SA Mechanical Engineer October 2014

S MECHANICAL A ENGINEER Oct 2014

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

Oil & Gas Expansion in Africa No Possibility of Corrosion THE SOUTH AFRICAN MECHANICAL ENGINEER

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Chris Reay

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

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Supply Chain Today MECHANICAL Sept 2014 ENGINEER THE SOUTH AFRICAN

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Greg Perry

The monthly circulation is 3 947

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The audience at a LEESA soapbox presentation

Forthcoming Workshops – November 2014 Programmes and Registration Forms obtainable from Carey Evans, Tel. 031 764 7136 or Email: carey@saimeche.org.za Code

Title

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A7014

Leadership & Management 5-Nov-14 Roles in Engineering

6-Nov-14

Durban

A8314

Fundamentals 11-Nov-14 of Six Sigma

12-Nov-14

Durban

C7014

Leadership & Management 12-Nov-14 13-Nov-14 Roles in Engineering

Cape Town

C8314

Fundamentals 18-Nov-14 19-Nov-14 of Six Sigma

Cape Town

Leadership & Management H7014 Roles in Engineering

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Start Date

October 2014

19-Nov-14 20-Nov-14

Rivonia

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Geared Motors \ Drive Electronics \ Drive Automation \ Industrial Gears \ Services

1THREAD_6925_SAM

We drive heavy industry

The new SEW girth gear – flexible concepts for diverse combinations Girth gears - the latest offering in our industrial gear range - are used to drive large, rotating systems such as dryers, rotary kilns or horizontal mills. Traditional girth gears generally consist of two to four segments that are assembled together for processing. In contrast, SEW-EURODRIVE girth gears are split into several identical segments in order to keep the component parts short and easy to handle.

We deliver not only girth gears, but the entire drive package!

Main advantages: ∙ Guarantee flawless casting quality on critical areas ∙ Individual segments of girth rings are interchangeable ∙ Only damaged individual parts need to be replaced instead of changing the whole ring ∙ Handling of each individual segment is easier ∙ Segmented design enables easy and cost-efficient transportation Tel: +27 11 248 7131 Web: www.sew.co.za

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Professor Jim Petrie, Energy Director in the Western Cape Department of Economic Development and Tourism

Ebrahim Takolia, CEO of the South African Oil & Gas Alliance (SAOGA)

Lindo Mkhize, manager: port planning and development for Transnet National Port Authority (TNPA)

Kaashifah Beukes, executive for stakeholder relations at the Saldanha Bay Industrial Development Zone

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Specializing in : Unistream, Thrustream, Eurostream, Aquastream and Instream pumps supply, spares and service. Also including fire prevention sets.

SPP Pumps (South Africa) (Pty) Ltd are authorized distributors of the Global Sterling Fluid Systems Group originally founded in 1895.

Our experience spans all pumps and associated parts, but is not limited to those designed and manufactured by SPP and Sterling Fluid Systems. The extensive SPP, SiHi, Halberg and LaBour range of specialist pumps is a prime example of the extent of our capability.

JHB / Head office Tel : 011 393 7181/2 Email : ph@spppumps.co.za Web site : www.spppumps.com

CT Branch PE Branch KZN Branch 021 852 3962 041 364 0204 031 700 3773 ft@spppumps.co.za ng@spppumps.co.za rh@spppumps.co.za

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Academic

Projects

Career Path

Commentary

Achievements

WHEN YOU PUT THE RIGHT PEOPLE TOGETHER, THE RESULTS CAN BE REMARK ABLE. And in our experience, they usually are. Find out why it pays to keep the right company at www.pps.co.za

63464 PSS brand camapign - strip ad V2.indd 1

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Excellent Minerals Solutions

WARMAN® Centrifugal Slurry Pumps ENVIROTECH® Centrifugal Slurry Pumps ISOGATE® Slurry Valves Lower your operational costs with the Weir Minerals Solution In slurry and dewatering pumping, processing and control applications where the cost of ownership often outweighs capital cost as a priority, we help our customers address such issues as longevity, capacity, efficiency of operation and maintenance.

Warman® slurry and Envirotech® dewatering pumps are among the world’s most comprehensive range of pumps for use in mining, chemical and industrial applications. These pumps are designed for ultra heavy duty applications such as mill discharge, process plant and tailings, high pressure pipelines, as well as other speciality applications.

Expertise where it counts

Robust design and rugged heavy-duty construction, the Isogate® slurry knife gate valve is designed for long life and high reliability.

The Isogate® valve range now also includes Autoball™ 3 way check valves, swing check valves, and a diverse range of mechanical and pneumatic pinch valves.

Copyright ©2012, Weir Minerals Africa (Pty) Ltd. All rights reserved.

WARMAN is a registered trademark of Weir Minerals Australia Ltd and Weir Group African IP Ltd; ISOGATE is a registered trademark of Weir do Brasil Ltda; AUTOBALL is a trademark of Weir Minerals Australia Ltd.

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For more information contact us on: +27 (0)11 9292600 www.weirminerals.com

October 2014

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CERadvance Engineering Ceramics

Francois Thuynsny from CERadvance Engineering Ceramics used the event to promote existing products and to network with existing and potential new clients.

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Understand operational specifics of each country  Local support in Angola, Botswana, Cameroon, DRC, Ghana, Kenya, Mauritania, Namibia, Nigeria, South Africa, Zambia and Zimbabwe  1 872 000 weeks experience in Africa

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South Africa: +27 11 723 6000 Ghana: +233 30 27 664 90

www.zest.co.za

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MITIGATING

FROM MADAGASCAR TO GHANA

TO YOUR ELECTRIC MOTOR

FROM YOUR SUBSTATION

it is based on a proportion of width and height of 2-to3. The distance between the GRID elements is 1/3 of the height of an element.

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THE SOUTH AFRICAN MECHANICAL ENGINEER mAd

22 24/7

TECHNICAL SUPPORT

24/7

24/7 technical back-up Fully qualified technicians  5 Fully equipped training centres across Africa  187 site visits across Africa per year 

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TECHNICAL SUPPORT

STRATEGIC STOCKHOLDINGS IN AFRICAN COUNTRIES

Where you need it, When you need it

SUppORT

POWER

GENERATION

T O D A Y

Dr David Johnson

Existing mine operation case studies

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Power -30+%

Pressure -15%

Figure 1: Fan curve using input guide vanes

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Figure 2: Typical fan curve and actual operating point

Figure 3: Flow, pressure and power curves for a fan

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Figure 4: BEP efficiency decrease of a pump

New mining operations

Figure 5: Mine air system with flow control

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Solar Power Generation

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Liezl Smith

There are two types of forecasts: wrong ones and lucky ones

•wt4820 verder sa mechanical engineer advert feb 2014.pdf

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2014/02/07

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FCB CAPE TOWN 10006238CT/E

Salt-spray test on 3411-coated flange, showing no corrosion

THE BLUEPRINT FOR AFRICA’S FUTURE. Engen is committed to an African success story.

With a dedicated team on the ground and a wide range of quality Industrial Lubricants, we can ensure smooth operations no matter what extreme conditions you face.

Contact us today on +27 21 403 5090 or visit www.engenoil.com.

Also available at The Oil Centre, approved distributor of Engen Lubricants.

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Challenges faced at one of the UK’s largest power stations included facilitating the maintenance and cleaning of sluice valves in a return pit. After a site assessment, Xylem decided on a temporary installation of four 150 mm quiet enclosure pumps to handle a total flow of 1200 m³/h. These pumps operated around the clock until the job was done, which ended up saving the power station both capex and labour costs.

Mobile rental engineers deliver, install and commission temporary pumping systems at short notice to overcome emergency situations, are offered professional and bespoke system designs and on-site support when and where the customer requires it.

Every business should have a CEM® A Certified Energy Manager (CEM®) has the knowledge and skills to ensure sustainable energy savings for any business CEM® is an intensive 4-day training course followed by an examination that requires a 70% pass-mark, after which the candidate may apply for international certification which is recognised in 90 countries. Note that re-certification is required every 3 years.

An Association of Energy Engineers (AEE) qualification programme presented in Southern Africa by the AEE’s sole approved training partner for the region, the Energy Training Foundation (EnTF).

EnTF is also EWSETA accredited and a training provider of the SAEE.

Tel: +27(0) 87 942 5513/4 | Cell: +27(0) 76 401 3881/2 info@entf.co.za | www.entf.co.za

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Girth gear drive mill systems

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Discipline : Process

Discipline : Mechanical

Discipline : Structural

Function

: Specifies process requirement

Function

: Design process equipment

Function

: Designs the Support Structure

Input

: Ore body characteristics

Input

: Ore Resizing requirements

Input

: Equipment Characteristics

Output

: Resizing requirements

Output

: Loads and operation manual

Output

: Structural loads and mass

Discipline : Mining

Discipline : Operation

Discipline : Geotechnical

Function

: Mining methods

Function

: Specifies process requirement

Function

Input

: Ore body characteristics

Input

: Operation Manuals

: Determines suitable ground support

Input

: Structural loads

Output

: Mineral size

Output

:

Output

:

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Drive Train

Girth Gear

Mill Tube Motor

Foundation

Figure 2: Typical mill system

Discharge End

Feed End

Figure 3: Typical mill drive schematic

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Mill Tube with charge Girth Gear Drive Train

Concrete Foundation showing Reinforcement

Pinion

Concrete base + backfill

Soil Foundation Figure 6 : Finite element model

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VB

A HB

HA

B

VA C

Figure 5: Drive forces Motor

Figure 7: Vibration measurement points

High Speed Coupling

Low Speed Coupling

Gearbox / Reducer

Pinion

Girth Gear

Case Study

Figure 4: Typical drive train

Figure 9: Measurement point C

Figure 8: Measurement points A & B

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Waterfall Display

Speed (RPM) 0 0 Frequency (Hz)

Figure 10: Operation deflection measurements

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Figure 12: FEA response at 55,5Hz

Figure 11: FEA response at 54,5Hz 1.8

Pre-repair

Acceleration RMS (g’s)

1.6

Post repair

1.4 1.2 1 0.8 0.6 0.4 0.2 0

Figure 13: Solution option, wedging

A

B

C

Figure 16: Time series measurements comparison Measured Response ar 54,5Hz 0.4 Pre-repair

Acceleration RMS (g’s)

0.35

Post repair

0.3 0.25 0.2 0.15 0.1 0.05 0

Figure 14: Solution option, diaphragm

A

B

C

Figure 17: Measured response comparison

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0.6

Acceleration RMS amplitude (g)

Point A - Diaphram model Point B - Diaphram model

0.5

Point C - Diaphram model Point A - Wedge model

0.4

Point B - Wedge model Point C - Wedge model

0.3

0.2

0.1

0 49

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54

55

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Frequency (Hz) Figure 15: FEA frequency response comparison of repair options

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MARKET FORUM

An example of a trommel for mineral sands applications

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MARKET FORUM

New CatFinesMaster Separator

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DN1000 TP350 KPA wedge gate valve

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The bulk facilities store hundreds of thousands of litres of fuel and lubrication onsite

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MARKET FORUM

On The Move

Craig Less

Craig Less has been appointed branch manager in the Western Cape for valve manufacturer, Mitech.

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SAMHYDRAULIK, which is one of the leaders in the field of hydraulic transmission, has been operating for over 25 years in the international market, offering a complete range of orbital hydraulic motors and power steering units, axial pumps and motors for medium and high pressure ranges, all characterised by excellent performances.

SAMHYDRAULIK employs 120 people who operate inside a very modern and efficient plant that spans over 6 000 square metres to assure a high standard and flexible production capacity.

The latest computer technology is used for both design and production, combined with strict quality control procedures during all production phases, which translates into innovative, reliable and functional products that meet the various needs of the market.

Its ISO 9001 certification, held since 1994, is the result of a qualityorientated philosophy on which SAMHYDRAULIK has always based its operation.

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AXIOM HYDRAULICS (PTY) LTD Tel: (011) 334-3068 / 334-3086 Fax: (011) 334-4543 E-mail: axiomjhb@mweb.co.za 17 Heidelberg Road, Village Main, Johannesburg, 2000 P O Box 260248, Excom, South Africa, 2023

THE ENGINEER SOUTH AFRICAN THE SOUTH AFRICAN MECHANICAL VOLMECHANICAL 62 May 2012ENGINEER

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