosen based on an initial cost estimation, but with gas you are not only saving in terms of emissions, but on a number of other aspects including electrical power, labour, cleaning and maintenance,” Grant highlights. “Gas, while it is more expensive per energy unit, brings an overall cost saving to a project.” With coal, at best, only using 70% of the energy compared with a gas-fired boiler where 90% energy use is guaranteed, less gas is also needed to deliver the same amount of energy. Considering the sheer cost of running a boiler plant, savings are critical. “The solution is to ensure that the boiler works at continuous levels of efficiency, throughout the boiler and burner’s firing range. The products and guarantee we offer is what differentiates us and saves our clients’ money,” Grant emphasizes. He has determined that a company wasting between 3 and 5% of energy could in essence pay for a new boiler every five years regardless of its size. “Our customers who have opted for gas-fired boilers are seeing the rands and cents savings, but more importantly, they are reducing emissions which is fast becoming a critical element in the business environment.

Downstream benefits

“The downstream benefits of having better quality steam and improved reliability in their boiler operations also results in better overall plant productiv-

Coal conversion at ABInBev Rosslyn

ity.” At face value, one could argue that if the boiler is already 90% efficient how could it effectively be improved by any more than 10% unless Grant has developed a way of making energy perhaps? “Not at all,” he says. “All of this is linked to the downstream processes of a company and making sure that the boilers adapt and are set up correctly for particular processes. It is then a matter of ensuring that emissions stay within the limits set, thereby achieving practical efficiency.”

A company wasting between 3 and 5% of energy could in essence pay for a new boiler every five years regardless of its size With gas offering very real fuel savings and considering that it stands a very good chance of being exempt from the carbon tax, it is the way of the future. “Ironically the biggest complaint about gas more often than not from companies is the price. The trick in all of this, however, is to reduce the energy consumption, reduce fuel usage by being more efficient which is exactly what we offer and which results in immediate cost reductions.”

Watchful eye

In the automated world with clever machines that no longer require people to be in the boiler house, monitoring systems can be challenging. With much trust placed in automated systems, it is easy to forget that these are just machines after all. Grant says boiler management services are critical in this modern-day environment providing much-needed monitoring which is vital to understand, in real-time, how any given boiler in a plant is performing. “Who is checking on the boiler in an operation is an important question,” he explains. “For optimum efficiency, you have to know what is going on in a boiler house 24/7. Our management systems provide the necessary data, monitoring fuel usage and emissions as well as all boiler and burner functions, water levels and temperature, and pressure for example.” Installing a management system brings further fuel bill savings to a company thanks to the ability of such a system to read O2, CO and CO2 emissions which enables the user to know immediately when fuel is being wasted but also to track where and when any problems arise. In addition, monitoring the changing ambient conditions, the varying CVs and the conditioning of fuel, are all critical factors in an efficient operation. For Grant, however, it is about more than just having the products and technology available to service customers well. It’s a commitment to deliver solutions that are real. “Energy efficiency cannot just happen on paper,” he concludes. “It has to translate into the balance sheet of the business and we guarantee to do exactly that.” Combustion Technology, Grant Renecle Tel: 021 715 3171 Email: info@combustiontechnology.co.za www.combustiontechnology.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

We WILL be Hungry Tomorrow Average is the enemy that leads you to complacency, according to Gerhard Pienaar, BI (Bearings International) Agriculture Segment product manager. Average certainly isn’t good enough in the agriculture, food and beverage industries where hygiene is essential, thus posing a unique challenge to bearing manufacturers.

ML corrosion-resistant, food-grade ball bearings offer a solution. BI is the exclusive distributor of KML bearings in Southern Africa. “SA Mechanical Engineer” set out to find out why they are uniquely suited to the food and beverage industry. Food is an essential part of life, and in the modern age, so are bearings. “Nothing we do, work or drink happens without a bearing somewhere along the line. Anything we manufacture and process involves a bearing,” Gerhard says. When you’re working in the food chain, bearings need to be efficient and affordable, and most importantly, safe in terms of hygiene.

There are many factors that can compromise food safety, but bearings that meet required standards and offer fewer opportunities for contamination go a long way towards making facilities hygienic Challenging applications

South Africa felt the effects of compromised hygiene standards in food processing factories last year when a listeriosis outbreak claimed over 180 lives. Several factories were shut down for testing and the Polokwane factory, to which the outbreak was traced, was only fully operational again at the end of October 2018. The total cost of the outbreak is estimated to be about R12 million, including the recall of all the affected products. There are many factors that can compromise food safety, but bearings that meet required standards

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

BI agriculture product manager, Gerhard Pienaar

and offer fewer opportunities for contamination go a long way towards making facilities hygienic. “Food and beverage processing machinery is the most challenging for bearing-unit performance,” Gerhard explains. “However, the KML housings more than meet the specific requirements for materials used in food and beverage equipment.” He points out that KML’s thermoplastic and stainless steel mounted food-processing bearings have been designed specifically to deal with frequent washing, contaminants, exposure to cleaning agents and constant temperature changes.

Smooth surfaces

A distinguishing feature of these bearings is their smooth surfaces on both the stainless steel and thermoplastic bearing housing units. The 2-bolt, 4-bolt and offset flange housings have solid back faces and the housings include stainless steel sleeves for fixing bolts and stainless steel grease fittings. Units also feature the KML Poly-Guard multiple stage sealing system that virtually eliminates cavities. Smooth surfaces make the units easy to clean,

November 2018

and with fewer cavities there are fewer places where debris can collect. Special features of the bearings include their ability to reduce the number of interfaces by integrating functions and a compact design. They are lubricated throughout their lifespan so require no maintenance. The stainless steel mounted units are made from 304 fine grain stainless steel and the US FDA approved antimicrobial thermoplastic mounted units feature reinforced PBT (polybutylene terephthalate) that contains 10% long stand glass fibre for strength. The thermoplastic units can operate at temperatures up to 141 degrees Celsius. Corrosion resistant 440C grade stainless steel is used in all wear surfaces. The bearings are filled with Mobil FM222 food grade grease, which is approved for use in HACCP compliant facilities. The low maintenance, food-grade components make for an affordable, long lasting bearing, which means a safer factory and lower maintenance costs.

Agriculture in the spotlight

While the product is not new to Bearings International, putting it in the spotlight ties in with the company’s focus on the agriculture sector. “We identified the potential in agriculture, which includes food and beverage processing and manufacturing, a few years ago and are giving the sector special attention. It’s a bare field for us to explore and we are looking for ways to add value,” Gerhard tells us. The KML range adds real value by offering a solution to one of biggest problems facing the agriculture market today. Importantly, the range is extremely competitively priced while still meeting the required standards. “The quality of the product is what our customers remember the most about KML,” claims Gerhard. With a love and passion for work in the agriculture market segment, coupled with work experience in IT, tractors and animal feed, he is uniquely qualified to offer solutions for agriculture applications. “I really enjoy working with the sector which, unlike some others, is always there and a part of our life. We’ll always be hungry tomorrow.”

No standstill

This year in South Africa, the matter of land without expropriation has been top of mind which some believe has led to a complete halt in the industry. Gerhard explains that this is not the truth. While there is a lack of large scale new investments, the industry is not at a standstill. Food production and processing continues, and there are customers who

are looking for solutions to their problems. This is what Bearings International is focusing on. “We want to talk to our customers and really get closer to them so we know their needs and can fulfil them. I believe we need to talk to each other because the customer doesn’t need my product, they need a problem solved. Bearings International is a solutions partner.”

We identified the potential in agriculture, which includes food and beverage processing and manufacturing, a few years ago and are giving the sector special attention He highlights that one way to achieve this is to ask questions. “Perhaps sometimes we don’t ask our customers the right question, we want to sell the product we have instead of asking about their needs. “And needs there are aplenty. South Africa has a large population and a lot of potential. The future is bright in the agri sector. We are sitting at the best place we’ve been for the last three years, the maize price is going up and the drought has passed,” Gerhard concludes. And yes, we will be hungry tomorrow. BI (Bearings International) Gerhard Pienaar Tel: (011) 899-0000 Email: gerhardp@bearings.co.za www.bearings.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

The Local Manufacturing Expo Aims to:

21 – 23 MAY 2019

Promote local manufacturing

EXPO CENTRE, NASREC,

Demonstrate Southern Africa’s export potential

JOHANNESBURG, SOUTH AFRICA

Provide access to global markets

A Showcase of Southern Africa’s Manufacturing Capabilities Who Will Exhibit?

Networking opportunities Develop public / private partnerships Public / private sector collaborations Identify industry challenges and opportunities for growth

Manufacturers across a variety of sectors, including:

Agriprocessing

Automotive

Business Process Outsourcing

Capital Equipment

Chemicals

Construction

Engineering

Food and Beverage

Furniture

ICT and Electronics

Metals

Mining

Plastics

Textiles/ Clothing/ Footwear

Transport

www.localmanufacturingexpo.co.za In association with:

Endorsed by:

THE SOUTH AFRICAN MECHANICAL ENGINEER

Implemented by:

VOL 68

Brought to you by:

November 2018

wth

SA INSTITUTE OF TRIBOLOGY

The Global Harmonised Standard (GHS) and Safety Data Sheet (SDS) requirements for South Africa The UN GHS (Global Harmonised Standard) was developed as a result of the international mandate provided by the 1992 United Nations Conference on Environment and Development (UNCED) and as reflected in AGENDA 21 paragraph 19.27: “A global harmonised hazard classification and compatible labelling system, including material safety data sheets and easily understandable symbols should be available and feasible by year 2000”.

he work was further coordinated and managed by the IOMC (Interorganizational Programme for the Sound Management of Chemicals) and the completed and handed over to the GHS Sub Committee which was established in 1999. The UN GHS sub-committee is responsible for maintaining the GHS. The document (The UN Purple Book) is regularly revised - the first version for global implementation was approved in December 2002 and published in 2003. The Purple book is updated every 2 years and the current version is Version 7 published in 2017. Refer to www.unece.org for updates and further information The UN GHS Purple Book provides for the following: • Defines the layout of a UN GHS Safety Data Sheet (SDS) and content requirements; • Allows for countries to adopt their own rules/regulations within the UN GHS framework; • Defines the level and categories for physical, health and environmental hazards; • Applies agreed criteria to classification and labelling of chemical • Defines communication tools: Safety Data Sheet (SDS) and Labels

The purpose of the GHS: • To enhance the protection of human health and the environment; • To provide an international recognised standard for the classification and labelling of chemicals; • To provide a recognised framework for countries that do not have a system to implement;

South Africa

At what stage is the implementation of the GHS in South Africa? • The National Road Traffic Act 93 of 1996 (Chapter VIII – Dangerous Goods) and SANS 10232-4:2018 (TEC cards)(Transport Emergency Card) requires the TEC to be compiled from an SDS that is compliant with SANS 10234 (UN GHS) and SANS 11014; • SANS 10234: 2008: Labelling and Classification of Chemicals requires classification and labelling of chemicals and mixtures/products that classify hazardous as per SANS 10234 up to the point of “intentional intake” i.e. SANS 10234 is not applicable beyond “Intentional intake” for pharmaceuticals, cosmetics, stock remedies, food additives and residue pesticides in food. Besides these products, SANS 10234 is applied to all other hazardous substances and products throughout their life cycle i.e. manufacturing, handling, storage, transport and use (e.g. labelling of consumer products). SANS 10234:2008 is based on the UN GHS Purple Book. • The Hazardous Substances Bill proposes certain controls of all chemical substances or mixtures that classify as per SANS 10234; • The OHSACT Act 55 of 1993 (Hazardous Chemical Regulations) Section 9A requires an SDS to be compiled according to SANS 11014 and the GHS (i.e. SANS 10234 in South Africa) • Draft Regulations for “Hazardous Chemical Agents” – OHSACT Act 55 of 1993 released for comment 14 Sep 2018 providing regulations for implementation of the GHS at the workplace and the requirement to conform to the latest version of GHS Purple Book • Important to note that the definition of a supplier in terms of SANS 11014 (and referenced in the OHSACT) is defined as: “Party responsible for making a chemical product available to a recipient”

• To reduce the need for testing of chemicals;

• The OHSACT requires that a “Supplier” must provide an SDS that contains information on all the known hazards or potential hazards associated with the product and the Supplier Information must be made available on the SDS.

• To promote global trade through a uniform classification and labelling standard

• The OHSACT and Regulations require that the employer must ensure that the exposure of

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

ELECTRA MINING 2018

SA INSTITUTE OF TRIBOLOGY

an employee to a hazardous chemical substance (HCS) is either prevented or where not practicable, minimised through adequate control measures and by introducing appropriate work procedures which the employee must follow. This cannot be achieved unless the detailed information of the hazards associated with the product are available through the SDS • Waste: NEM:Waste Act (Act 59 of 2008) has implemented the GHS for waste through the classification regulations 2013 by including SANS 10234. This means that ALL waste except for Medical Waste that classifies hazardous as per SANS 10234 must carry a representative Safety Data Sheet (SDS) and label as per its classifications – i.e. if a waste is a mixture, the concentration of the components must be determined and used for the classification; • South Africa as signatory to Global Treaties that serve to protect human health and the environment against the adverse effects of hazardous chemicals - Stockholm and Rotterdam conventions;

• ISO 11014: Any SDS drawn up in accordance with SANS 10234 must meet SANS 11014 requirements; • An SDS of a product must represent the chemical product as a whole i.e. must be relevant to ether the substance or the mixture i.e. exact components and % content and the chemical product must be classified as per the GHS classification rules. Once the classification is known, the SDS is compiled according to the classification • NOTE: Each country or region (e.g. the EU) have their own SDS and GHS classification requirements based on the UN Purple Book GHS requirements – the SDS must be in the format as prescribed by the country – i.e. in South Africa it must comply with SANS 10234 and UN GHS Purple Book. In the EU it must comply with the CLP regulation ((EC) No 1272/2008), in the US the SDS must comply with HAZCOM 2012 Regulations. Belinda Berry Lisam South Africa for the SAIT

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

SUSTAINABLE SOLAR ENERGY

Film over Reservoir Continental has installed the first floating solar cover in Cyprus, thereby reliably protecting all the water collected in a reservoir in the Limassol region against evaporation and unwanted contamination. At the same time, the photovoltaic modules integrated in the special film generate electricity from sustainable solar energy. This is used to power systems that pump the water.

here is a huge demand on our planet for off-grid water and power supplies, especially in arid regions. Innovations such as this generate more agricultural products cost-effectively,” explains Hans-Jürgen Duensing, who is responsible for the ContiTech division on Continental’s Executive Board.

“This is the first system to combine an effective means of water protection with climate-protecting energy generation. The floating solar film compensates in a straightforward manner for the water scarcity and lack of power and ensures lower algae growth in the water thanks to the film’s decadeslong resistance to UV light,” says Hans-Jürgen.

The film used is a three-ply, semi-flexible laminate made of PVC that is strong enough to allow people to walk on it and features decades-long resistance to UV light

The water reservoir has an area of 6 500 square metres, is 4.50 metres deep and has been completely covered with the functional film. The first stage of the project in March involved applying 80 photovoltaic modules with a power rating of 20kWp to the film. Around 700 more elements will follow in a second phase. The film used is a three-ply, semi-flexible laminate made of PVC that is strong enough to allow people to walk on it and features decades-long resistance to UV light.

The innovative solar film enables water to be transported to remote regions via self-sufficient pumping stations and reservoirs. An additional advantage is that areas without any appreciable access to other energy sources can ensure the autonomous supply of solar energy.

PISTON SEALS

Water reservoir has an area of 6 500 square metres, is 4.50 meters deep and has been completely covered with a functional film. The photovoltaic modules integrated on the special film generate electricity from sustainable solar energy, for example for systems used to pump the water.

There are also immersion pumps from Germany installed on the reservoir that are capable of pumping away any rainwater on the surface.

Several decades

The product is easy to install, thanks to the high degree of prefabrication. A digger is all that is needed to excavate the reservoirs. There is no need for costly concreting and large construction sites. The sheets are up to 1.80m wide and are easily positioned and joined to each other. It is possible to walk on the tear-resistant films, so maintenance work is easy to perform. Wind and sand have little effect on the flat modules. The system has a lifetime

of several decades. Discrete floating solar units offer little or no cover for the water. Such systems are also used to cover water reservoirs near airports. â&#x20AC;&#x153;Flocks of birds that rest on the usually artificial ponds would therefore not impede nearby flight operations,â&#x20AC;? addsHans-JĂźrgen. Furthermore, the quality of the stored water is improved, since algae growth is prevented. As a result, algae does not clog screens or filters. In addition, any potential odour nuisance is avoided since fermentation or digestion processes can no longer occur. www.contitech.co.za

THESE BRANDS SUPPORT RESPONSIBLE RECYCLING OF USED OIL

Support brands that care for the environment Use ROSE approved collectors and recyclers to dispose of your used oil. 021 448 7492 • usedoil@iafrica.com • www.rosefoundation.org.za

COMPRESSED AIR

To the Customer’s Needs Drill to deeper depths while using less fuel on average with the groundbreaking dualpressure PG 1200S350 ELGi compressor from IAS

ntegrated Air Solutions, an industry power house in the supply of turnkey air compressor solutions and services, is one of only a few OEM companies with the ability to locally customise compressors to OEM warranty. The Air Solutions team have decades of experience in providing individually tailored high-pressure ELGi compressor packages to the water production, construction, mining, drilling, forestry and general industry sectors in the Sub Sahara African region. When the company secured the sole regional distribution rights for the globally renowned ELGi compressor brand in October 2016, it became apparent that the existing premises could no longer house the fast growing business and the company relocated to a larger facility in Boksburg, Gauteng.

This new kid on the block is the answer to improved efficiency and productivity “In order to maintain our customer-centric approach and our reputation, we needed premises that would complement our premium compressor brand,” explains Integrated Air Solutions CEO, Graham Russell.

Tried and tested

The comprehensive ELGi compressor range comprises of both electric oil-lubricated and oil-free rotary screw machines, high-pressure diesel-driven as well as centrifugal and portable air compressors. Tried and tested over two decades, the range has shown itself to be perfectly suited to Southern Africa’s rugged environment. In fact there are over 300 ELGi high-pressure diesel-driven compressors operating within the sub-Saharan region, the majority of which, notes Russell, are operational in South Africa. Key applications for ELGi’s high pressure diesel-driven

compressors include water well, exploration, post hole, down-the-hole (DTH) and auger drilling. Russell and his team are excited about the recent introduction of the new ground-breaking PG 1200350 compressor. “This new kid on the block is the answer to improved efficiency and productivity and reduced operating costs, critical factors both in determining the sustainability of any business. This dual-pressure machine enables the end-user to drill to deeper depths while using less fuel on average.” According to Russell, they have seen a notable increase in the demand for highly customised compressors, adapted specifically to the customer’s individual need. “We are perfectly positioned to meet this demand given our capability to locally customise under OEM approval, combined with ELGi’s compact skid-mounted 475 to 1500 cfm high-pressure diesel compressor range which is ideally suited to this application.”

Customisation

Russell cites some current successful customisation projects. “We replaced the counter-weight at the rear of a JCB excavator modified for blast hole drilling application with a customised ELGi 900cfm 14 bar diesel compressor which was shortened to under 3,2m. We also fabricated the custom sub-frame compressor housing, adding Fogmaker high-pressure water-mist fire suppression to both the excavator and compressor.” With service quality deemed as important as product quality, the company offers a comprehensive service package to support its air compressor solutions. Alongside installation and commissioning, services extend to the testing of large electric machines, the rebuilding of air-end by specialised air-end technicians as well as air audit capabilities. Air Solutions Tel: (011) 894-2906 www.air-solutions.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

PUMPS

Reduces energy consumption by 50 percent

The functions and properties of glass are becoming increasingly diverse and smarter. The demands placed on glass production systems are also increasing accordingly. This not least includes vacuum technology, which forms a central component in the production and processing of glass products. For example, the evacuation of glass moulds, the coating of architectural glass or bottling under vacuum ensures high product quality and process productivity.

n addition, vacuum lifters guarantee the safe internal transport of heavy and sensitive glass parts. Atlas Copco presented its new variable speed drive vacuum pump series GHS 38005400 VSD+ at the Glasstec Expo in DĂźsseldorf precisely for such applications with a high vacuum requirement.

The series is a durable plug-and-play system in a single housing. â&#x20AC;&#x153;The energy efficient units deliver higher volume flows per hour and kilowatt power consumption than vacuum pumps with comparable

With the introduction of these new screw vacuum pumps, the company underlines its commitment to sustainable glass production. In December 2017, the vacuum supplier therefore expanded its portfolio with the modern GHS 3800-5400 VSD+ vacuum pump series. Thanks to their long service life and greatly improved oil cooling and retention, these robust pumps contribute to savings in production processes. Compared with existing technologies, their use has resulted in significantly reduced life cycle costs.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

PUMPS Efficient, variable speed drive GHS VSD+ vacuum pumps are available for intake flows up to 5004 m 3/h. They support central vacuum supply systems

In addition, suction filters and oil separators can be replaced without dismantling the piping.”

performance,” explains Christoph Angenendt, of Atlas Copco. It therefore makes particular sense to convert several decentralised pumps to a central vacuum supply. “With a GHS VSD+ system, users can significantly increase their productivity. Energy savings of up to 50 percent can be achieved in glass production compared with conventional rotary vane vacuum pumps. The payback time for a converted system is correspondingly short,” Christoph points out.

Cleaner, cooler environment

The screw element at the heart of the pumps offers a lifetime guarantee, while intelligent turbo and humid versions ensure trouble-free performance even in the most difficult application environments. The coarse vacuum pumps are optionally equipped with air or water cooling. An energy recovery option makes it possible to use the work of the IE3 high-efficiency motor. A clear advantage in ergonomics: the oil retention improves the quality of the exhaust air compared with alternative technologies. “This results in a cleaner and cooler working environment,” Christoph explains

Via Smartlink software, the operator can dial in and remain up to date on necessary maintenance work. The system displays all relevant information on an intuitively understandable, graphical user interface. The operating vacuum can be adjusted or changed by pressing a key. This allows users to easily adapt the pump’s erformance to the respective process requirements.

There are no rotary vanes that need to be replaced, and the screw element is also maintenance-free for years Remote monitoring

While the Elektronikon Mk5 system allows integration into the user’s plant management system, Atlas Copco’s Smartlink provides the ideal solution for remote monitoring. It simplifies maintenance and the provision of data also for service technicians to adjust operating settings in real time. Equipped with customer-oriented plug & play design principles and a compact design, the series is quick and easy to install. All necessary components are supplied to the users as a complete package. Trained Atlas Copco engineers are available to ensure smooth commissioning.

Low maintenance requirements

The Elektronikon Mk5 control system and the speed-controlled drive system (VSD+) make pump operation extremely economical. The pressure setpoint control function ensures that the pumps deliver the lowest possible vacuum flow to maintain the required vacuum. This minimises energy consumption and reduces operating costs over the lifecycle. The low maintenance required by the series also contributes to efficiency. “No rotary vanes need to be replaced, and the screw element is also maintenance-free for years.

To learn more about the new GHS 3800-5400 VSD+ range of oilsealed screw vacuum pumps, please visit our website www.atlascopco.com/vacuum If you have any questions, please contact our team at Glasstec in Düsseldorf, Christoph Angenendt Communications Manager Industrial Vacuum Division +49 (0)172 29 650 75, Christoph.Angenendt@de.atlascopco.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

PUMPS

Forward-thinking Municipality Pumps tion (PaT) effectively brings online one of the largest such project of its kind in South Africa, able to generate 57 kW (all mechanical and electrical efficiencies taken into account) with three turbines, which is enough to power the entire region’s water infrastructure of treatment plants, pumphouses, offices and other infrastructure for an entire year. “The water comes from the City of Cape Town Wemmershoek Dam and is gravity-fed to our city regions via our main reservoir. For one month of the year during the driest month the pumps need to be switched on to pump 400 litres per second upstream to Paarl whereafter the pumps would usually be switched off.

technical team serving the requirements of the Drakenstein Municipality in the Western Cape has designed one of the country’s largest pump and turbine stations to be used for water reticulation to the nearby town of Paarl in dry periods, and as turbines to generate electricity for the city during the remainder of the year. The City’s engineer for water operations, Hein Henning, says the city was faced with the dilemma of having to pump water to its neighbour for just one month a year. For the rest of the year the pump station would be dormant and require hundreds of thousands of Rands maintenance due to possible corrosion, perishing, lubrication and bearing damage to the idle infrastructure.

The higher elevation of the reservoir allows us to rotate the pumps backwards to act as small turbines for the rest of the year which is able to generate electricity at more than an 80% efficiency Instead, the progressive municipality chose to innovate and rather generate an income while simultaneously reducing the requirement for maintenance by effectively allowing the pumps to run backwards against the pressure of water from its elevated Leliefontein reservoir and generate electricity for the region’s electrical grid.

Generating power

The commissioning of the pump and turbine sta-

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

“However, the higher elevation of the reservoir allows us to rotate the pumps backwards to act as small turbines for the rest of the year which is able to generate electricity at more than an 80% efficiency. Unlike turbines however, the pumps are standard stock items from the supplier, KSB Pumps and Valves and do not require specialised support and servicing. What’s more, the pumps are durable enough to allow us to design the infrastructure with a 40-year lifespan.” says Hein Henning, the city’s engineer for water operations. “With this long lifespan in mind, we decided to make use of KSB pumps as we already have a number of these installed throughout our municipality and are aware of their reliability, as well as long track record of support to our municipality and many other municipalities and water utilities throughout South Africa.”

Upgraded pump station

Before commissioning the project, the municipality spelled out its requirement to replace its existing 96 litre-per-second pump station with a new one and discussed the ability to generate electricity in the off season with consulting engineers, Aurecon. Having designed and planned a solution, the main contract was awarded to Hidro -Tech systems (Pty) Ltd for mechanical and electrical work. Kiewiet Viljoen, projects director for Hidro-Tech systems (PTY) Ltd, said the primary role of the project was to develop an efficient and reliable booster pump station to ensure uninterrupted water supply to nearby Wellington. Only once that need had been fully met could the project managers consider its secondary role to generate power in off-peak season. “We therefore knew we needed a technologically savvy and reliable service provider and approached KSB Pumps and Valves to procure three KSB ETA200-40 pumps to meet and exceed the

November 2018

PUMPS

Kiewiet Viljoen, projects director for Hidro-Tech systems with Drakenstein Municipality engineer for water operations, Hein Henning, at the KSB pumps that are being used as turbines in the wet season

requirements of the tender. These not only perform brilliantly as pumps, but in turbine mode have a better than 80% efficiency even considering hydraulic and electrical losses. This speaks volumes for the overall efficiency and design of the pumps,” says Kiewiet.

Technology integration

“We are an international leader in the supply of PaT solutions and offer a wide range of pumps that are suitable for this purpose. With growing pressure on the country’s power generating infrastructure, it pays for local authorities, farmers and landowners with access to water to investigate the installation of PaT systems as a cost- effective and reliable source of electricity that is not reliant on wind or sun to drive it,” Stefano adds.

Project success

Following the commissioning of the pump station and turbines, the system has begun operating at full capacity and the Drakenstein municipality has started reaping the rewards of its forward-looking water management systems.

Electrical systems integrator, Brian Cooper, of Hidro-Tech systems, says despite the relative simplicity of the mechanical design, it does require complex integration of controls to deal with “We are pleased with the outthe hydraulic force and convert the electricity Electrical systems come and commend everybody generated into a useable form. This requires integrator, Brian Cooper involved in the project for their pump speeds to be controlled via a variable innovation and dedication to building a system that speed drive to prevent overspeed as well as convert can be used as a blueprint by other municipalities the wave produced to a pure 50hz wave form that around the country and across the globe. It has been is compatible with the city’s power grid. a brilliant project characterised by lots of challenges “Thereafter the system is designed with full PLC and innovation with the end result being the delivery control which can be managed on site via Human of a successful project. We will definitely do similar Machine Interface (HMI) or can be accessed reprojects with this team in future,” concludes Hein. motely via computer or a mobile device to give users Annett Kriel, Tel: (011) 876 5600 infinite control and monitoring of the site wherever Email: Annett.Kriel@ksb.com, www.ksbpumps.co.za and whenever required. The industrial network also provides automated control of the entire system KSB Pumps and Valves’ branches and dealer including controls of the three pumps, valves, level manager for South Africa, Francois Naude with indicators, flow meters and other parameters that are regional sales manager sub-Sahara Africa), critical to the systems efficient operation to either David Jones pump water or generate electricity. “In addition to providing seamless control of the system, it ensures redundancy in all operating conditions and provides emergency measures in the event of failure of any part of the system, including valve controls, bypassing of the system or parameter changes as required to rectify any problems incurred.”

Solution provider

KSB Pumps and Valves specialist, Stefano Testi, applauded the project, saying its success paves the way for numerous similar projects throughout the Southern African region, wherever there is a reliable supply of water at a high enough elevation to drive the PaT. “It is particularly useful in areas that would otherwise require the installation of pressure reducing valves to deal with water from high elevations, as a PaT can fulfill the same requirement while generating electricity for nearby infrastructure or communities, especially rural ones.

TRACE Inte is a globa anti-br or leading pr party risk

TRACE due diligence solutions are based on internationally accepted best practices and our experience and familiarity with the compliance needs of multinational companies. Services range from a denied parties screening to enhanced due diligence, including TRACE Certified Due Diligence.

International, Inc. globally recognized ti-bribery business organization and g provider of third risk management solutions.

SOLAR CHALLENGE

Eight-day Road Trip The Dutch Nuon Solar team has won the 2018 Sasol Solar Challenge, clocking a distance of 4,030.4 kilometres on public roads from Pretoria to Stellenbosch. Arriving in Stellenbosch on Saturday after a tough final loop, they narrowly beat the Tokai University Solar Car team, who completed 3,941.4 kilometres.

ogether, the nine teams competing this year in October drove 16,249.1 kilometres, stopping in 18 towns. Kids en route were also treated to virtual reality tours of the inside of a solar car as it travelled through the country, as well as various other science and engineeringbased games to stimulate interest.

The solar cars become travelling laboratories, demonstrating to the schools that join them at each stop exactly what practically applying those subjects can achieve The Sasol Solar Challenge is held every second year as a testament to the power of science, engineering, maths and technology. On their journey through South Africa, the solar cars become travelling laboratories, demonstrating to the schools that join them at each stop exactly what practically applying those subjects can achieve. “This was a very tough round of the Sasol Solar Challenge because we significantly reduced the

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

size solar array teams were allowed to use,” says founder and director of the event, Winstone Jordaan. “Despite the 33% reduction in space, top teams still managed 80% of the performance they achieved in previous years. This means that there has been an incredible improvement in efficiency.” The competition pushes universities, and the major technology companies that sponsor them, to develop new processes and equipment to make the efficiency needed for an eight-day road trip possible. “Regulation changes like these push teams to innovate, and we’ve seen incredible ingenuity from teams over the years,” adds Chris Selwood MA, President of the International Solar Car Federation. Coming in third with a respectable 2,642.1 km were the Solar Energy Racers from Switzerland. Their car SER-3’s cockpit cover sustained damage early on in the eight-day challenge, and the team had to repair it overnight. The group of students rallied, and still managed a comfortable 300 kilometre lead on the next car. Back on the road within several hours, they credited SA’s TUT team for inspiring them to push on.

November 2018

SOLAR CHALLENGE

AWARDS

Teams were also given special awards for their extraordinary spirit: Rookie Award: Solar Energy Racers from Switzerland African Spirit Award: Tshwane University of Technology Communication Award: High school team Sonke and the Central University of Technology Technology and innovation Award: Nuon Solar team Professionalism and Safety Award: Think Bike Environmental Award: Tokai University

No slouches

In the local battle, Tshwane University of Technology’s Sun Chaser 3 finished an impressive 2,397 kilometres, 120.7 kilometres ahead of the NorthWest University car, Phoenix. TUT’s solar team also experienced a tough first day, with their solar panel blowing off on the road to Kroonstad and having to be significantly rebuilt. NWU’s Phoenix carried the university’s new purple colours, and had an entirely unique rotating solar panel, allowing them to follow the sun as they drove through the country. High school team Sonke covered an admirable 656.9 kilometres with their first ever solar car, something which the two schools hope to repeat in coming years, given sponsorship. The kids, aged 14 to 18, built all elements of the vehicle under guidance of team manager and teacher Rob Lodge, who runs the project to demonstrate the practical side of STEM subjects, and inspire young people en route.

Virtual reality

Newcomers from the Central University of Technology and Cape Peninsula University of Technology demonstrated the spirit of never giving up, working tirelessly all eight days to troubleshoot challenges with their cars. The Bloemfontein-based CUT clocked a full 110.3 kilometres. They were also responsible for the virtual reality experience that put kids right in the driver’s seat. “We really wanted to give them the feel of being in the solar car,” says Nico Nicholson, spokesperson for the CUT team. “And the only way to really do that is with virtual reality headsets. So those students got a very special insight into what we experience every day of this epic event.” After persevering with their car until the very last, CPUT managed just more than 30 kilometres,

and both crossed the line to high praise from their fellow competitors for their incredible work ethic and determination. From Hong Kong, the sole competitor in the Sustainability class, for which charging is allowed, City University completed 175.5 kilometres. With their hyper-realistic car, Reysol, a crowd-pleasing addition to the event this year, they aim to use this experience to return in 2020 with an all improved vehicle. As title sponsor of the event for the third year, Sasol hosted the teams at an awards event in Cape Town on Sunday 30 October. Sasol also supported two of the local newcomers, CUT and Sonke. Sasol Solar Challenge, www.solarchallenge.org.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

POWER GENERATION

Integrated Solutions According to Alastair Gerrard, integrated solutions executive at Zest WEG Group, the energy sector on the continent is seeing a growing number of power-related projects funded by recognised lenders and financiers. The African Development Bank, for example, has committed to fund $12 billion for energy development in Africa over the next five years.

“

Energy investment needs to target the whole value chain, including local content and supplier development as well as local skills development and the building of manufacturing capabilities,” says Alastair.

The energy opportunities that are presented therefore require extensive analysis, in which the needs must be clearly understood, and all constraints and challenges unpacked before the most appropriate technologies are selected “This focus will lead to improved skill levels and more self-sustainable economies, which can contribute towards the projected return-on-investment in the projects themselves; the approach will also promote further investment on the continent.” He emphasises that project developers in the public and private sector therefore need to partner with companies that understand these requirements and have the capability to provide cost-effective and reliable power generation solutions.

Horses for courses

“At Zest WEG Group, we are acutely aware of the needs, challenges and dynamics of the African continent. “We are continuously looking at new and innovative ways to contribute towards the stimulation of investment in all markets, including the power generation sector.” Such innovation is particularly important in an environment where electrical infrastructure is not always available or well-maintained. These factors often preclude the development of large scale power generation projects. The energy opportunities that are presented therefore require extensive analysis, in which the needs must be clearly understood, and all constraints and challenges unpacked before the most appropriate technologies are selected. “In this context, solutions must be carefully customised to suit the need, and may require a combination of different resources to fuel a power plant, making up a hybrid power generation solution such as diesel combined with solar,” Alastair points out. “These hybrid systems then need to be supported by the right electrical infrastructure.”

A complete integrated 12,5 MW continuous diesel power generation plant in Mozambique, designed for harsh operating conditions associated with graphite mining

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

High securtiy welded mesh

Pallisade

Gates

Gate Automation

Razor wire and more ....

What is High Security Weld Mesh HIGH Security Weld Mesh is wire fused and welded at a Horizontal distance of 76.2mm and a vertical distance of 12.7mm also known as 35B/3510 where 3 denotes 3”(distance between vertical wires), 5 denotes 0.5” (distance between horizontal wires), and B or 10 denotes gauge of wire

Salient Features • Difficult to Climb: The spaces between the Horizontal wires are too narrow for fingers to have grip • Impregnable: Extremely difficult to cut with a hand cutter as the beak of a wire cutter will not be able to penetrate the horizontal wires • Excellent Replacement option to Solid Wall as: 1. More economical than a solid wall 2. Faster to install than a solid wall 3. CCTV Camera has a clear view • Further upgrade possible with electric security system • Anti-corrosive & low maintinance

Standards

• Manufactured according to BS EN 10016-2 • Wire Sizes in accordance with BS EN 10218-2 • Tolerance on Mesh Size in accordance wiht EN 10223-7 • Tolerance on Panel Size in accordance with EN 10223-4 • Welding Strength in accordance with BS EN 1461 • Zinc Coating in accordance with EN 10245-1 • Anti Corrosion in accordance with BS En 3900 E4/F4

Tensile Strength • Wire has a tensile strenght of min 550 MPA

MARK: 083 454 6488

Email: mark@palifence.co.za

www.palifence.co.za

POWER GENERATION Containerised gas generator set, complete with controls and heat recovery system, used to produce energy from treated biogas in the waste water treatment industry.

As specialists in integrated energy solutions, the Zest WEG Group can meet these requirements through the products it supplies, the equipment it manufactures and the services it provides.

Altogether

A recent project was to provide a 12,5 MW continuous power diesel generation facility, to be potentially expanded to 20 MW, to a graphite mine in Mozambique. The complete integrated solution included containerised power generators, an ‘electrical house’ (E-house) with medium voltage board and control room, with generator synchronisation and plant control system. Also provided were all the supporting ancillary systems including the fuel and oil systems, the cooling system, and the air filtration and pressurisation system. “The majority of the main power plant equipment was sourced within the Zest WEG Group,” says Alastair, “while the plant installation was also conducted by our construction company within the group.”

Skills and experience

Reflecting its diverse expertise in engaging with various energy resources, the group designed and commissioned several 380kW containerised biogas generators, complete with radiator cooling systems, synchronisation switchgear and heat recovery systems, at two different sites for a public sector customer in South Africa. This integrated solution also included step-up transformers, medium voltage integration switchgear, a containerised control room and plant A 48 MW multi-extraction condensing steam turbo auxiliary distribution generator set, with board as well as the associated auxiliary electrical installation systems, used for coof all equipment generation in the pulp supplied. and paper market

The company also developed, installed and commissioned a steam turbo generator set solution for a large KwaZulu-Natal customer, using a 48 MW multi-extraction, condensing steam turbine, complete with a 57 MVA, 11 kV two pole generator. Ancillary equipment included the condensing system, lubrication oil system, turbine control panel, generator protection and synchronisation panel and battery systems and chargers.

The group can meet these requirements through the products it supplies, the equipment it manufactures and the services it provides As part of the project, the Zest WEG Group provided a long term service contract for a five year period, and was required to guarantee 98% availability of the system throughout the warranty period. “With 38 years of experience in Africa, we have a team of qualified experts dedicated to the development of the business on the continent,” Alastair concludes. “Our footprint is a testament to our commitment. Apart from our head office and manufacturing facilities in South Africa, we have a fully-fledged branch in Ghana, registered entities in several African countries and a wide network of distributors and agents across Africa. “Our knowledge of the African environment ensures that the products we manufacture are well suited to handle the conditions that we commonly encounter.”. Zest WEG Tel: (011) 723-6000 marketing@zestweg.com www.zestweg.com

Packaging and assembly of customengineered generator set solutions underway at the manufacturing facility located in Cape Town

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

WELL DONE TO THE INNOVATORS! THE SASSDA COLUMBUS STAINLESS AWARDS 2018 Congratulations to our winners and finalist, both local and international,

OVERALL WINNER

WINNER:

JOHN ROWE

RECOGNITION:

RON HOLLANDER

WINNER: 1 ST RUNNER UP: 2 ND RUNNER UP: MERIT:

HAZLETON PUMPS DESERT WOLF CONSULTING ROCK SOLID INDUSTRIES ND ENGINEERING

WINNER: RUNNER UP: MERIT: MERIT:

ND ENGINEERING AFRICAN CRYOGENICS SOLAR PRIMEG VESSEL FAB

P R OD UC T D E VE L OP MEN T

WINNER: 1 ST RUNNER UP: 2 ND RUNNER UP: MERIT:

SENIOR FLEXONICS SA JACO PRINSLOO SATURN STAINLESS INDUSTRIES

AGRO -PROCESSI NG FOOD & BEVERAGE

WINNER: 1 S T RUNNER UP: 2 N D RUNNER UP: MERIT: MERIT:

ANDERSON ENGINEERING MPUMALANGA STAINLESS INITIATIVE FP ENGINEERING ROAR CONSTRUCTION ND ENGINEERING

WINNER:

DESERT WOLF CONSULTING

RUNNER UP:

CHAD-O-CHEF

ENVI RONMENTAL

WINNER: 1 ST RUNNER UP: 2 ND RUNNER UP: MERIT: MERIT:

INOX SYSTEMS & EASYFLEX HLAKANI ENGINEERING SOLUTIONS SENIOR FLEXONICS SA JACO PRINSLOO SPIRAL ENGINEERING

SE RVI CE S

WINNER: 1 ST RUNNER UP: 2 ND RUNNER UP:

ONE-EIGHTY-DEGREES SYAM DISTRIBUTORS CNC CLEAR CUT DEVELOPMENT

W EL D I NG

WINNER: 1 ST RUNNER UP: 2 ND RUNNER UP: MERIT: MERIT:

HLAKANI ENGINEERING SOLUTIONS ND ENGINEERING ROAR CONSTRUCTION ROAR CONSTRUCTION SENIOR FLEXONICS SA

L I F ET I M E ACH I E VE M EN T

EXP ORT ACH I E VE M EN T

D UP L EX ST AI NL E SS ST EEL

C ONSUMERW AR E, H OSP I TAL I TY & CATE RI NG

sPONSORED BY

INTERNATIONAL SOLUTIONS ENGINEERING

ND ENGINEERING

B US INE S S E X CE LLE NCE

MOS T TR ANS F OR ME D

FE R R IT IC S TAINLE S S S T E E L

ARCHITECTURE, BUILDING & CONSTRUCTION

AR T

E NGINE E R ING

MANUF ACTUR ING INNOV ATION

S TUDE NT

WINNER: 1 STS TRUNNER UP: N DRUNNER UP: 2 ND

FABRINOX P&A FABRICATORS SELLOâ&#x20AC;&#x2122;S GUTTERS

WINNER: RUNNER UP: RUNNER UP: RUNNER UP: MERIT:

SKY HILL HEAVY ENGINEERING DESERT WOLF CONSULTING HLAKANI ENGINEERING SOLUTIONS ONE-EIGHTY-DEGREES NATIONAL STAINLESS STEEL CENTRE

WINNER:

ROCK SOLID INDUSTRIES

WINNER: 1 ST RUNNER UP: 2 ND RUNNER UP: MERIT:

ANTONINI DARMON ARCHITECTS ARGOWELD STEEL STUDIO SPIRAL ENGINEER ING & NF INOX

WINNER: RUNNER UP: MERIT:

SPIRAL ENGINEERING COSTER MKOKI HAILOS CONSTRUCTION

WINNER: 1 ST RUNNER UP: 2 ND RUNNER UP: MERIT:

S T Y RI A S T A I N L ES S S T E E L F AB R I C AT I O N VIC ANDERSON ENGINEERING FP ENGINEERING

WINNER: RUNNER UP: MERIT:

ND ENGINEERING CNC CLEAR CUT DEVELOPMENT S T Y RI A S T A I N L ES S S T E E L F AB R I C AT I O N

WINNER: 1 ST RUNNER UP: 2 ND RUNNER UP:

BRIDGET ZUMA-RUBAMBURA ANJA POPARA ARNOLD NYENDWA

TELEMATICS

Filling stations and forecourts Amber Group, a Jamaican-based technology conglomerate, has launched a telematics offering called Amber Fuels. A digitised refuelling solution, it will revolutionise the way in which drivers purchase fuel at selected filling stations and forecourts worldwide.

he Amber Group have announced that they have signed an exclusive engagement with GB Energy ( Texaco) to roll out their newest innovation Amber Fuels into their fillings stations. Says Dushyant Savadia, Amber Group CEO & founder, we plan to launch Amber Fuels in a big way in all our current territories including South Africa, India and Namibia. This partnership with Texaco, one of the world’s largest brands will give consumers and fleets, a new age refuelling experience by making their visit to the fuel pump quicker and more secure, at no incremental cost.

We plan to launch Amber Fuels in a big way in all our current territories including South Africa, India and Namibia This announcement comes hot on the heels of Amber Group’s foray into the US market with one of its subsidiaries Amber Connect, striking a deal with US electronics retail giant, Best Buy Inc. Amber Fuels works with the latest Radio Frequency Identifier (RFID) technology and secure banking transaction platforms interfaced through an engaging mobile consumer application. High levels of finetuning, customisation and implementation based

on Texaco fuel stations’ existing infrastructure has been taken into consideration to ensure ultimate customer satisfaction.

A smooth experience

Much faster than traditional card reading machines, Amber Fuels’ payment process is user friendly and designed to make the users experience at the fuel pump quicker, less stressful and more secure. Customers will no longer need to swipe a credit or debit card or show an ID in order to complete their purchases. Apart from making cash/card less payments possible at fuel stations, analytics on fuel expenditure, automatic invoicing, customer friendly dashboard of its mobile application, fuel alerts and loyalty programme make for customer convenience. Amber Fuels utilises a cash/card less multichannel payment system which is designed to ensure secure transactions and a smooth payment experience for customers. It is also equipped with onsite tools to simplify the pump attendant’s responsibilities. Built to operate under extreme weather and environmental conditions, the payment devices, which will be handled by pump attendants, are ruggedly designed with state of the art peripherals as well as high security and anti-tampering standards. Amber Group www.amberfuels.com

• Secure payment platform and reduced risk of fraud • Accurate record keeping for VAT, tax submissions and claims. • Shorter waiting times at filling stations • The availability of Fuel stock levels at the station prior to arrival. • Information about amenities available at gas station: ATM, restrooms, convenience stores or a car wash. • Self-service enabled • Ability to link loyalty programme with customers. • Purchasing of LPG gas from selected stations

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

Ms Lebogang Letsoalo is a Supply Chain coach and currently a Director of Sincpoint, an organisation focused on sustainable supply chain coaching and optimisation solutions. The new merSETA Chair has 18 years experience in different facets of the supply chain fraternity, including in the energy, chemicals and mining industries. She is a former Vice-President of Supply Chain in Sasol and has held executive roles in projects development, capital procurement and other roles in Eskom, De Beers, Fluor and IBM. In 2008, Ms Letsoalo was profiled and cited in the Financial Mail as one of the top 10 most inspiring women in State-Owned Entities. She has also been nominated for the Global Business Leadership Award - International Conference on Gender & Sustainability - New York 2017. Among her qualifications are a Diploma - Purchasing; Btech Logistics; and a Masters of Business Administration. She is currently enrolled for doctoral studies. She is a Director at the Black Industrialist Group (BIG) and also the Founder and Chairperson of African Women in Supply Chain Association (AWISCA), the first and only association in southern Africa focusing on functional mentorship and coaching in supply chain to build skills and capacity in the sector. She is a member of the Advisory Committee of Universities to ensure alignment between industry requirements and Supply Chain curricula offered by universities. Ms Letsoalo provides supervision for MBA and MBL students at UNISA.

The merSETA welcomes its new chairperson, Ms Lebogang Letsoalo WE CARE

It’s about caring for people we render services to

w www.merseta.org.za

WE BELONG

It’s about working together with colleagues

merSETA Social

WE SERVE

It’s about going beyond the call of duty

@mersetasocial

LEADERS IN CLOSING THE SKILLS GAP

SARACCA

Focus: Maintaining HVAC systems

nnually, heating and cooling systems in residential and commercial buildings keep the interior temperature even. However, users seldom realise how the wear and tear on a heating and cooling system can mount up over time. Ideally, a heating, ventilation and air conditioning (HVAC) system requires a maintenance inspection twice a year, once in the winter before the heat pump heating system is used and once in summer before the cooling cycle of the air conditioner is activated.

Maintaining a poorly installed system can prove pointless and rather harmful These inspections help ensure that the installed system is functioning at its most efficient and providing optimum comfort. A maintenance inspection will also extend the life of equipment, increase cost-effectiveness, and ensure safe heating and cooling. It should be remembered that air filters need cleaning more frequently. HVAC systems are a big investment. This fact is often only apparent when an entire air conditioning system has to be replaced due to poor maintenance. Frequent system inspections and maintenance checks help keep a system effective for a longer

period, sadly most systems are only attended to when they have broken down and likely to be a safety and health hazard.

Safe installations

Of course, regular inspections are important but the actual installation of an HVAC system carries heavier importance. Maintaining a poorly installed system can prove pointless and rather harmful. It is vital to only use a registered installer when installing HVAC equipment, so as to avoid accidents which result in refrigerant gas leaking into the atmosphere. SARACCA is the Association of South African Refrigeration and Air Conditioning Contractors whose members have agreed to a set of governing standards while freely competing against each other. The Pressure Equipment Regulations (PER) were put in place to ensure that all gas installations meet safety standards. These regulations set out the requirements regarding the design, manufacture, operation, repair, modification, inspection and testing of pressure for all equipment used in the HVAC Industry. In terms of the Occupational Health and Safety Act, 1993, (PER) also requires all who intend on working on gas equipment to undergo specific training and to be registered with the South African Qualification and Certification Committee â&#x20AC;&#x201C; Gas (SAQCC Gas). SARACCA, www.saracca.co.za

TRANSFORMING FREIGHT LOGISTICS

TRANSNET FREIGHT RAIL

www.transnet.net www.transnetfreightrail-tfr.net

MARKET FORUM

OUTSOURCING REFRIGERATION

SaatchiCPT451126

Businesses are prone to wasting a lot of money through additional electricity costs by using refrigeration systems that have become inefficient. Newer, more efficient systems are available, but the capital outlay required to install a state-ofthe-art refrigeration system often seems too high in the short term. The argument to be made for this is clear: in addition to the significant costs that a company spends on the operation and regular maintenance of modern refrigeration systems, managing refrigeration often diverts precious resources and time away from a company’s core activities. The rest of Africa, however, is grow-

ing more receptive to the notion of outsourced refrigeration, and this is where the benefits of outsourcing really makes the difference between failure and success. “One of our recent refrigeration contracts in Namibia is a prime example of this, where a major retailer has elected to outsource refrigeration for one of its plants as a test case. The two major challenges to running these systems effectively and efficiently, are the vast distances and the shortage of available skills to maintain all of the plant at optimum condition,” says Dawie Kriel, Head of EP Refrigeration - a division of Energy Partners and part of the PSG Group.

“The outsourcing solution that we provide includes an online monitoring system, state-of-the-art refrigeration units and a maintenance team that can be on-call to travel between the locations as needed. In addition to energy cost-savings, the most important benefit that these clients will see is a significant improvement in temperature compliance.” The biggest challenges of Africa are infrastructure and skills. Refrigeration systems cannot run without reliable electricity supply and falls apart after a few years if not well maintained. “We can assist in innovative ways to reduce the reliance on poor infrastructure through our integrated approach to energy. We are able to supply energy systems that are assisted by Solar PV and generators to increase up-time. Our intelligent information systems allows our local partners to maintain effectively with technical support from an expert team,” Dawie concludes. www.energypartners.co.za

ENGEN TURBINE OILS. UNCOMPROMISED PERFORMANCE.

At Engen, we understand the need for higher productivity. With higher operating temperatures, higher pressures and potential water contamination, you need an oil that you can rely on. Engen turbine oils meet the most rigorous industry and OEM specifications, ensuring your machinery runs smoother, for longer. And with a supply network across South Africa, our products and expert services are always on hand to keep you going. Engen Customer Service Centre: 08600 36436 | www.engenoil.com

With us you are Number One

RR451126 Engen Turbine Oil_130x180mm.indd 1

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

2018/09/17 11:41 AM

MARKET FORUM

Lightweight Food-Grade Vibrators A series of food-grade pneumatic vibrators that enhance movement of moist, powdered, granular or pelleted material through small hoppers, bins, and tubes, is now on the market. The Bantam series by Martin Vibration Systems (MVSS) offers powerful vibration and versatility in a small package. The low-noise, linear units are washdownsafe and are purpose built for sanitary applications. They are engineered to endure continuous use, even at high and low ambient temperatures (32°-140°F). Operating lubrication free with a low air consumption results in consistent bulk material flow with less downtime, at a lower cost of operation. Processing and packaging operations in the food, pharmaceutical, chemical or plastics industries can have narrow choke points, leading to reduced throughput and production stoppages.

The Bantam series designs are small and durable, packing a surprising amount of power that helps move material efficiently without damaging the vessel.” With three options in the series -- the NTS 80, the NTP 18 and the NTK 8AL HA -- the new models serve a wide range of applications. Sealed in a sturdy PTFE clad aluminum alloy housing, the units attach to the facility’s existing compressed air network using an 1/8 NPT nickel-plated adapter fitting. The frequency can be adjusted by varying the pressure of the air supply and the amplitude by throttling the exhaust (NTK 8AL HA).

However, according to global bearing manufacturer NSK, these errors can easily be avoided.

www.shake-it.com

The series addresses the concerns of those customers using small vibrators for industrial applications about low output, high energy consumption, insufficient equipment life and poor mounting of other units on the market.

From day one

The mounting of bearings is a practice that requires the correct knowledge and skills. Historically, this task has seen maintenance personnel make a certain number of mistakes, which consequently reduces the lifespan of bearings. Further factors compromising service life include a failure to keep the bearings clean, not respecting the recommended clearances between the bearing rings and the shaft, and failing to use professional mounting tools.

“With the Bantam series and the Stick and Shake system, we feel we’ve addressed their concerns and provided a great replacement to the low efficiency and quality issues of older designs and models,” says Michael Holland of MVS.

Up to 20% of all bearing issues originate from faulty mounting, and this type of problem can lead to the stoppage of whole systems or production lines. This is reason enough to take extra care when mounting bearings. For those concerned about this issue or simply keen to learn more, bearing users can access support from NSK. For example, NSK offers training that focuses specifically on the correct mounting and dismounting of bearings. Moreover, training can be held at the user’s site or in co-operation with sales partners.

In addition to the training provision, as part of its AIP+ (Added Value Programme) service package, the company offers tools for mounting bearings in a professional manner. These special tools are needed to apply the correct force necessary to press the bearing ring into place. In the case of cold mounting, it is important to ensure that mounting forces are never transferred through the rolling elements of the bearing, otherwise damage may occur, not just to the rolling elements, but also the raceways. Even when performing hot mounting with hydraulic tools and induction heaters, damage can still occur to the bearings if the selected tools are not suitable for the application or used incorrectly. Such a scenario can lead to dents in the raceways, deformed seals, damage to adjacent components and even cracks in the bearing rings. Here an induction heater makes an important contribution to the proper functioning of bearings over a long period of time. NSK www.nsk.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

MARKET FORUM

No Contamination BMG, the only official distributor for Hallite Seals International Ltd in Central and Southern Africa, supplies an extensive range of hydraulic and pneumatic seals and sealing solutions for demanding environments. “Hallite sealing systems are manufactured from robust materials which include nitrile rubbers, rubber and fabric compounds and thermoplastic elastomers. These are all proven to keep a system free from external contamination,” says Marc Gravett, business unit manager of BMG’s Seals and Gaskets division. “The design engineers and material technologists have given careful attention to seal profile design and material selection while product properties are methodically studied to ensure the finished component has the required qualities to cope efficiently in harsh operating conditions.

“Seals are subjected to extensive testing that reproduces continuous operating conditions where leakage, dynamic and breakout friction are recorded and performance factors like pressure, speed and temperature are carefully monitored.” Included in this range of hydraulic and pneumatic seals are rod and gland seals, piston and static seals, as well as support and bearing components, which are constantly upgraded to keep abreast of changing market demand. Hallite type 780 double acting piston seals with a robust assembly for efficient operation, offer reduced wear resistance and extended service life on any hydraulic cylinder application. Although these piston seals have been designed especially for one piece pistons, they are also suitable for two piece pistons. The type 780 is similar to the popular DAS seal.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

These double acting seals consist of a nitrile rubber sealing element, two split support rings and two split L-shaped bearings, one of each is located on either side of the seal. BMG, which has been exclusive distributors in Southern Africa for Hallite Seals for over 35 years, provides a technical advisory and support service in all sectors. BMG www.bmgworld.com

November 2018

MARKET FORUM

More than an aspiration One operational area that stands to benefit significantly from innovations that can assist with dewatering is mineral processing. For instance, there are many cases across Africa where a mineral processing plant has been developed onsite, or nearby, but there aren’t smelters for the beneficiation of the product afterwards. This means that mine companies are paying to transport a product to the beneficiation plant, but because it still contains so much water the company loses out on the cost of the water weight versus tonnage of product transported. Currently, few traditional centrifugal pumps on the market are able to transfer slurry at the high specific gravities required to save water. Those that can will certainly experience increased wear rates. However, adopting peristaltic pump technology will improve the dewatering of the product and water conservation, and in the process contribute to higher

production capacity and a reduction in maintenance and operating costs. Such thickener transfer pump solutions are designed to pump slurry at a higher specific gravity at a steady flow rate, which will significantly reduce the amount of water to product ratio thereby increasing the per tonnage of product being transported. “Local mining companies are undoubtedly under increasing pressure to balance costs, increase productivity and reduce water usage, while still ensuring safety and meeting all stakeholder expectations. However, navigating the technical obstacles of pumping solutions for specific mining applications can be complex in

operations and the costs of equipment churn that can be caused by having an inferior solution,” says Darryl Macdougall, Managing Director, Verder Pumps South Africa. Installing original equipment manufacturer (OEM) solutions therefore gives the added quality and performance assurance of a well-functioning and long-lasting pumping solution that could lead to substantial savings in costs and improved application in performance, not only in the shortterm, but the longer-term too. Verder Pumps South Africa Kirstin Adam Tel: (011) 704-7500 Email: kirstin.adam@verder.co.za

Online calculation of service life The 3D printing of lubrication-free and maintenance-free plain bearings made of tribo-polymers allows a high degree of freedom in engineering design while maintaining a high level of wear resistance of the components that are used. In order to achieve this, igus is researching and developing new 3D materials for moving applications. Thanks to the extensive series of tests conducted in the industry’s largest

test laboratory, the company is able to predict the service life of the additive manufactured customised polymer bearings for users online. Knowing the service life of the bearing system is an unbeatable advantage when it comes to operating moving applications safely and reliably. This is exactly where online tools step in. They enable the exact calculation of the service life of igus products on the basis of the research and test results in the industry’s largest test laboratory. In the test lab all iglidur plastics, among other things, are intensively tested for wear and friction. In the process, 10 000 tests per year provide the database for the online service life calculator. In just four steps, the iglidur expert system registers the individual requirements and then provides the user with a comprehensive suitability and service life analysis of all lubrication-free and maintenance-free iglidur materials online. This precise service life calculation is not limited to injection-moulded iglidur plain bearings, but is also available for 3D-printed bearings. www.igus.de

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

MARKET FORUM

Keeping ‘tag’ Representative Matthew Campbell reveals.

An easy-to-read and install identification system for everything from hoses to heavy equipment is available from Banding & Identification (ID) Solutions Africa. Easy Read means maximum tagging effectiveness for enhanced traceability. Such has been the success of the Easy Read system locally that it has been adopted exclusively by a major hydraulic equipment manufacturer for the past decade to tag hoses, Banding & ID Sales

A diversified power management company has also deployed Easy Read for a similar application, while a leading supplier of engineering support services to the energy, process, mining, and construction industries uses the system to tag maintenance records for its rental equipment. Easy Read is essentially a tagging system comprising pre-cut characters (A to Z) and numerals (0 to 9), in addition to special symbols, and available in a range of sizes. Being pre-cut, there is no need for specialised tooling. End users can also only acquire those letters, numbers or symbols applicable to their specific serial numbers, enhancing the system’s holistic effectiveness.

The Easy Read characters are slid onto a carrier, which is then attached to any items such as hoses, cables, machinery, or they can be used as ‘flag’ tags. They are manufactured from Grade 316 stainless steel, meaning that they can withstand highly-corrosive environments. Easy Read can also be used in conjunction with PPA-coated Grade 316 stainless steel reusable cable ties to provide a total cost-effective ‘tag-and-clamp’ solution. These cable ties are, in turn, also colour-coded for easy identification. Characters can be slid directly onto a 10 mm or smaller cable tie to create a self-contained ‘wrap’ tag. Banding & ID Solutions Africa Rosa Dos Remendos Tel (011) 974-0424, rosa.remendos@banding.co.za, www.banding.co.za

An advisor of choice Bank), private equity (eg, sovereign wealth funds) and Chinese entities. Private-Public Partnerships (PPP) are an increasingly important mechanism for funding transport infrastructure in SSA and the wider region. With the incorporation of a PPP offering, Advisian is well placed to provide the advisory services critical to unlocking the full range of development funding sources. Adam Boughton EMEA Regional Directorof Sectors

Advisian’s Transport and Master Planning Service Line provides advisory, planning and engineering services in two key growth areas, notably ports and rail infrastructure. Although transport infrastructure projects in the MENA region continue to be generously funded by state-owned and private entities, the SSA region is predominately reliant on funding by donor organisations (eg, World

Advisian is providing transport advisory services to several parties across the EMEA region and just over the past 12-month period, this has included prefeasibility support to a rail sector project in the Middle East; lenders advice for deep sea ports in Gulf locations; tender support for various marine structural and coastal development projects in the Gulf; due diligence for LPG terminals in Eastern Africa; benchmarking studies and review of railway operational contracts; sea level rise and other climate change related impacts assessment for the South African coastline.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

Also transport network, port and SEZ master planning for a mega port development in the Middle East; coastal and marine engineering and master planning advisory services for a major nuclear development in SSA; and marine intake/outfall advisory services on various desalination projects in South Africa, KSA, UAE and South America. Advisian’s diverse offerings are also key to adding value to its clients. For example, Stepwise, Advisian’s fully integrated financial and technical process model, has enabled an offshore gas company to use an options analysis to provide surety to investors to release funds for the next stage of their project. In addition, Advisian assisted a precious metals mining company to develop and utilise an integrated modelling approach using Stepwise to assess the potential of a new mine. Advisian, division of a Worleyparsons Group Company, Adam Boughton, Adam.Boughton@Advisian.com

November 2018

MARKET FORUM

SILTING AT CHROME OPERATION “One of our mining customers had a tailings dam that was filled with slurry to over 110% of its capacity and the sediment needed to be removed to ensure optimum functioning of the tailings facility,” Lee Vine, managing director of Integrated Pump Rental, explains. Equipped with 37 kW Bravo 700 Grindex pump, and with capacity to pump 70tph of slurry, Integrated Pump Rental’s SlurrySucker Maxi operates at an average of about 40% concentration, depending on factors such as the material’s specific gravity and how solid the sediment has become. “The beauty of this dredging unit is that we only need one small area to begin the desilting work,” says Lee. “In this case, we started in one corner of the dam and created a cut by attacking the sediment to create space for more water to re-enter the working area.” He highlights that the mine needed the dam to remain on line during the dredging, so water would continue to enter the pond from the processing plant. “The SlurrySucker only needs a 400mm draught of water above the sediment for the floating unit to operate,” he explains. “A dewatering pump takes the top layer of water and feeds it down to the dredge-head, where the slurry is agitated so it can be pumped away.”

LEADERS IN THE STEAM BOILER INDUSTRY             

Reconditioned Boilers New Boilers Burners Spares—Boiler & Burner Repairs & Maintenance Statutory Inspections Control, Monitoring & Optimisation Feed pumps Steam Outsourcing Boiler Hire Boiler Rental Boiler Purchasing Boiler Operator Training

4 Dan Jacobs Street Alrode, Gauteng, 1450 Tel: (011)864—2984 sales@drydencombustion.co.za www.drydencombustion.co.za

The dredging unit is pulled back and forth across the dam, creating a new cut on each journey by removing a lane of silt at a time. Despite its capacity of 75 dry tph, the SlurrySucker Maxi model’s compact design makes it simple to move and operate. It measures just 5,4 metres in length and is 2,5 metres wide and 3 metres high. Integrated Pump Rental, Lee Vine, Cell: 072 627 6350, lee@pumprental.co.za, www.pumprental.co.za

The SlurrySucker dredge units is suitable for dredging and cleaning areas where silt has become an issue.

THE SOUTH AFRICAN MECHANICAL THE SOUTH ENGINEER AFRICAN VOLMECHANICAL 74 October ENGINEER 2018

VOL 68

November 2018

MARKET FORUM a 1 016mm diameter. Interchangeable conical inlet throats with diameters of 766mm and 1 016mm allow underground operating conditions to be simulated with ease. Eugene says that while subjecting the ventilation fan to operating conditions, it is possible to test various critical parameters including static pressure, air flow, shaft power and speed, vibration and kW rating as well as overall total efficiency. â&#x20AC;&#x153;The test facility allows for accurate reporting data to be produced which provides assurance for customers that the ventilation fan will meet the operating criteria,â&#x20AC;? he says.

A first on the copperbelt Access to a ventilation fan performance test column installed at Marthinusen & Coutts Zambia, a division of Actom (Pty) Ltd, offers a major advantage to mines on the Zambian and DRC Copperbelt. Significantly, this is the only fan test column in the region and was commissioned at the Kitwe based facility in the second quarter of 2018. The

BMG-BEA25102018 - SAME Thursday, 25 October 2018 4:12:13 PM

custom engineered test column will facilitate verification of ventilation fan performance following repair work prior to installation. According to Eugene Lottering, general manager at Marthinusen & Coutts Zambia, the test column will ensure that ventilation fans are tested and validated to the requisite parameters prior to being installed. The test column has been designed to perform tests in accordance with the current BS ISO 5801:2007 standard and equipped with common test airways with

Marthinusen & Coutts Zambia has a selection of OEM reference fans should it be necessary to test these on the column for verification purposes. Recently, the company conducted a comparative test for a customer on ventilation fan installations. Eugene says that interestingly the competitor installation only achieved 64% on a 45 kW fan and 50% on a 37 kW fan, while the Marthinusen & Coutts fans both achieved an 80% rating. Marthunisen & Coutts Richard Botton Tel: (011) 607-1700 richardb@mandc.co.za, www.mandc.co.za

MARKET FORUM

Cyclone refurbishment service even wear distribution, in addition to continuous improvement of the actual cyclone lining,” Thabisho highlights. Here the key measurements in performance monitoring are the sharpness of separation, the misplacement or rejection of product, and the separation point itself. A unique DMS cyclone refurbishment service

With the mining industry under increasing pressure to cut costs and increase productivity, Tempo Mineral Processing offers a unique service whereby Dense Medium Separation (DMS) cyclones can be refurbished for even wear distribution and extended life. This allows for improved mass balance of DMS cyclones in terms of the separation or cut size, the flow split between the over- and underflow, the sharpness of the classification, and the capacity (pressure drop). This all translates into a dramatic increase

in total efficiency, Tempo Mineral Processing Director Thabisho Malatji comments. The lifecycle of a DMS cyclone can be extended significantly by the application of a reaction-bonded silicon carbide lining (RbSiC) lining on the spigot and lower cone portion in particular, with the lining pattern running against the material flow for minimum gaps and steps and optimal joint sealing between components. “We offer our customers the lowest total cost of ownership by means of

HVAC drive for three-phase

With a large footprint and customer base in food-and-beverage, automotive, and mining, drive and automation specialist SEW-Eurodrive South Africa is now targeting niche sectors such as Heating, Ventilation and Air-Conditioning (HVAC) in order to ensure sustained growth. In this regard, its LTP-B Eco HVAC drive is starting to make inroads in this

market thanks to its combination of innovative technology and easy-to-use features. “Energy-saving is a major focus in HVAC. Our drive caters for this with an advanced ‘sleep’ and ‘wake’ function that maximises energy efficiency by only switching on a pump, for example, when it is required,” explains SEW-Eurodrive SA Regional Sales Manager, Clive O’Reilly.

Maximum operating efficiency is guaranteed thanks to an automatic pump-cleaning function, along with additional features such as the fact that the drive allows for the operation of multiple pumpsets, for example, without any need for a costly PLC. Instead, a built-in PLC function allows customised applications to be programmed directly into the drive. Pump maintenance requirements are

Tempo Mineral Processing also offers pneumatic conveying lined pipes for applications as diverse as pulverised fuel pipes for power stations, furnace feed pipes, and for pneumatic drier systems. Its hard-facing service provides for excellent strength, being welded directly onto a mild steel backing, in accordance with American Welding Society (AWS) standards and procedures. Hard-faced bolts, with galvanised Nyloc nuts and washers, are also available for specific applications. The company is not only 100% blackowned, but also has a Level 1 BroadBased Black Economic Empowerment (B-BBEE) rating. Rio-Carb, www.rio-carb.com

reduced dramatically due to blockage detection and run-dry protection. A built-in energy consumption meter has a clear display, which means that end users can calculate energy savings quickly. A motor preheat function allows for smooth start-up every time, without any internal condensation forming inside the drive if the ambient temperature is low. The LTP-B Eco HVAC drive is available in single-phase variants (220V) from 0.75kW to 2.2kW. This allows for added flexibility in applications where three-phase power is unavailable, a major constraint in Africa. Three-phase variants (440V) range from 075kW to 160kW. A 525V range (0.75kW to 11kW) is available specifically for mining-industry applications. Of particular interest to the building industry is the drive’s fire-detection capability, which means that ‘fire run’ mode can be activated in the event of any fire. This allows for the normal safety features to be bypassed, and for the fan to keep running for as long as it takes to extract any smoke in the immediate vicinity. SEW-Eurodrive www.sew-eurodrive.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 68

November 2018

MARKET FORUM

On the Move

Joe Ndala

Ernie Smith

Hudaco Industries has appointed Ernie Smith as Portfolio Executive within the group. Ernie will initially be responsible for leading suppliers BI and Bauer Geared Motor divisions, with additional divisions to be added to his portfolio in due course.

Bridget Ssamula

Aecom promoted two key leaders in its African operations. Joe Ndala has been appointed as Managing Director of the South African business. Walter Awinda

Bosch East Africa Consulting Engineers Ltd, a member of the Bosch Holdings group of multidisciplinary consulting engineering companies, has appointed Walter Awinda, managing director.

Bridget Ssamula has been appointed as Managing Director of the East African business.

Promech Publishing wishes all its readers a wonderful December break and a prosperous New Year

46 SAMechEng.indd 1

THE SOUTH AFRICAN MECHANICAL ENGINEER 12/12/2017 18:17:18

VOL 68

November 2018

dŚĞ ƐƐŽĐŝĂƟŽŶ ŽĨ ^ŽƵƚŚ ĨƌŝĐĂŶ YƵĂŶƟƚǇ ^ƵƌǀĞǇŽƌƐ

QuanƟty Surveying… …at the heart of every successful construcƟon project

Find out more… info@asaqs.co.za

T 011 315 4140/1 F 011 315 3785

www.asaqs.co.za

P O Box 3527 Halfway House 1685 I Suite G6 Building 27 Thornhill Oﬃce Park Bekker Road Vorna Valley Midrand •

•

MegaCPK At the dawn of a new era With continuous research and investments, we have developed a totally new generation of products. A milestone in KSB's history and the dawn of a new era focused on quality, efficiency, safety and reliability in one package, worldwide. Our innovative new product line-up offers first-class quality and a host of new features that combine to make this pump truly unique. • • • •

Maximum operating reliability Outstanding efficiency from improved hydraulic systems Optimum energy efficiency Global availability

KSB Pumps and Valves (Pty) Ltd www.ksbpumps.co.za

> Our technology. Your success. Pumps• Valves, Service

KseliJ