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AN ENGINEER’S VIEW
Chris Reay
Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)
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From our engineers to you. As a member of the Engineering Council of South Africa, you could qualify for exclusive offers*, a guaranteed 3-day service booking as well as PremiumDrive, our 6 year/100 000km maintenance plan. To take advantage of this outstanding opportunity, inform your nearest dealer of your ECSA status.
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The monthly circulation is 3 947
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Gain Peer Recognition, a New Networking Experience and a New Income Source To best serve its members and the industrial community, the National Events Department seeks SAIMechE members and members of ECSA recognized organisations who wish to earn income from developing material and presenting workshops on their specialised subjects. Applicants may contact Linda Robinson (Tel: 031 764 7136, Email: linda@ saimeche.org.za) to receive an application form and guidance on the processes required. To have your workshops on the 2014 calendar, please contact Linda without delay. Cost Saving, In-house Training Workshops SAIMechE has a variety of 69 workshops that may be booked as In-house training events. To book an In-house workshop on a date that suits your organisation, or to obtain a comprehensive list of these workshops and to learn more, contact Linda Robinson on Tel. 031 764 7136 or linda@saimeche.org.za. Programmes and Registration Forms obtainable from Carey Evans, Tel. 031 764 7136 or carey@saimeche.org.za Event Code Title Date Region Heat Transfer in Practice: Heat Transfer via Conduction & Convection; 25 - 26 A3113 Durban Evaporative Cooling and Sep 13 Drying Processes and Radiant Heat Transfer The Management of Health E2113 26 Sep 13 East Rand & Safety Risks/Hazards Preventive and PredicE2413 tive Maintenance Best 27 Sep 13 East Rand Practice Continuous Improvement C6713 of the Organisation 2-Oct-13 Cape Town (Kaizen) by Engineers Developing Effective Standard Operating C6813 3 Oct 13 Cape Town Procedures and Practices for the Organisation Finding Inventive Solutions to Engineering 3 - 4 Oct 13 East Rand E6013 and Technical Challenging Problems Continuous Improvement A6713 of the Organisation 9 Oct 13 Durban (Kaizen) by Engineers Practical Lubrication and E2913 9 Oct 13 East Rand Lubricants Tank Design, Construction C6413 9 Oct 13 Cape Town and Installation Developing Effective Standard Operating A6813 10 Oct 13 Durban Procedures and Practices for the Organisation E6913 Lubricants & Oil Monitoring 10 Oct 13 East Rand An Executive Overview on Why TRIZ is the World’s C4310 14 Oct 13 Cape Town Leading Inventive Problem Solving Tool Leadership and 16 - 17 H7013 Management Roles in East Rand Oct 13 Engineering 17 - 18 E0613 The Engineer as Manager East Rand Oct 13 Practical Lubrication and C2913 23 Oct 13 Cape Town Lubricants Leadership and 23 - 24 A7013 management roles in Durban Oct 13 engineering C6913
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Lubricants and Oil Monitoring
24 Oct 13 Cape Town
Date:
Saturday 16th Nov 2013
Time :
18:30 for 19:00 Wanderers Golf Club
Venue :
Cnr Rudd/Corlett, Illovo, Sandton
The Chairman and Committee of the Central Branch of The South African Institution of Mechanical Engineering,
Dress: Cost:
Black Tie/ Traditional R4 000 per table of 10 or R400 per individual ticket
cordially invites
After dinner the dance floor will be opened to boogie the night away to the fabulous music of Havana Gas, a dynamic duo covering a diversity of musical hits.
................YOU.................
Companies are invited to book tables of 10 Sponsorship opportunities are available.
to their
2013 Dinner Dance
R.S.V.P. by no later than 12 October 2013 Contact: Lynne on (011) 615-5660/ central@saimeche.org.za
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We not only achieve an average saving of 50% on energy consumption compared with a fix speed compressor, but overall uptime is improved
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The larger oil-injected GA range from 90 KW through to 315 KW has been upgraded to a totally new packaged machine which is much more energy efficient than before
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CAREERS
Prominent Professionals Gavin White, General Manager, Engineering at Tenova Takraf Africa
3D model on the computer, but it will be great if we can get a client willing to develop it further.
Academic
Projects Most challenging
School:
St Stithians College in Johannesburg.
The Kusile project is challenging because of the complexity which comes with many interfaces. Graduate studies: Our three contracts include the materials hanB Mechanical Engineering at Stellenbosch dling packages for limestone, the coal stockyard University. and the terrace coal and ash handling. Our Post-Graduate: responsibility covers all disciplines; from civils A management advancement programme (MAP) to mechanical, structural and electrical while Gavin White at Wits business school. fully involving the client, the client’s engineers as well as our suppliers. There are very specific systems, Professional Bodies Member of the South African Institution of Mechanical En- requirements and procedures prescribed by Eskom. On top gineering. Registered with ECSA as a professional engineer. of that, we’re spending several years on site, a high risk factor which has to be carefully and continuously managed.
Career Path
First employer
I started in the Cape at De Beers Marine doing test work aboard the diamond mining vessels for about a year.
Growth path
In 2001, I moved to Johannesburg to join Bateman Engineered Technologies (BET) in the Pneumatics and Environmental department. I spent a lot of time on site commissioning pneumodriers (pneumatic conveyor drier) which allowed me to develop the design programme still used today to design these driers. After a couple of years I moved over to the Bulk Handling department to design conveyors and materials handling systems. This culminated in becoming the project engineer for the Richards Bay Coal Terminal (RBCT) Phase V expansion project. In that time I was promoted to engineering manager of bulk engineering. About four years ago I became the general manager of engineering for BET, now known as Tenova Takraf Africa.
Achievements
Most Rewarding The RBCT project, mainly because of the opportunity to take a complete project through all its phases. Currently I find satisfaction in a broader sense in that I can contribute to all the projects the company is executing in terms of optimisation, design approach, systems, processes and standardisation. It is rewarding when it all comes together in the end even though you weren’t involved in all the finer detail of each project.
Commentary Are there shortcomings in the Mechanical Engineering Industry in South Africa?
I think in our industry specifically we need to focus more on understanding what the client really wants and to fully understand his needs in order to arrive at the best solution. As an industry we could also look to support and involve the universities more from a technology development point of view.
How would you mend this?
A project
The Richards Bay Coal Terminal Phase V expansion project. It was the biggest project that I took from start to finish. In my current position I’m involved in many projects, but never fully from A to Z in terms of full ownership of the project like RBCT was.
Future – a concept, a dream or a wish
Our immediate future involves building our in-house basic machine design capability, and promoting and driving innovation. As for further into the future – we have patented a high speed chute design. The faster conveyors run, the more critical a chute becomes. Our design takes the material into a circular chute before discharging it onto the next conveyor belt with very little impact and wear. At the moment it is a
We need to invest enough time on project and tender setup where you engage with the client eye to eye in order to ensure that the enquiry document is fully understood and has been interpreted the right way. It’s amazing how often just slight differences can be misinterpreted altogether.
Message to young engineers
Mechanical engineering is a fantastic base degree, even if you don’t venture into a strict line of engineering in the end. Unlike most other degrees, mechanical engineering is so broad you can easily follow any of an abundance of opportunities. Hopefully you do stay in the engineering field, especially right now in South Africa where there are shortages of specialists in most disciplines.
PPS allocateD a recorD r3 billion to itS memberS* for the 2012 financial year. WoUlDn’t yoU liKe to be inclUDeD thiS year? For more info SMS ‘MECH’ and your NAME to 42097, consult a PPS product-accredited financial adviser or visit www.pps.co.za PPS is an authorised Financial Services Provider. *Members with qualifying products share our profits. Standard SMS rates apply.
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In terms of speciality greases which are custom developed in-house, however, our laboratory is well equipped to make batches from as little as two, four or eight kilograms at a time
Of the vast range of products manufactured by Strub, only about 40% are branded under the company’s own name, the rest is made for various wellknown petrochemical companies
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The production line consisting of seven kettles produces around 500 tonnes of grease a month
The laboratory even makes small quantities of special lubricants
We’re now up to a production line consisting of seven kettles from which we can produce around 500 tonnes of grease a month on a normal one-shift schedule
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Which is the best part of your current job?
Your favourite author?
The title of the last book you’ve read? How was it?
MAN ITEMS Y BE OFF CAN ER FROM ED STOCK
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12/20/12 9:45:24 PM
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The reflux classifier (RC) from FLSmidth is state-ofthe-art technology
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POWER
GENERATION
T O D A Y
PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: samecheng@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial: Kowie Hamman Advertising: Mark Bennett Circulation: Catherine Macdiva DTP: Zinobia Docrat/ Donovan Vadivalu Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.
Copyright
Eben Mulder, chief executive officer at STL
TICKER TAPE
All rights reserved. No editorial matter published in “Power Generation Today� may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.
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Wayne Holt of Shield Technologies
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To complete the system an economiser can be installed on compressed gas systems
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Jean Greyling
Figure 1. Breakdown of energy usage by process
Figure 2. Nodes and elements
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Figure 3. Vaal River compressed air ring Weekly Average Total Compressed Air Consumption (Peak/Off Peak) - Quarter 2
Weekly Graph Peak
Weekly Graph Off Peak
Figure 4. Average consumption during peak and off peak
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Capacity Increase Summary Consumption
Consumption
Consumer
Kg/s
Consumer
Kg/s
64 Level
0.6
64 Level
0.7
70 Level
1.2
70 Level
2.5
73 Level
1.7
73 Level
5
76 Level
2.5
76 Level
6.7
85 Level
2.2
85 Level
3.2
88 Level
3.1
88 Level
4
92 Level
0.7
92 Level
2.6
95 Level
2.2
95 Level
3
98 Level
3.1
98 Level
3.4
100 Level
0.5
100 Level
0.6
101 Level
4.8
101 Level
6
Losses System
2.5
System Losses
2.8
Total
22.7
Total
40.5
Figure 13. Kg/kWh Vaal River Vaal River Compressed Air Tonnage Comsumed Daily Set 1: UCL = 8043. Mean = 6375. LCL = 4708 (2011/01/11 - 2011/04/20) (mR = 2)
Figure 14. Consumption profile – Vaal River
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Figure 15. Kg/kWh West Wits
Figure 16. Consumption profile – West Wits
Range (kg/s)
Old Configuration
Kg/s
MW
New Configuration
Kg/s
MW
Saving
70 - 75
Kop No1, VK 100
70 - 75
23.2
VK 100, 4#, GNM No2, RIK 56
70 - 75
23.2
0
75 - 80
Kop No1, VK 100, 4#
75 - 80
26.9
VK 100, 4#, GNM No2, RIK 56
75 - 80
23.7
2.5 MW
80 - 85
Kop No1, VK 100, 4#
80 - 85
28
VK 100, 4#, GNM No2, RIK 56, GNM No1 80 - 85
28
0
85 - 90
Kop No1, VK 100, 4#, 2#
85 - 90
31.2
VK 100, 4#, GNM No2, RIK 56, GNM No1 85 - 90
29.4
1.8 MW
90 - 95
Kop No1, VK 100, 4#, GNM No2
85 - 90
33.7
VK 100, 4#, GNM No2, RIK 56, GNM No1 90 - 95
29.4
2.5 MW
95 - 100
Kop No1, VK 100, 4#, 2# GNM No2
95 - 100
35.5
VK 100, 4#, GNM No2, RIK 56, GNM 95 - 100 No1, GNM No3
35.1
0.4 MW
VK 100, 4#, GNM No2, RIK 56, GNM 100 - 105 35.1 No1, GNM No3
2.2 MW
100 - 105 Kop No1, VK 100, 4#, 2# GNM No2
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100 - 105 37.3
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MARKET FORUM
Three-month Deadline
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MARKET FORUM
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MARKET FORUM
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MARKET FORUM
EFAS in de-activated position on steel guide within test rig
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MARKET FORUM
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MARKET FORUM
Air Products area sales manager of the Eastern Cape, Pierre Fourie (left), with site foreman, Basil Goliath, from SBT Building.
C
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Promech Publishing has a BEE rating of 125%
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Rain, mist & fog do not have to give you filtration and air-intake problems Air intakes for fresh-air make up, for generators, large compressors and many other applications that require filtration to prevent the dirty outside air from entering the system are often compromised due to rain water spray, mist or fog entering the air-filtration.
Munters mist eliminators are highly efficient in eliminating the fine water particles that wet filters, reducing the flow, increasing the system pressure until the system over-loads or shuts down the air-intake system or plant. Munters range of eliminators ensures normal trouble-free filter life without productivity/efficiency loss.
Munters (Pty) Ltd Phone 997SOUTH 2000 / Email: info@munters.co.za www.munters.co.za/ 0860 MUNTERS 48+27 11 THE AFRICAN MECHANICAL/ Website: ENGINEER VOL 63 September 2013