Zero Harm We make it happen!
Bulk Material Services Construction Services Logistics Services Transformer & Switchgear Services Turbo Gen Services Ash Products
Prevent power outages by protecting the source
About us Bee Tee Projects is one of the largest installation and refurbishment contractors. We specialize in Cabling, Stringing, Earthing and Erections of new and existing Substations. All our staff are trained and accredited to work up to 765KV. We have been in the High Voltage environment since 1972. Bee Tee Projects was established in 1979 and the registered at various companies as substation erectors.
Bird Guards • Manufacturing of Bird Guards with 100% recycled material from (bottle grade material) • Supply, installation and maintenance anywhere in South Africa and SADEC countries, (also retail to the UK) • Manufacturing of Quick Release Clip • Erection of Bird Guard and line Labels
• Level 2 BWO company
Bird Guards & Tower Labels
Telephone: (011) 894 - 5573 or 082 377 0085 Fax: (011) 894 – 7328 or 086 210 4677 Email:firstname.lastname@example.org email@example.com
Bird guard history
Bee Tee projects started in 1999 with the supply a metal bird-guard to Eskom. Through the years Bee Tee’s bird guard has evolved into a non corrosive, non-conductive plastic bird-guard.
Zero Harm We make it happen!
Bulk Material Services Construction Services Logistics Services Transformer & Switchgear Services Turbo Gen Services Ash Products
22 O PERATIONAL DIVISIONS Understanding Rotek’s business units
27 T RANSFORMER & SWITCHGEAR SERVICES Servicing the demand for energy sector maintenance 34 TURBO GEN SERVICES Energy in motion
02 FOREWORD A message from Rotek 04 HISTORY Company timeline of the last 100 years 06 INTRODUCTION About Eskom Rotek Industries 12 STRATEGY Poised for growth
36 C ONSTRUCTION SERVICES Civil, electrical and everything in-between 38 B ULK MATERIAL SERVICES All systems go 42 LOGISTICS SERVICES Africa’s fleet experts
46 ASH PRODUCTS 18 IMPROVED PRACTICES Why ash is big business Q&A with Rotek’s New Business Development 50 CASE STUDY Marketing division A lesson from Africa
Note: Eskom Rotek Industries statistics have been taken from publically available documents that may or may not reflect the absolute correct numbers applicable at the time of going to print.
150 Rivonia Road, Morningside, Gauteng PO Box 92026, Norwood 2117, South Africa t +27 (0)11 233 2600 f +27 (0)11 234 7274/75 www.3smedia.co.za Publisher Elizabeth Shorten Managing Director Candice Landie Head of Design Beren Bauermeister Chief Sub-editor Tristan Snijders Sub-editor Morgan Carter Production Manager Jayshree Maharaj Financial Manager Andrew Lobban Distribution Manager Nomsa Masina Distribution Coordinator Asha Pursotham
NOTICE OF RIGHTS This publication, its form and contents vest in 3S Media. All rights reserved. No part of this book, including cover and interior designs, may be reproduced or transmitted in any form or by any means, without permission in writing from the publisher, nor be otherwise circulated in any form other than that in which it is published. The authors' views may not necessarily reflect those of the publisher. While every precaution has been taken in the preparation and compilation of this publication, the publisher assumes no responsibility for errors, omissions, completeness or accuracy of its contents, or for damages resulting from the use of the information contained herein. While every effort has been taken to ensure that no copyright or copyright issues is/are infringed, 3S Media, its directors, publisher, officers and employees cannot be held responsible and consequently disclaim any liability for any loss, liability damage, direct or consequential of whatsoever nature and howsoever arising.
Contact us for a free consultation For a free specialist engineering consultancy, plant walk-down, or oil and/or vibration analysis at your plant, please contact Tendani Ndwamise on NdwamiTP@eskom.co.za or call her on +27 (0)11 629 4178 for more information.
General Enquiries: Tel: +27 (0)11 629 4000 ERIinfo@eskom.co.za www.rotekindustries.co.za
InterSystems | Profile Logistics Services Foreword | ERI
The success stories that go untold At Eskom Rotek Industries, our heritage is in our inheritance. We have a history that spans more than 100 years, and we are proud of the exceptional service we have provided to the development of South Africa.
eliforP | s m eForeword t s y S r|e tERI nI Logistics Services
e live in a South Africa rich with possibilities. As a state-owned company, Eskom Rotek Industries has the interests of all South Africans at heart. When Rotek Engineering and Roshcon officially merged to become Rotek in 2015, we undertook to have not just one name, but also one brand, one operating model and one culture – synonymous with the democratic South Africa in which we live today. This can be filtered down to our business ethos, in which all our operations are underpinned by Zero Harm, Integrity, Sinobuntu, Innovation, and being Customer Centric. Today, Rotek comprises the following operating divisions: Bulk Material Services, Construction Services, Logistics Services, Turbo Gen Services, and Transformer and Switchgear Services. And it doesn’t end there. A dedicated unit within Rotek’s Bulk Material Services specialises in the selling of coal combustible products such as ash, gypsum and salts. Rotek manages and sells ash from eight South African coalfired power stations – all while complying with legislative requirements. Over 2.4 million m3 of fly ash concrete was supplied for construction of the mighty Katse Dam in Lesotho. Standing 185 m high and with a double-curvature arch, it was the highest dam in Africa for over a decade. Too often, municipalities, government departments and state-owned companies enter the media spotlight for all the wrong reasons. At Rotek, we would much rather focus on the positive contributions that we are making towards building our country and uplifting the nation – having achieved remarkable success stories in the communities in which we operate.
Making a difference We have gone deep into the heart of rural communities to turn on the lights in households where this was not previously possible. By 2017, Rotek’s Construction Services had electrified five rural communities in the Eastern Cape, providing connections to 1 800 households in dire need of this basic service. We constructed the electrification backbone infrastructure that included medium-voltage lines, low-voltage lines, transformer installations and house connections. As a result, socio-economic development increased in these communities, which increased the realisation of the ideal of long-term sustainability. Thanks to our various business units, Rotek’s services don’t stop with electrification. We have been managing the reliable water transfer from the Komati Water Scheme for decades, and we also repaired 122 000 m2 of potholes in our country in just one year. Furthermore, we are currently managing one of the largest road supply chains in South Africa – a success story made possible by the passionate and dedicated teams within our Logistics Services division.
Expansion outside of SA But Rotek’s capabilities are not only limited to South Africa., as we strive to reach beyond our country’s borders. Over the decade, Botswana, Namibia, South Africa, Zambia, Zimbabwe and recently Tanzania have had to resort to load-shedding as a stop-gap measure in order to conserve energy. South Africa, SADC’s economic powerhouse, was particularly badly hit by energy shortages back in 2008 with its mining industry, the mainstay of its economy, temporarily shutting down operations in January that year to allow for the power supply situation to be stabilised. Mining accounts for about 15% of South Africa’s electricity demand. Massive investment in generation, transmission and distribution infrastructure will be required to sustain the projected increase in power demand in the region. The SADC region is estimated to require between US$93 billion and US$212 billion on short- and long-term projects to boost power supplies between 2015 and 2027. Rotek is part of the journey in the SADC region has done extensive work into Africa. We even played a role in the iconic Burj Khalifa in Dubai when Rotek transported the gigantic 828 m high steel structure for this hotel and produced the fly ash mixed in the 45 000 m3 concrete foundation. In Uganda, we are leading the way in the generation of reliable and affordable power for the country’s National Development Plan. Our market share in terms of generating electricity into Uganda’s national grid now stands at 40%, currently making us the cheapest generator of electricity in that country at US$0.01 per unit. Further to this, Eskom embarked on corporate social responsibility (CSR) projects within Uganda. The rehabilitation of Njeru Primary School is a fine example, which included the replacement of asbestos roofing, and fencing of the school. Another sterling CSR project saw Eskom partnering with Jinja West Member of Parliament Hon. Grace Moses Balyeku to construct and equip a maternity ward at Kimaka Health Centre II to the tune of USh200 million (approx. R687 000). On the skills transfer front, graduate trainees in Uganda have been given an opportunity by Eskom to gain hands-on experience in hydro generation. Eskom continues to offer industrial training to students every year and has a current intake of graduate trainees at any given time in the graduate training programme, which runs for 18 months. These are just some of the many success stories and capabilities within Rotek that go untold. Through this publication, we aim to give you insight into our business, the way we operate, and our varied abilities of which we are extremely proud. Welcome to the world of Eskom Rotek Industries.
Eskom Rotek Industries 2018
InterSystems | Profile Logistics History | Rotek Services | ERI
ONE Our heritage is our inheritance – the things we received from generations before us. Eskom Rotek Industries has a history of exceptional service to the development of South Africa. And in order to understand where we’re going, we must know how far we’ve come.
historical step at a time 1906 The Victoria Falls Power Company is established to supply South Africa and then Rhodesia (now Zimbabwe) with electricity.
The Rosherville Workshops were established to provide maintenance to the first three power stations: Rosherville, Simmerpan and Brakpan.
1948 The Victoria Falls Power Company is integrated into Eskom and the Rosherville Workshops are incorporated into Eskom Central Maintenance Services.
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The Rosherville Power Station is built on the banks of the Rosherville Dam, halfway between Johannesburg and Germiston. It brought South Africa’s electricity utility, Eskom, to the area.
e l i f o r PHistory | s metsy r|e tERI nI Logistics Services | SRotek
1989 Eskom Central Maintenance Services is commercialised into Rotek Industries, which became known as Rosherville Engineering.
Rosherville Construction (Pty) Ltd (later named Roshcon) is established. This company incorporated Rosherville Properties and Rosherville Vehicle Services, a transport arm later known as Rotran.
Rotek Industries, better known as Rotek Engineering, is incorporated into Eskom Enterprises.
2010 The drive to incorporate Rotek, Rotran and Roshcon into a single entity starts. Known as Rotek and Roshcon, the Eskom subsidiaries operated as one company while waiting for Public Finance Management Act approval.
2015 Rotek and Roshcon officially merge to form Eskom Rotek Industries SOC Ltd. The companies now have one name, one brand, one operating model, and one culture.
Eskom Rotek Industries 2018
InterSystems Profile Logistics Services Introduction || ROTEK | ERI
Serving the electricity industry for
over 100 years Eskom Rotek Industries, a wholly owned subsidiary of Eskom Enterprises, has been in existence in various forms for more than a century. It has a rich history in electricity generation maintenance, with the Rosherville workshops established in 1913 to provide maintenance to the first three South African power stations, namely Rosherville, Simmerpan and Brakpan.
oday, this maintenance service continues in the same space where it germinated from so many years ago. The organisation’s business units form the operational backbone of Eskom Rotek Industries (ERI) and house years of technical expertise and experience.
Turbine and generator refurbishment Rotek business unit Turbo Gen Services has the ability to service and refurbish all rotating equipment and related components, and can deliver complete turnkey engineering solutions. The Turbo Gen Services workshops in Johannesburg span 58 000 m2
Eskom Rotek Industries 2 0 1 8
under cranage and can handle up to 325 t, 365 days a year, 24 hours a day. The services offered include all maintenance, refurbishment, modification and repair of power generating and auxiliary equipment on-site or at the workshops, and include: • G enerator Services focuses on the rewinding and overhaul of rotating equipment. • Mechanical Services offers heavy, medium and light machining capabilities and specialised welding. • Balancing Services refers to the balancing of rotating machinery from 5 kg to 300 t, and 100 rpm to 3 600 rpm. • Bearing Services can refurbish and
manufacture white metal bearings and components. • Valve Services refurbishes low- and high-pressure steam and water valves mostly on-site. •N on-destructive Testing Services determines the quality and condition of components without changing the functionality of the material.
Transformer services Similarly, Rotek business unit Transformer and Switchgear Services has the ability to conduct major transformer overhauls, rewinds, manufacture and refurbishment of tanks and parts. It can accommodate single-phase units of 666 MVA and 765 kV, and three-phase double-
e lIntroduction iforP | s metsy r|e tERI nI Logistics Services | SRotek
winded transformers of up to 910 MVA and 420 kV. In addition, it offers boilermaking capabilities, as well as limited steelwork manufacturing and repairs. The workshops boast all the facilities necessary for untanking, dismantling, testing, modification, assembly and painting. Other facilities include: • The winding facility can manufacture regulating, disc, interleaved disc and screw windings up to 1 000 MVA. • The vapour phase facility cuts drying by more than half of the time required by conventional heat and vacuum drying processes. • The test bay facility has a 3 200 kV lightning impulse generator for impulse testing. • The oil depot performs sampling, storage, treatment and purification of transformer oil. • The bushing, tap-changer and current transformer facility services
and repairs most makes and models of transformer components to OEM specifications.
ROTEK fact file
Transforming for change The mark of any world-class organisation is its ability to change within the needs of a changing environment. Broadening its service offering, what is now Rotek entered the construction, bulk material handling and logistics arenas in the 1990s. These services are still in existence today and complement the maintenance services already provided by the three standalone business units that follow. Bulk Material Services specialises in bulk material handling for coal, ash, limestone and gypsum, water services, project management and related engineering solutions. In addition, it also offers plant maintenance, water treatment solutions, coal transportation
• Shareholding: Rotek is a subsidiary of Eskom Enterprises, which is a subsidiary of Eskom Holdings • Merger: Rotek is the result of the amalgamation of three entities: Rotek, Roshcon and Rotran • Location: Rotek has its head office at Rosherville, with a national footprint in all major centres close to key customer sites • Revenue as at 31 March 2017: R10 billion • Staff complement: ±12 000
Eskom Rotek Industries 2018
TOUGH, SAFE, DURABLE Established in 1978, Allbro employs more than 800 people and has 20,000 sqm of production facility. Allbro engineers, designs, and manufactures solutions for some of the toughest ts enviroments n e on earth. pon
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www.allbro.com Tel: +27 11 894 8341 Fax: +27 11 918 1072 Email: firstname.lastname@example.org
e lIntroduction iforP | s metsy r|e tERI nI Logistics Services | SRotek
logistics and the selling of coal combustible products such as ash, gypsum and salts. Construction Services specialises in mixed civil construction projects focusing on earthworks, concrete works and drainage, fencing, water management solutions, as well as road construction and pothole repairs. Electrical construction refers to a turnkey solution from initiation phase to final handover of electrical construction services such as energy-efficient installations, power line and substation construction, cabling and switchgear, and electrification services. Logistics Services offers road transport, material handling and consolidation, warehousing, fullscope waste management, and road
logistics services. These encompass the transportation of plant and auxiliary components to remote sites, the removal of both general and hazardous waste, as well as the haulage of all heavy and abnormal sized equipment. With the largest multi-axle fleet in the southern hemisphere, Logistics Services has the capacity to transport anything up to 500 tonnes.
Building a lasting legacy In answering the challenge set by government to continually strive to uplift the economy of South Africa, Rotek has achieved remarkable success stories in the communities in which it operates. By 2017, Rotek Construction Services had electrified five rural communities in the Eastern Cape, for a total household connection of 1 800
households. The rural electrification included the construction of the electrification backbone infrastructure that included medium-voltage lines (11 kV to 22 kV), low-voltage lines (230 V to 400 V), transformer installations and house connections. Socio-economic development increased in these community areas, which increased the realisation of the ideal of long-term sustainability. Other legacy projects include: the transportation of the enormous 828 m high steel structure for the Burj Kalifa in Dubai; managing reliable water transfer from the Komati water scheme for decades; repairing 122 000 m2 potholes in one year; and currently managing one of the largest road coal supply chains in South Africa. The South African power utility identified Rotek as its preferred turbine
Eskom Rotek Industries 2018
InterSystems Profile Logistics Services Introduction || ROTEK | ERI
generator maintenance service provider, with the result being that Rotek has been involved in outage maintenance and refurbishment on all local powerÂ stations.
Looking towards the future With the ever-changing challenges presented by its macro and micro operating environs, Rotek will continue to investigate innovative methods and
refine them into effective solutions to meet clientsâ€™ needs. While Eskom remains a major focus area for Rotek, the organisation can now expand the Rotek footprint to include a diverse customer portfolio with tailor-made solutions to suit individual customer demands. The product knowledge gained over more than a lifetime is of particular
+27 11 316 7512
value and, like goodwill, needs to be shared in order for it to grow. Rotek invites stakeholders in the energy, manufacturing, mining and oil and gas industries to contact it for future collaboration. By building on the strengths that have stood the test of time, Rotek can assist clients in developing new, integrated solutions to business needs.
We supply a comprehensive range of equipment and tools to the power distribution industry Insulators
General Electrical Products
Transformers & Reactors
Medium Voltage Products
Specialised Lightning Detection
Line Trackers & Transfer Monitoring
e l i f o r PAllbro | smets SretnI | yProfile
of local manufacture and innovation As a truly local company, Allbro has been at the forefront of addressing some of the unique challenges associated with South Africa’s electrification.
onnecting more than 12 million homes to the grid across what is often a very challenging landscape resulted in the creation of solutions that are unique and, in some cases, world firsts. The additional challenge associated with many of the regions having harsh climates contributed to the development of robust and durable solutions that are different than those typically found in Europe, from where our local standards originate. Split metering and prepaid electricity were local innovations in need of housings that would address all the challenges already mentioned, while also being cost-effective.
Allbro is the largest producer of ready boards and weatherproof pole top boxes in the world.
A new ready board The latest innovation, which is also a world first, is a new generation of expandable ready board. Although effective, the extremely basic single electricity point that has been the standard over the last 20 years does not allow for expansion into multiple rooms. The new-generation ready board has a port that allows for a ‘room extender’ to be safely and simply deployed in a chain, for up to four rooms – with a light and two sockets available in each. The room extender can be provided by the utility, or can be purchased in an after market scenario by the consumer and can be easily fitted as a sort of appliance.
A near-indestructible enclosure Another innovation that has garnered tremendous attention since its release at Africa Utility Week earlier this year is AllVault. As the value and complexity of equipment being deployed across vast geographical areas have increased, so has the need to protect the function of these networks and devices. Lost revenue due to the bypassing of meters amounts to vast sums of money that dwarf the cost of the physical infrastructure.
AllVault’s vault-like high-security box can withstand very high levels of abuse. www.youtube.com/watch?v=zk35crHMKek
Enter the AllVault, which is designed to withstand high degrees of abuse. The unique composite material used in its fabrication was developed locally for manhole systems and is able to absorb the impact of hammers, chisels and axes, among other things. Also, intelligent locking systems allow the utility to monitor the behaviour of the technicians maintaining the network, further improving the integrity of the network and the security of the revenue.
About Allbro Allbro employs over 800 people and has factory space of close to 20 000 m2. Competencies include: • Raw material compounding – 3 900 t of raw material produced annually. • Design and development – Products are designed by an in-house team of mechanical engineers using the latest design tools. • Toolmaking – Moulds are made on-site (some as large as 8 t). • Manufacturing – Performed according to ISO 9001 global quality standards. • Testing – Laboratory on-site to verify ongoing compliance. With more than 100 million enclosures in service – some for as long as 40 years – Allbro has learned much from the real-world environment in which its products are expected to perform.
Eskom Rotek Industries 2018
InterSystems | Profile Strategy | rotek
Poised for growth In order for Rotek to achieve its objective of being a world-class energy industry services company, certain growth strategies need to align with those planned for the SADC region’s energy sector.
ccording to the SADC Energy Monitor, South Africa accounts for more than 83% of the total regional electricity production,
Being a highperformance organisation with an enabling culture
Equipping the business to align with customer requirements
Ensuring the future financial sustainability of the organisation
followed by Mozambique, Zambia and Zimbabwe. There are power generation projects in nearly all SADC Member States, which are at various stages of development in
Focusing on company transformation and customer orientation
Increasing safety, health, environmental and quality performance
Eskom Rotek Industries 2 0 1 8
order to meet or surpass demand. Other than Mozambique and the Democratic Republic of Congo, most of the countries have a supply deficit that they are struggling to manage – giving investors a great opportunity for investing their money into power generation and transmission projects in the SADC region. The energy sector has been particularly critical to the economies of Nigeria and Angola, both of which have become major oil exporters over the past decade, as is stated in PriceWaterhouseCoopers’ ‘Africa Gearing Up’ report. The report further states that oil and particularly natural gas are also important to Egypt, but energy exports look likely to shift a bit in the coming years. Angola and Nigeria will, to a different extent, need to cope with decreasing demand from the US, where the shale gas boom has started to impact oil imports.
e l i f o rStrategy P | smetsy retnI | SROTEK
While the US is Nigeria’s main trading partner, Angola’s oil exports have been directed to China rather than America in recent years. New players may also emerge in East Africa. The International Monetary Fund (IMF) believes that Kenya will begin producing commercial quantities of oil in six to seven years. One must not forget that Tanzania has natural gas reserves, too, and Mozambique has massive reserves of both coal and natural gas. Accessing Mozambique’s coal can prove to be challenging, but thankfully South Africa is not faced with the problem of access to coal.
Energy resources Given the dominance of South Africa in terms of power generation – accounting for almost 76% of the overall generation capacity in mainland SADC – coal is the most dominant source of electricity in the region. More than two-thirds of all the electricity produced in the region comes from coal-fired plants. At least 86% of South Africa’s total generation capacity of 44 170 MW (March 2016) came from coal-fired plants, while
82% and 63% of electricity was produced from coal in Botswana and Zimbabwe, respectively. Hydropower is the sole source of electricity generation in four Southern African Power Plan (SAPP) member countries – the Democratic Republic of Congo, Lesotho, Malawi and Zambia – while hydropower also accounts for a sizeable proportion of capacity in Angola, Mozambique, Namibia, Swaziland and Tanzania. South Africa is the only SADC Member State that has a nuclear power station, owned and controlled by Eskom. The Koeberg Nuclear Power Station in the Western Cape is, in fact, the only nuclear power station in Africa. It contains two uranium pressurised water reactors, and supplies power to the national grid so that over-capacity can be redistributed to the rest of the country on a needs basis. The power station has generation capacity of 1 800 MW and has two large turbine generators, each producing 900 MW. With the exception of South Africa, capacity constraints have also seen most SADC Member States failing to
76% In terms of power generation, South Africa accounts for almost 76% of the overall generation capacity in mainland SADC
fully embrace renewable energy and energy efficiency technologies, such as solar and wind power. For instance, solar thermal-electric systems have the long-term potential to provide a significant fraction of SADC’s electricity and energy needs. Research has shown that most countries in southern Africa receive more than 2 500 hours of sunshine per year. Knowledge on solar energy technology is widespread in the SADC region but its use is still limited partly due to the prohibitive
Oil rig at Nigeria’s capital, Lagos: The energy sector has been particularly critical to the economy of Nigeria, which has become a major oil exporter over the past decade
Eskom Rotek Industries 2018
InterSystems | Profile Logistics Services Strategy | ROTEK | ERI
72.6% Rail and air transportation accounts for 27.4% of the total freight mode, while road accounts for 72.6% The Democratic Republic of Congo scores among the worst of all nations for logistics performance, ranking at 143rd
initial set-up costs involved coupled with capacity constraints.
Trading electricity Construction of a new power transmission line linking Mozambique and Zimbabwe is on the cards and is expected to improve connectivity and electricity trading in the region. Commonly referred to as the MOZA Transmission Project, the venture involves the three countries that are linked to the regional grid. The three utilities in each country have since entered into a memorandum of understanding to develop an interconnector and have formed three joint project development teams – a steering committee, technical committee and commercial committee – all of which have been tasked with spearheading the implementation process being coordinated by SAPP. As part of the MOZA project, there is a need for various separate developments in each of the countries involved to complement the project and ensure that the MOZA interconnector is a success. Once completed, the interconnectors are expected to promote regional electricity trade and enhance security of electricity supply. Even better, the interconnectors will decongest existing transmission corridors and offer another wheeling path that will fully integrate all mainland SADC countries to the regional power grid. Just as the SADC region has set out to explore alternate avenues for electricity generation and supply, one of Rotek’s main strategies is to explore new revenue streams, drive
Eskom Rotek Industries 2 0 1 8
cost containment and align itself with strategic partnerships. As a performance driven contractor, Rotek is especially proud of its cidb 9 grading. A grade denotes the maximum value of a contract the contractor is deemed capable of performing within a particular class of works, with grade 9 having an unlimited tender value range. It also allows the organisation to afford opportunities to SMMEs. Coal is the most dominant source of electricity in South Africa and accounts for almost 76% of the overall generation capacity in mainland SADC
2020 It is estimated that if SADC implements its short-, medium- and long-term generation projects, the region could meet its medium-term energy demand by 2020
Capitalising on logistics South Africa stands out, ranking number one in Africa and 23rd in the world in logistics performance, according to the ’Africa Gearing Up‘ report. Egypt scores well too, coming in at number 57 worldwide, while the Democratic Republic of Congo scores among the worst of all nations, ranking 143rd. These differences in infrastructure and logistics performance translate into real costs for supply chains. According to the World Bank, it takes just 12 days to export a container from Egypt, at a cost of US$625. The journey lasts four times as long – over a month and a half – to export a container from Angola, at nearly triple the cost. And it can get even trickier if you need to cross borders within Africa. In contrast, at the world’s largest ports in Hong Kong and Singapore, it takes just five days to export a container at a cost of US$575 and US$456 respectively. If you were to transport that same container from landlocked Botswana, rail would be the best and most cost-effective option. Rotek’s Logistics Services division has great opportunities with its transportation offering spanning diverse sectors. The division is identifying key segments for its growth strategy – each one to be explored further. It is important to note that all Rotek’s strategies, regardless of the business unit, are underpinned by its six key values, namely: Zero Harm, Integrity, Sinobuntu, Innovation, Customer Satisfaction and Excellence. Rotek is committed to the highest standard of ethical conduct in all its actions and decisions.
InterSystems | Profile Logistics Q&A: HeadServices of Marketing | ERI | ROTEK
Improved practices, better results
The New Business Development Marketing division at Rotek discusses the multimillionrand savings that can be realised through the organisation’s improved turbine maintenance practices.
The outcome: The it was observed that development of the new conventional cylinder technology was completed alignment methods were proving unsuccessful within Rotekand has been The African Union, in its Agenda 2063, during major turbine executed successfully on has identified energy overhauls. three units to date. By as one of the key With many of these utilising this method, the infrastructure Are there any projects Rotek clients’ fleets operating turbines were refurbished, pillars for connecting the continent is involved in at the for longer hours, in a drive assembled and returned moment that you are particularly to meet customer energy to service successfully. In excited about? demands, distortion becomes a major future, the distortion-compensation We are very excited about the millions challenge and had been a major driver method will be the norm for cylinder of rands in savings that can be realised for higher maintenance costs, as well as alignment of cylinders with above-normal through our improved turbine longer outages. The industry norm for distortion. One of the major advantages maintenance practices. In the past, major power plants with similar conditions of the new method is that it can be performance and vibration problems would be to replace the turbines or executed within a shorter period than the were experienced by clients remove the distortion conventional methods and tends to be following major outages. by machining or heat much more accurate. The challenge: Rotek’s treatment. These options Where in Africa is Rotek active? engineering department are very costly and timeTraditional biomass Rotek is a currently a 100% worked tirelessly with clients consuming, and would such as wood and coal accounts for South African company with limited within the power utility sector often mean material more than 45% maintenance contracts cross-border. The to address vibration problems life exhaustion of major of final energy company maintains a strong ambition on turbines that led to components, which in consumption in the SADC region to grow and expand its construction distortions on these rotating turn would drive costs. and maintenance services to the rest of machines. The challenge was The solution: An the continent. further aggravated by machine ageing, as alternative solution was investigated well as general misalignment. Vibration and implemented by Rotek. This solution What is Rotek’s vision for problems had become a norm on these involved retaining the distortion of the the energy sector on machines, following every outage casing, as it is often a function of the the continent? (planned or unplanned). It is quite normal operational temperature distribution Rotek is guided by our values – Zero for high-temperature turbine cylinders to in the casings. Doing so improved the Harm, Integrity, Innovation, Sinobuntu, distort over time due to operational stress life expectancy of the assets’ major Customer Satisfaction and Excellence – and age. During this period, however, components, as the casing was retained for this operating model and our strategy to longer in the secondary creep zone cycle. shift performance and grow sustainably Furthermore, the team went on and will realise our vision to be a world-class investigated solutions to ensure a energy industry services company. reliable operational turbine without any vibrational or process problems. To this end, a method was designed to With a planning horizon execute accurate cylinder alignment in stretching from 2010 to 2020, the presence of distortion. The distortion the Southern African Power causes cylinder components to move Pool (SAPP) revealed that relative to each other during assembly. SADC stands to make huge cost savings of up to US$48 billion Based on global best practices, These movements affect the small internal as well as enjoy better the Southern African Power clearances and can lead to mechanical coordination if they pursued Pool (SAPP) requires a 10.2% contact between rotating and stationary their projects collectively as a electricty reserve margin at components, which in turn may lead to region rather than as individual any time in order to avoid Member States load-shedding major vibration and mechanical damage.
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InterSystems | Profile Logistics Services operational divisions | ERI| Rotek
A specialised offering
like no other Eskom Rotek Industries has provided diagnostic and engineering services for more than 100 years. The company boasts a national footprint and prides itself on being a dynamic business with expertise in five technically specific business areas.
skom Rotek Industries specialises in engineering consultancy, construction, plant operations and general maintenance services for all power generation equipment and associated power infrastructure. It has serviced clients across a range of industries such as energy, water, oil and gas, abnormal load transportation and the tyre industry, to name but a few. Rotek collaborates effectively with a range of original equipment manufacturers (OEMs). The company upholds its commitment to work towards reducing operational downtime and increasing uptime for all clients.
The Turbo Gen Services service offering
Turbo Gen Services is one of the few exclusive and strategic major turbine and generator maintenance service providers. This business unit is positioned to refurbish large power generation turbines, generators and related equipment, with a special focus on the maintenance engineering of the turbine and the generator island. Service offerings include turbine and generator refurbishment, engineering solutions, condition monitoring and first line maintenance.
Specialist offerings include: • Manufacturing of small components • Generator services related to stators and rotors • Mechanical services – heavy, medium and light machining
The Bulk Material Services service offering This business unit of Eskom Rotek Industries offers a wide range of general bulk material handling services for coal, ash, limestone and gypsum and also provides project management and related engineering solutions. In addition, it also offer plant maintenance, water treatment solutions, coal transportation logistics and the selling of coal combustible products such as ash, gypsum and salts. It further manages bulk water schemes to supply water to power stations through its bulk water handling function and has the ability to manage coal and ash stockyards, as well as to provide maintenance to coal conveyor operations.
Eskom Rotek Industries 2 0 1 8
• Balancing services • Bearing services • Non-destructive testing services • Conditioning monitoring • Specialised engineering support
Specialist offerings include: • Coal logistics • Bulk water handling • Ash and coal handling operations • Power station maintenance
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Specialist offerings include:
• T ransport services • Waste - 0 - 32 tonne fleet management - 32 - 80 tonne flee • Materials handling - 80 tonne plus fleet and consolidation
The Logistics Services service offering The Logistics Services business unit offers road transport, material handling and consolidation, warehousing, a full scope waste management solution and road logistics services. In short, these encompass the transportation of plant and auxiliary components to remote sites, the removal of both general and hazardous waste, as well as the haulage of all heavy and abnormal sized equipment. With the largest multi-axle fleet in the
southern hemisphere, Logistics Services has the capacity to transport anything up to 500 t. For the management of waste, the business provides a wide range of services from collection and disposal of various waste types to advance services such as asbestos and dismantling projects, removal of healthcare risk waste, operating landfill sites, waste awareness training and onsite waste management training.
The Transformer and Switchgear Services service offering
This business unit of Eskom Rotek Industries offers maintenance, design and rewind, refurbishment, repair and modification services for power transformers and switchgear. These services are offered both on-site and at Eskom Rotek Industries’ advanced,
well-equipped workshops in Johannesburg. The overhead crane in the workshop has the capacity to safely lift up to 600 t and the highvoltage test facility has a range up to 3 200 kV to perform lightning and switching impulse testing.
Specialist offerings include: •P ower transformer workshop overhauls and rewinds (1.25 MVA to 920 MVA) • Power transformer site maintenance, repairs and re-gasketing (1.25 MVA to 920 MVA) • Tap changer and diverter overhaul, maintenance, OEM modifications and upgrades • Switchgear maintenance, repairs, OEM
• • • •
modifications and upgrades on 6.6 kV and above Transformer and bushing oil sampling and analysis Transformer insulating oil supply, purification and regeneration Electrical testing site related (380 V) SF6 gas analysis and recovery
The Construction Services service offering
The Construction Services business unit specialises in both civil and electrical power generation infrastructure construction. Services include terracing and reticulation, the building and cabling of substations, reticulation network electrification and installation, cable management and installation, as well as erecting power lines and towers. These services effectively allow for product delivery on power line, substation, cabling and mixed civil projects.
Specialist offerings include: •M ixed civil construction - Earthworks - Concrete works - Drainage and water management services - Facilities maintenance • Genereal road maintenance • Electrical construction - Cabling and switchgear - Substation constructon - Powerline construction - Electrification • Renewable energy services
Eskom Rotek Industries 2018
InterSystems | Profile Logistics Civil & Power Services Generation | ERI Projects | Profile
Excellence through experience Civil & Power Generation Projects (CPGP) is one of the largest thermal insulation and scaffolding organisations in Africa, with a proud reputation for successfully delivering projects of various complexities across South Africa.
oday’s competitive commercial environment presents numerous challenges to businesses, with everyone out to beat each other to the punch. That’s why delivering effective, quality service matters and is an important part of CPGP’s commitment. The company’s vision is a multifaceted one, with aims to “provide quality service that combines performance and safety with competitive pricing while establishing a successful relationship with our clients and our suppliers, and in addition, provide a safe, healthy and rewarding workplace for employees.” With senior staff members
whose individual experience exceed 30 years of involvement within the construction environment – in fact, the least experienced management team member has 11 years of experience in the sector – the company is in very sure hands. And, as a Level 4 BBBEE contributor with a procurement recognition of 100%, as well as a registered entity with the Construction Industry Development Board, CPGP is excellently positioned to service the needs of its clients and partners.
Areas of expertise
CPGP’s areas of expertise are thermal insulation, turbine insulation, scaffolding, sheet metal work, the construction of supporting structures, and project management. CPGP delivers a comprehensive service that includes: • the supply of materials • the design of insulation thicknesses and grades of material • the supply of insulation and sheet metal • the design and application of insulation and sheet metal supporting structures • the erection and dismantling of scaffolding both CPGP economically and specialises professionally. in the supply and erection of scaffolding, thermal insulation and sheet metal work
Thermal and turbine insulation Thermal insulation is a vital component in a number of industries and processes, utilising materials of low thermal conductivity to ensure extreme temperatures do not endanger lives, equipment or machinery. Thermal insulation is an absolute necessity to conserve energy and save costs for clients, identify and prevent corrosion that may lie under the insulation, and perform damage assessments and preventative maintenance. CPGP’s insulation service covers both hot and cold applications, between -100°C to 870°C, to the standards and specifications required by the various industries. CPGP’s unique insulation expertise perfectly positions it to design and install insulation on major construction, maintenance and repair projects. The company designs its insulation systems to provide the best possible solution for the anticipated conditions, helping clients to optimise efficiency, while reducing risk and costly unforeseen maintenance/repairs. The deployment of turbine insulation at various power stations has long been part of the team’s insulation expertise. The company has the latest spray lagging machinery at its disposal, ensuring work is done to the highest standards and according to its design specification.
Scaffolding Access scaffolding is an important piece of the puzzle in most large construction projects, and is also often utilised during maintenance and repair operations. CPGP specialises in providing scaffolding for commercial, industrial and niche applications.
Civil & Power Generation Projects | Profile
Servicing the nation CPGP’s highly competent staff and exceptional standards of workmanship are currently deployed at two of Africa’s largest power stations – namely Eskom’s Kusile and Medupi sites. Each power station has a power output of 5 220 MW, with six turbines each producing 870 MW. That’s 10 440 MW in total.
Through meticulous planning and close monitoring, CPGP ensures that its work is executed safely and to the highest standards The variety of factors that come into play in the design of scaffolding make for quite a complex equation. Everything from required platform workloads, equipment type and tie-in points, specialised design and environmental aspects must be taken into account. So, in order to ensure that the scaffolding it assembles is safe and fit for purpose, the company has developed its own scaffolding design software in line with South African National Standard specifications. This software calculates safe working loads for the scaffolding, ensuring a structurally sound design. After design, CPGP’s expert scaffold team members collaborate with health, safety and environment officers to compile the
appropriate documentation and hand over a scaffold structure in which both the client and CPGP can have the utmost confidence.
equipment, which eliminates the chances of human error creeping in and results in the fabrication of precise, cost-effective products. CPGP’s journeyman welders are deployed to spot-weld insulation pins or studs to ensure insulation can be properly secured with the appropriate clips, while welding sheet metal supports is also a core function of the team.
Sheet metal work and supports
The highly qualified and experienced developers and applicators that comprise CPGP’s sheet metal development team boast years of experience across a range of sheet metal applications. Whether it’s a flat and profile sheeting application or lobster back-bends on piping, CPGP delivers products of exceptional quality that can be fabricated from a range of materials and to suit any product or client design/specification. This business unit prides itself on the timely delivery of work, through the use of highly specialised mechanical
CPGP possesses a unique set of skills and offers a comprehensive service that can support the following sectors: • power generation • petrochemical • pulp and paper • nuclear • liquefied natural and petroleum gas • mining • mineral processing • sugar • offshore plants • parastatal • retail and commercial sectors in South Africa.
Ensuring quality As a stickler for detail and delivery, CPGP regularly monitors and evaluates progress and efficiencies throughout the duration of a contract. Through meticulous planning and close monitoring, CPGP ensures that its work is executed safely and to the highest standards. The company observes to the highest safety standards in terms of OHSAS and ISO specifications and is committed to the principles of sustainable development and zero harm. It further adheres to ISO 9001: 2008 Quality Management System relating to procedures, work instructions, standard operating procedures and relevant working documentation.
Eskom Rotek Industries 2018
Civil & Power Generation Projects is one of Africa’s largest Thermal Insulation & Scaffolding Organisations.
CORE SERVICES Thermal & Acoustic Insulation incl. Design
Sheet Metal Work
Scaffolding Services, Design & Hire
+27 (11) 918 6335
+27 (11) 918 6329
e l i f o r Pservices | s metsy r|e tERI nI Transformer & Switchgear Logistics Services | SROTEK
Servicing the demand for maintenance in the energy sector
outhern Africa faces many daunting developmental challenges. Although rich in natural resources, industrial and commercial development remains slow, poverty remains high, and access to clean affordable energy for households is nowhere near where it should be. In 2010, at the peak of South Africa’s infrastructure development and as the continent braced itself to host the largest football spectacle in the world, it was estimated that only 24.7% of households in the Southern Africa region had access to electricity, while biomass remained the primary energy source in many of these countries at the time. If we look specifically at the Southern African Development Community (SADC) countries, energy resources and supply and demand within this region varies greatly. While most Member States of SADC have abundant energy resources, they sometimes lack the technical capacity to put them to use, which is the reason for the variation in energy production and consumption. The extensive energy resources in the region are used within SADC as well as exported from the region. Energy is also traded between states: for instance, South Africa imports and exports electricity to and from neighbouring states, and also imports natural gas from Mozambique.
The Southern African Power Pool noted the need to reduce support and maintenance costs for its future trading platform. Rotek prides itself on both its on-site and workshop maintenance services.
Infrastructure development According to the ‘SADC Energy Monitor 2016’ report, energy infrastructure development in the region has been guided by instruments that include the Regional Indicative Strategic Development Plan (RISDP) – first adopted in 2003 and revised in 2015; the SADC Protocol on Energy; the Energy Cooperation Policy and Strategy of 1996 and the SADC Energy Action Plan (1997), among others. Energy is a critical area of Priority B of the Revised RISDP 2015 – 2020, which focuses on provision and improvement of infrastructure support and maintenance for regional integration and industrialisation. Considerable preparatory work has been undertaken in this area to develop enabling policies, systems and processes such as the Regional Energy Access Strategy and Action Plan of 2010 in support of the SADC
Eskom Rotek Industries 2018
InterSystems Transformer |&Profile Switchgear services | ROTEK
Industrialisation Strategy and Roadmap 2015 – 2063. It is expected that the environment created will help to attract private sector investment and further promote public-private partnerships.
Power pool The Inter-Governmental Memorandum of Understanding (IGMOU) of 1995 was reviewed in 2006 by SADC Energy Ministers in order to allow Independent Power Producers (IPPs) to be members of the Southern African Power Pool (SAPP), with Eskom being one of these member utilities. SAPP was created with
One of SA’s leading manufacturers of steel structures:
the primary aim of providing reliable and economical electricity supply to the consumers of each of the SAPP members, consistent with the reasonable utilisation of natural resources and effects on the environment. SAPP has identified a number of priority energy projects for commissioning over the next few years to address energy shortages in the region. Between 2015 and 2019, SAPP plans to commission a total of 23 585 MW. If this is achieved, SADC will finally be able to meet most of its power needs after several years of shortages. Despite its limited role and functions, SAPP is regarded as the most advanced power pool on the African continent. SAPP was the first formal international power pool outside of North America and Europe. It was also the first power pool in Africa to establish a competitive power market that allows countries connected to the regional grid to trade surpluses. In its business plan of 2013 on the competitive market, SAPP noted the need to reduce support and maintenance
Transmission line monopoles Sub station steelwork Lattice communication towers Electricity Pylons Gantrys and Walkways Foundations and Installations
T&SS WORKSHOP fact file
• Winding facility: Manufactures regulating, disc, interleaved disc and screw windings up to 1 000 MVA, using either a solid or continuous transposed conductor on horizontal and vertical winding machines. • Test Bay facility: Handles medium (120 kJ – 1 200 kV) and large (360 kJ – 3 200 kV) lightning impulse generators for impulse testing.
costs for its future trading platform. As a way forward, a decision was made to develop a new trading platform with reduced support and maintenance costs,
Vanderbijlpark: Tel: +27 (0)16 986 1135 Fax: +27 (0)16 986 2682 e-mail: email@example.com
CIS Engineering is a member of the Structa Group and is a Level 3 BBBEE Contributor
CIS is Eskom approved
Engineering (Pty) Ltd
e l i f o r Pservices | s metsy r|e tERI nI Transformer & Switchgear Logistics Services | Srotek
Transformer services facilities
while at the same time giving SAPP the option to add other trading products that will assist in increasing liquidity within the competitive market. Rotek’s reliable and rugged components of the primary equipment for transformer and switchgear services are often in use for decades at a time, answering to the need to keep maintenance and support costs low.
Transformer services Rotek’s on-site transformer services range from loading and off-loading, transporting, installation and commissioning, and treatment of oil with mobile oil plants, to performing various transformer tests together with technical assessments that determine the condition and general health of the transformer. Testing, servicing, repairs and replacement is performed in the field on tap-changers, bushings, and auxiliary equipment by trained and experienced site teams. These services are provided anywhere in sub-Saharan Africa on a routine basis, or after faulting has occurred on the transformer. Clients include power stations, transmission and distribution substations, industrial installations for power utilities and the private sector. In cases where un-tanking of the active part is required, the transformer is taken to Rotek’s workshop in Rosherville, which offers all the necessary facilities for bushing, tap-changer and winding services, as well as un-tanking, dismantling, inspection, testing, repair or overhaul, modification, assembly, drying, and painting – all under one roof and all done professionally and efficiently.
Switchgear services Switchgear maintenance is one of T&SS’s core competencies, and the division is able to work on all types of circuit-breakers, disconnectors and isolators, both AC and DC equipment, of voltages from 11 kV to 765 kV. Switchgear services include installation and removal,
routine maintenance according to OEM specifications, as well as refurbishment and repairs on-site. Service accreditations include Delle, Alstom and ABB generator breakers, as well as installation and maintenance of GIS switchgear. T&SS also services, repairs and tests all types of compressor plants related to air-break type switchgears. Just as in the case of transformer services, for extensive repairs or modifications, equipment is decommissioned and taken to the workshop in Rosherville, where it is refurbished under required clean conditions, with specialised equipment and testing facilities at hand. Specialised teams perform the work and these services are delivered anywhere in sub-Saharan Africa.
Engineering services Furthermore, T&SS offers transformer and switchgear engineering services that will perform investigations into plant failure or poor performance, and advises on repair strategies and cost versus benefit analyses. Independent design reviews are regularly carried out and equipment redesigned and modified for uprated capacity. Engineering services include: Service engineering, such as scope development and risk analysis
engineering, such as mechanical 2 Wandorkselectrical inspection ngineering development, such as 3 Eproduct specific technology improvements engineering, such as turbine 4 Specialised and generator engineering
Transformer engineering, such as failure investigation (un-tanked)
site engineering, such as 6 Transformer plant walk down audits.
A vapour-phase plant, capable of drying large transformers or a number of smaller units simultaneously. The use of kerosene vapour to displace the moisture molecules reduces the drying time by more than half of that required by conventional heat and vacuum drying processes. This plant is capable of drying the insulation to less than 0.5% of the total mass of the insulation
20 MVA A heat and vacuum pot, suitable for drying transformers up to 20MVA and specifically suited to equipment that requires conventional oven drying methods
OEM A bushings, tap-changers and current transformers facility enables T&SS to offer both skills and knowledge to service, refurbish, repair, re-design and modify most makes and models of transformer components, according to the original equipment manufacturers’ (OEMs’) procedures and specifications. The workshop can also newly manufacture current transformer and tap-changer components, based on the OEM’s manufacturing drawings, or from designs produced by Rotek’s internal engineering department
Electrical and mechanical health of assets are measured and tracked on a regular basis, determining the short- and long-term condition of the asset. The benefit lies in identifying problems early and nursing assets to the next planned outage, resulting in an increased lifespan, lower cost of ownership and reduced unplanned plant down time. Source: ‘An analysis of energy consumption for a selection of countries in the Southern African Development Community’ by Bruno Merven, Alison Hughes and Stephen Davis of the Energy Research Centre, University of Cape Town;‘SADC Energy Monitor 2016’ report
Eskom Rotek Industries 2018
The world world leader leader in in The The worldand leader in solutions pumping service pumping and service solutions pumping and service solutions for power generation for power generation for power generation Proven expertise Proven expertise • Full-scale test facilities for reliable pumping solutions • Full-scale test facilities for reliable pumping solutions •Proven Extensive application coverage expertise • Extensive application coverage • Experience gained through a large and varied worldwide installed base Full-scale test facilities for reliable • Experience gained through a large pumping and variedsolutions worldwide installed base • Extensive application coverage Value you can count on • Experience gained Value you can count on through a large and varied worldwide installed base • Customized solutions for your process improvements • Customized solutions for your process improvements • Reliable and competitive solutions for your applications you can count on •ValueReliable and competitive solutions for your applications • Energy-efficient products withlow low lifecycle cycle costsand anda alighter lighterenvironmental environmental footprint • Energy-efficient products life costs footprint Customized solutions forwith your process improvements • Reliable and competitive solutions for your applications Service at your your doorstep doorstep Service at • Energy-efficient products with low life cycle costs and a lighter environmental footprint • Wherever you are,Sulzer Sulzerisisclose closeby bytotoprovide providepersonal, personal,knowledgeable knowledgeable support • Wherever you are, support and qualified services for the entire product life cycle, day and night. and qualified services for the entire product life cycle, day and night. Service at your doorstep • Wherever you are, Sulzer is close by to provide personal, knowledgeable support Sulzer Pumps Pumps (South (SouthAfrica) Africa)(Pty) (Pty)Ltd, Ltd,99Gerhardus GerhardusRoad/Private Road/PrivateBag Bag X23, Elandsfontein 1406, South Africa Sulzer X23, Elandsfontein 1406, South Africa and qualified services for the entire product life cycle, day and night. Phone +27(0)11 8206210, 6210, www.sulzer.com Phone +27(0)11 820 www.sulzer.com Sulzer Pumps (South Africa) (Pty) Ltd 9 Gerhardus Road Bag X23 | Elandsfontein | 1406Road/Private | South Africa Sulzer| Private Pumps (South Africa) (Pty) Ltd, 9 Gerhardus Bag X23, Elandsfontein 1406, South Africa Phone +27(0)11 820 6210, www.sulzer.com Tel: +27(0)11 820 6000 | www.sulzer.com
e l i f o r PSulzer | s mets S r|e tERI nI Logistics Services | yProfile
The power of
The formal partnership between Sulzer and Eskom dates back to the early 1990s when contractual agreements were put in place to define a working partnership to benefit both parties and ensure world-class availability of boiler feed pumps on Eskom power stations. Partnering contract timeline:
1982 – 1990
July 1991 – June 1993
Restyled contract: management, site service and reconditioning, spares with Sulzer
Incentives based on pump and contractor performance introduced; decision to exclude spares from contract (joint spares committee formed)
1997 Scope increased at several stations to include critical auxiliaries
2001 Majuba Power Station included into contract
2005 – 2007
Partnering contract renewed till 2007; further scope increased at several stations to include Camden, Grootvlei and Komati power stations
2012 – 2013 Partnering contract extended till 2013 to facilitate contract negotiations
2015 Unit 6 of Medupi goes on the grid and is added to the partnering contract
Kusile 1 goes on the grid and is added to the partnering contract; major restructuring of the Sulzer partnering team to better serve Eskom’s needs.
Labour rate (heavy overhead burden for Eskom)
Five-and-a-halfyear partnering contract in place
1996 Customised station KPIs introduced for pump availability
1999 New partnering contract in place to end 2001/2
2002 Partnering contract renewed till 2006; further scope increased at several stations
2008 – 2012 Partnering contract renewed till 2012
2013 – 2018
Units 4 and 5 of Medupi go on the grid; additional resources added to Medupi and Kendal power stations
hroughout the duration of their partnership, Sulzer and Eskom have worked closely together on various projects concerned with plant performance improvement, refurbishment of existing plant, building up plant history regarding failures, and sharing knowledge and information.
05 Eskom and Sulzer Partners
Date: 23 May 2018 Enquiries: Willem van der Westhuizen 011 800 3491
Dear Eskom and Sulzer Partners Eskom/Sulzer Partnering 2017 MESSAGE FROM ESKOM’S CORPORATE - SPECIALIST PUMP TECHNOLOGY The Eskom/Sulzer Partnering Agreement Contract has reached the mature age of 25 Years. Much has been achieved during this time. The number of Critical Pumps (Steam Feed Pumps, Electric Feed Pumps, and Condensate Extraction Pumps) that are included in the Partnering Agreement Contract has increased from 124 pumps in 1993 to 365 pumps by 2017 – a 295% increase. The increased scope has resulted in Sulzer having to double the team supporting the Critical Pumps at the 14 Eskom Power Stations included in the Partnering Agreement Contract.
The availability of the Pumps (SFP’s, EFP’s and CEP’s) included in the Scope of Work as per the Sulzer Partnering Agreement Contract decreased from an initial value of 34.61 hours lost per pump in 1994 to a low value of 1.14 hours lost per pump in 2017. With the average hours lost per pump per year of 1.41 hours, the average availability exceeds 99.999%. This is the availability for the plant and the components included in Sulzer’s scope of work only. This is truly a significant achievement in spite of the increase in responsibility, number of pumps and auxiliary equipment included in the Partnering Agreement Contract. This resulted in a significant improvement in Critical Pump availability and reliability which contributed positively to the low UCLF attributable to the Boiler Feed Pumps, Condensate Extraction Pumps and overall performance of the various Power Stations. This performance is a reflection of the commitment from both companies which has developed in this much valued mutually beneficial business relationship.
One of the challenges is the steady increase of the ageing of the Critical Pumps that are included in the Contract and we will soon be faced with some new technical challenges in the upcoming years. The latter will be as a result of the majority of the Critical Pumps which have accumulated high running hours, and as such, require increased attention. The long term health of the plant and equipment must be retained to ensure a high level of performance, i.e. reliability and availability. The condition of the plant needs to be assessed continuously to ensure that both Eskom and Sulzer plan ahead to either repair/replace and or refurbish the pumps and the auxiliary plant components as required. This will ensure that neither Eskom nor Sulzer are at risk due to surprise component failures that have a limited life. The pump drivers (electric motors and turbines) of these Critical Pumps will also need the required attention in the upcoming years. Since the inception of the contract, in 1993, the relationship between Eskom and Sulzer has grown from strength to strength. These amazing results could not have been achieved without the co-operation, maturity and dedication of the team members and support from Senior Management at both organisations.
Partnering contract extended till end 2018
Sulzer | Profile
Willem van der Westhuizen Corporate Specialist (Pump Technology)
Group Technology Engineering Eskom Megawatt Park, Maxwell Drive, Johannesburg,2000 P.O.Box 1091, Johannesburg, 2000 SA Tel +27 11 800 3648 Fax +27 86 660 2806 www.eskom.co.za Eskom Holdings SOC Ltd Reg No 2002/015527/30
A letter of confidence in the partnership with the South African division of global pump manufacturing giant Sulzer refers to the success of the relationship since inception of the contract in 1993
Eskom Rotek Industries 2018
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The list below refers to a few of the may success stories resulting from the long-lasting partnership.
UPGRADING, MODIFICATIONS & RETROFITS • CEP upgrading and standardisation (Hendrina and Duvha) • EFP lube oil cooler replacement (Arnot and Hendrina) • SFP booster pump replacement (Hendrina) • Suction filter modification (Duvha) • Suction valve modification (Kendal) • Seal water pump replacement (Duvha) • Standardisation on mechanical seals (Matla) • Upgrading CEP’s gland packing with mechanical seals (Lethabo) • SFP mechanical seal conversions (Matla) • Feed pump shaft and bearing upgrade (Kriel)
REFURBISHMENT • EFP motor overhaul programme (Hendrina) • Arnot comeback project (Units 4-6) • Cartridge refurbishment programme (Matimba) • Cartridge refurbishment (All P/S’s) • Leak-off valves (Kriel)
LOCAL MANUFACTURE • Lube oil gear pump (Lethabo) • Working and lube oil coolers (Lethabo) • Cracked EFP impeller repairs (Duvha) • Approved weld repairs on cavitation damaged suction impellers (Arnot, Duvha, Matla and Lethabo) • Leak-off valve (Arnot) • New and replacement boiler feed pumps (all power stations)
NEW TECHNOLOGY • Replacing gear couplings with turboflex couplings (Hendrina, Lethabo, Matla, Tutuka, Camden and Arnot) • SFP leak-off valve replacement (Duvha, Hendrina, Matla and Tutuka) • EFP leak-off valve replacement (Hendrina and Matla) • Mechanical seals (Matla) • Voith Voricon variable-speed gearboxes (Medupi and Kusile)
TESTS & INVESTIGATIONS • EFP performance investigation (Hendrina) • Leak-off valve test and investigation (Arnot and Hendrina) • CEP second-stage bearing failure (Duvha) • EFP capability test (Duvha and Tutuka) • Barrel casing cover bolts inspection (Matla) • EFP prewarming (Matla) • Corrosion-erosion (Lethabo and Kendal) • CPP booster pump vibration (Lethabo) • CEP performance investigation (Kriel) • BFP efficiency test (Matimba, Tutuka and Kriel) • Mechanical seals (Tutuka, Lethabo, Kendal and Matla) • SFP barring gear tests (Duvha andTutuka) • LP heater drain pump performance investigations (Kendal) • EFP 4B vibration investigations (Lethabo)
The World Leader in Pumping and Service INFORMATION SHARING, Solutions TECHNOLOGYfor & Power Generation KNOWLEDGE
Value you can count on Proven expertise TRANSFER • Customized solutions for your • Full-scale test facilities for reliable process improvements pumping solutions • Reliable and competitive solutions for • Extensive application coverage • Continuous revising and updating of BFP protection your applications • Experience gained throughand a large • Regular meetings sharing of information between power stations • Energy-efficient products with and varied worldwide installed base • BFP cartridge prediction replacement programme low life cycle costs and a lighter • Road show environmental footprint • Technical presentations
Nuclear power plant
Pumped-storage hydro power plant
Coal- and oil-fired power plants
Service at your doorstep Wherever you are, Sulzer is close by to TRAINING provide personal, knowledgeable support and qualified services for the entire • Power station engineering, product life cycle, day and night. maintenance and operating staff • Sulzer works – theory and practical • Power plant pump short course (two days)
Solar thermal power plant
The sound principles on which a partnership like the Sulzer-Eskom one is based can weather economic storms and Sulzer remains confident in the need for such partnerships and its value to the client
Biomass-fired power plant
Eskom Rotek Industries 2 0 1 8
Gas-fired power plant
Geothermal power plant
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Operation OF POWER
GENERATING PLANTS The importance of having original equipment manufacturers (OEMs) in South Africa is crucial to building the local economy and capitalising on skills development of local people. Through strategic partnerships with OEMs, Rotek ensures access to specialised skills, as well as the training and development of its employees.
ajor issues surrounding OEMs in South Africa relate to questions around reliability and stability of products, but it is key to note that locally manufactured products and brands can be just as good, if not better than its international counterparts. The last 10 years have witnessed increased industry consolidation through mergers, acquisitions and alliances. This trend towards global integration has been propelled by ever lower trade barriers, the increasing dominance of regional trade blocks, as well as the increasingly global strategies of major international companies that dominate the industry. The global manufacturing industry is comprised of three broad market segments: OEMs, Original Equipment Suppliers (OES), and the independent aftermarket. Locally-based OEMs have developed a healthy relationship with a young, energetic workforce and have equally strong relationships with suppliers and service providers â€“ formulating the right mix of local and imported parts. OEMs enable mechanisms to assist industry to improve their competitiveness, productivity and quality management systems and in doing so optimise its operations and procedures to ensure South African industry integration into global supply chains. This is likely to see a strong focus on industry transformation as Rotek aims to increase local content in the manufacturing of its products while boosting skills development within South Africa. Turbo Gen Services (TGS), a division of Rotek, is a major turbine generator maintenance service provider. This division is uniquely positioned within the organisation because of its capability to refurbish large power generation turbines, generators and related equipment, with a special focus on the maintenance engineering of the turbine and the generator island. Due to the strategic importance of maintenance during electricity generation, Rotekâ€™s TGS division has embarked on an aggressive strategy to contribute to the future maintenance and skills development needs of its shareholder. A significant number of local graduates and engineers in training, as well as artisans are being mentored and coached to ensure transferring of skills and technical knowledge. Through strategic partnerships with OEMs, facilities are being built to ensure access to specialised skills, as well as the training and development of employees. The Generator Training Centre, built in conjunction with one of the worldâ€™s leading OEMs, focuses on transformer, boiler, turbine and generator training, which allows the training of local staff in the maintenance and refurbishment of a variety of power generation equipment. On completion, it will be equipped to simulate real working conditions on a generator stator and rotor. This will enable trainees to safely and competently perform similar tasks as they will be required and expected to do when they perform generator related maintenance work at power stations or in the generator services workshop.
Eskom Rotek Industries 2 0 1 8
e lGen i f o r PServices | smetsy retnI Turbo | Srotek
auxiliary equipment. These workshops offer specialised capabilities such as generator, mechanical, balancing, bearing, valve, and non-destructive testing services. In addition to project and capacity planning, dismantling, refurbishment and re-assembly of complete turbine islands, TGS’ on-site service capability includes logistical support, asset management, transport coordination, administration, rigging, crane driving and bolt heating. This enables the division to bring a 24-hour machine shop service directly to the job site – a vital function during breakdown situations where the affected plant is on the critical path. A unique quality of TGS is vested in Refurbishments its ability to assist clients in the holistic Turbine and generator refurbishment, monitoring of its plant and equipment. which forms the backbone of TGS, is a This has the objective of increasing the complicated process that takes place lifespan and cost-effective maintenance either on site, or at the Rosherville-based of the unit and reduces unplanned down workshops. The services offered refer to all time. This service is rendered through maintenance, refurbishment, modification condition monitoring either by remote, Safety and advertorial_The Standard_Eskom.pdf repair of power generating and 1 2018/05/11 online, or10:16 manual plant assessment.
TGS workshop fact file
A turbo generator is the combination of a turbine directly connected to an electric generator for the generation of electric power and is used the world over, not just for firing power stations. In fact, large steam-powered turbo generators provide the majority of the world’s electricity and are also used by steam-powered turboelectric ships. TGS’ services include: 1. Generator services 2. Mechanical services 3. Balancing services 4. Bearing services 5. Non-destructive testing services 6. On-site machining services.
• 58 000 m2 under cranage • Up to 300 tonnes rotor balancing plant • 2 500 engineering, maintenance and support staff
Through capacity planning, TGS ensures its maintenance and refurbishment capabilities always match demand and has adopted a modular spares strategy to address life extension of plant and equipment, in the process of pre-empting major refurbishment requirements.
Using telematics to change driver behaviour Fleet managers face a number of challenges on a daily basis, one of which is their duty of care to protect drivers 50% more likely to be hurt or killed in road crashes than any other type of driver1. This could be due to bad driving habits, negligence when driving, over-speeding or any other number of risky driving behaviours.
and expose at-risk drivers and take corrective action before a vehicles to capture vehicle and driver performance data. Fleet managers can then use the data captured to monitor their
Vehicle tracking on location, vehicle movements, status and behaviour Seatbelt usage Driver behaviour and performance (such as speed, harsh braking, harsh acceleration, etc.)
According to the UK’s Road Safety Observatory, 2015.
some astounding statistics on how a telematics solution can improve driver behaviour in less than three years:
Annual fatal road accidents
Uganda-based KK Traveller reported a 90% reduction in fatal road accidents and a 75% reduction in speeding violations. Tanzania-based M.A. Cargo reported a 40% reduction in accidents, a 42% improvement in delivery time and a 75% improvement in cargo safety.
Down in less than two years.
Tanzania-based Transcargo Ltd. reported a 70% reduction in accidents and an improvement in delivery time by two days.
Down in less than two years.
In addition, a fully integrated telematics solution can protect that are sometimes false and often unnecessary.
Decreased red scores.
Thanks to integrated in-cab video solutions like MiX Vision, to a crash, and they can support those views with accurate, relevant data.
KK Traveller (Ugranda)
please visit www.mixtelematics-africa.com. MOBILE INFORMATION EXCHANGE
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Civil, electrical and
he outlook for South Africa’s construction industry over the next four years will be moderate, compared to the industry’s performance between 2012 and 2016, says data analysis company Timetric. Contributing to this is poor investor sentiment as a result of slow economic growth, and the embattled rand, which both impact construction spending. However, infrastructure investment in the transport and logistics, energy, and low-cost housing sectors are expected to create growth in the industry over the next four years (2017 – 2021). These projects will be underpinned by the ever-increasing need for housing as urbanisation rates continue to rise. In a report by Statistics South Africa on human settlement growth rates, the number of building plans passed grew by 6% in nominal terms in the last financial year.
Generation & transportation • 20x bulk earthworks teams • 10x concrete teams • 4x road teams
This shows an increase from R101.4 billion in 2015 to R107.5 billion in 2016. The total value of completed buildings grew by 8.3% in nominal terms. This showed an increase from R56.7 billion in 2015 to R61.4 billion in 2016.
Investing in infrastructure In its 2017 budget, the South African government has plans to invest R947.2 billion in public sector infrastructure as part of its medium-term strategic framework. Housing will receive priority as will transport infrastructure, with roads being prioritised at the forefront, will also see considerable government investment in order to improve the mobility of citizens, freight and logistics.
Looking ahead According to Timetric, the local construction industry’s growth will be driven by government plans to increase the share of renewable energy in terms of total installed electricity capacity and encourage investment in renewable energy infrastructure. Based on the Integrated Resource Plan (IRP), government plans to increase the share of renewable energy in total installed electricity capacity from 16.2% in 2016 to 22.3% in 2020. Enter Rotek… from pothole repairs, road and generation construction projects to
• 4x electrification teams
Portfolios and competencies CS is split into five portfolios, which are aligned to the main Eskom divisions, namely: Generation and Transportation; Cabling; Distribution and Cape Coastal; Transmission and Electrification. CS has grown its skills and expertise in cable management and installation services, being involved from the walk-down phase, through to final handover of the cable systems. The division can assist with the quantification of cable requirements, offer technical and testing services, as well as reticulation and maintenance services, including the installation of medium- and low-voltage cables in residential areas. CS also assists with technical and testing services for cabling, including technical problem-solving, fault locating, reparations and breakdowns.
CS comprises the following internal and external (subcontractor) teams:
Cabling teams • 20x cabling teams Transmission teams
the installation of cabling systems in power stations and energy efficient lighting and control systems, Rotek’s Construction Services (CS) division specialises in both civil and electrical construction. Its purpose as sustainable business within the Eskom Enterprises group of companies is to provide high quality, mission critical services to the energy industry in South Africa and beyond.
• 10x substation teams • 8x line teams • 5x earthworks teams
Eskom Rotek Industries 2 0 1 8
Distribution teams • 8x overhead line teams • 11x substation teams
Going green Construction Services is now able to assist clients in reducing their carbon footprint created through power generation services. The service is called Energy Efficient Lighting Services. One of the first projects undertaken was the replacement of energyefficient lighting at 14 power stations across South Africa. This resulted in significant annual savings, was completed in record time, and has set the stage for future green power initiatives to be managed.
The past few years have highlighted the need for better coordination and monitoring within the construction industry – a challenge that the South African Government has welcomed with the rollout of its R847 billion National Infrastructure Plan. Implementation of the plan will require significant input from the construction industry.
Relieve aching feet with the Parabolic Range. Explorer
These Lemaitre safety footwear styles have passed Eskomâ€™s 20kV test. Locally sourced and manufactured
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All systems go
ven though the world is seeking greener energy solutions, coal continues to dominate in South Africa. Approximately 92% of coal consumed in Africa is produced in South Africa, with the country producing in excess of 225 million tonnes per year. In 2012, Eskom dominated the domestic steam coal market in South Africa, accounting for about 116 million tonnes. Even though the utility aspires to reduce its dependence on coal fired technology from 90% to about 65%, it will remain the countryâ€™s largest buyer of domestic coal for a long time to come. As such, Eskom announced its R9.79 billion investment in rail infrastructure, which would see 140 km of new rail being built in Mpumalanga. A large percentage of the coal produced in South Africa can be found in Mpumalanga. In fact, when Witbank
In South Africa, coal dominates the energy sector, and the efficient movement of this commodity from mines to power stations is essential in ensuring that government is able to keep the lights on.
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The amount of coal consumed at Eskom’s power stations per year
The number of coal-fired power stations that fall under Eskom
– the province’s biggest city – was renamed, it was called eMalahleni, which means ‘place of coal’ in Zulu. While conveyor carried coal is ideal, it would not be possible for these massive tonnage amounts, and the next best option is rail, which is cheaper, sustainable and eliminates road hazards. At the time, Eskom had been moving some 30 million or so tonnes of coal a year to its power stations by road and in 2008 it translated to 5 100 truckloads a day – the distance covered was equivalent to driving around the world 15 times daily. In 2015, Zimbabwe and Botswana agreed to cooperate in the transportation of coal, under which Gaborone will export about 10 million tonnes of the commodity per annum, using Harare’s underutilised railway system. Landlocked Botswana is continuously exploring alternative routes to export its abundant coal. It often finds it expensive to ferry its exports through the sea and is compelled to use ports in neighbouring countries.
Complete solution While rail makes business and environmental sense, the advantages of road transport for shorter distances, such as from mines to power stations, cannot be ignored. Rotek’s Bulk Material Services (BMS) is an important
4 000 litres
BMS owns various types of yellow plant equipment and is able to handle up to 30 000 t of movement per day
BMS supplies an average of 4 000 ℓ/s of water over a distance of 170 km through pipelines with a total length of more than 400 km for Eskom
component of the organisation’s structure. BMS offers a complete coal logistics solution, namely, the transportation of coal – by road, rail or conveyor belt – from mines to the power station stockyard. This includes vehicle registration management for Free Carrier Arrangement (FCA) transporters contracted to Eskom, monthly planning of vehicle allocations for FCA transporters, and information analysis to improve logistical operations. The division also manages, operates and maintains the conveyor systems on these sites and runs one of the largest road-based coal supply chains in the world. Particularly important to the division is public and driver safety, which is why BMS is actively involved in road safety monitoring, FCA vehicle inspections, tarpaulin management, route assessment, control and enforced route adherence, as well as continuous vehicle tracking, weighing and measuring of loads to ensure legal compliance. Through coal logistics management and coal load brokering, Rotek has also created successful BEE opportunities for previously disadvantaged individuals and groups.
Bulk water handling Another important role of BMS is that of bulk water handling. Rotek’s bulk water handling capability started around 1973 when BMS
was contracted to manage the Komati Water Scheme. The R1.2 billion project launched in 2013 was designed to solve water supply problems to Eskom’s Duvha and Matla power stations in Mpumalanga. It augments the Komati Water Scheme from the Vaal Eastern subsystem in order to help Eskom overcome its water challenges. In turn, the Matla Power Station reservoir will provide water to Kusile Power Station. This process has evolved over time into a unique body of proprietary knowledge, including correct reservoir and dam levels, as well as a documented network of interlinking pipes that deliver water to power stations. The interaction of water resources of the Komati, Usutu and Vaal River systems provides a higher assurance of water supply to all Eskom’s thermal power stations and other water users in Mpumalanga. Today, BMS continues to operate and manage sewerage and water treatment plants, bulk solid and slurry systems, dry material transport systems and is able to accurately regulate the pumping process according to water demand. Key to this success is a century-long history in successful management of the delicate relationships with landowners through whose properties these pipelines run. Source: www.transportworldafrica.com
Eskom Rotek Industries 2018
Vision Kopano Ya Basebetsi Ba Afrika – meaning – United Workers, “together” … - with the vision of being focused on delivering exceptional value, quality, service and growth to our customers, employees and members.
Mission Based on experience, consistent working methods and teamwork, we are committed to provide quality and value to our customers and the community. Our aim is to contribute to improving living conditions and essential infrastructure for previously disadvantaged people thereby creating a safe environment for all.
History Kopano Ya Basebetsi Ba Afrika cc is an electrical construction company which was formed in 1994. We have been mostly involved in the implementation of electrical reticulation systems in particular specializing for the past twelve years with the installation and commissioning of Protective Structures Enclosures. In 2013 Kopano expanded its operations and opened their manufacturing division with a licence agreement on the Protective Structures patent. Kopano Ya Basebetsi Ba Afrika now has developed into a strong, selfsustaining, experienced manufacturing and installation company.
Social development We believe that our organization has a social responsibility to the communities in our major projects, too leave a footprint (however small) to beneﬁt the community, children and/or the old aged.
Safeguarding the community
We specialize in: 6mm mild steel vandalized proof metering kiosks in the following sizes : 4 way, 6 way, 8 way, 9 way, 12 way, 16 way, 20 way, 24 way 6mm mild steel vandalized proof Mini sub shells cut to size 6mm mild steel low voltage distribution boxes 6mm mild steel pole mounted transformer enclosures and boxes 3 mm mild vandalized proof steel pole mounted boxes 4, 6 and 8 way 3mm mild steel pole light boxes
Our locking mechanism can be supplied with motor, solenoid or risi lock. All electronic locking systems are equipped with GPRS technology for communication from all enclosures to the control centre Opening of the enclosure with: key tags or cell phone opening or risi lock
Our electrical enclosures offer the client: Remote access control via GPRS communication Remotely monitor and control pre-payment meters Determine and report the status of the electrical enclosure every 60 seconds Protective electrical enclosures are vandal proof Monitor, restrict and control who access your electrical enclosures Eliminate illegal electrical connections and tampering with electrical equipment inside enclosures
+27 (0)11 894 1479 |
Credit control can be exercised remotely and prevent defaulters from reconnecting themselves We are more than a protective electrical enclosure manufacturer we also install, maintain, repair, monitor and control our protective electrical kiosks We manufacture according to the requirements of the client You are immediately informed of any unauthorized access or tampering
+27 (0)83 302 8848 | +27 (0)76 999 6663 firstname.lastname@example.org
InterSystems | Profile Logistics Services | ROTEK ERI
Make way for Southern Africa’s abnormal load expert Africa is made up of 54 countries with very low connectivity between them. Ten African countries, however, are the next places to be, offering huge potential for strategic investors in the transportation and logistics industry – with one of the top 10 being South Africa. Logistics Services, a division of Rotek, offers road transport, materials handling, warehousing and logistics. This division also boasts the largest multi-axle fleet in the southern hemisphere.
ollowing the abolishment of colonialism in the 60s and then the fall of apartheid in the 90s, the world had high hopes for both South Africa and Africa. In fact, the World Bank predicted a bright future for sub-Saharan Africa, with projected GDP growth of over 7% per year. But life got worse on the African continent and in May 2000, The Economist referred to Africa as the “hopeless continent”. Then from 2001 to 2010, six of the world’s 10 fastest-growing economies were in subSaharan Africa, partly due to the availability of natural resources. Following this growth, in March 2013, The Economist published a new report
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on emerging Africa, this time titled ‘Africa rising’. But what does this growth mean for transportation and logistics companies if the current bullish predictions don’t turn out to be another miscalculation? The PriceWaterhouseCoopers ‘Africa Gearing Up’ report offers brilliant insights based on extensive research. The report states that economic differences between the top ranking African countries are vast. For example, while South Africa has a US$400 billion economy, the Democratic Republic of Congo (DRC) with its fourth largest population in Africa and having significant mineral resources, has an estimated GDP of less than US$18 billion. Just like its economy, Africa’s terrain also
varies widely, which impacts greatly on critical transport infrastructure. Countries such as Algeria and the DRC are faced with many challenges when it comes to building road and rail networks, and especially bridges and tunnels. Angola has just 4 km of roads per 100 km2 of land, while Ghana’s road density is more than 10 times as high. South Africa has 62 km of roads per 100 km2. Put into perspective, Ghana’s road density is similar to that of China, while South Africa comes close to that of the USA. Another positive for South Africa is that it ranks number one in Africa in terms of logistics performance and 23rd in the world, out of 155 countries. In the report, Dr Dirk Baukmann, CFO of DHL Express Sub-Saharan
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Africa, says:“Express and logistics services are the engine of economic growth in Africa. Despite challenges like underdeveloped infrastructure, we extended our international Express Network to all countries in Africa. Compared to other regions, our Africa business is still small, but growing above average.” It is evident that transportation and logistics are vitally important in South Africa. Rotek’s Logistics Services (LS) include the transportation of boilers and turbines to and from power stations; transformers and switchgear from substations; poles and pylons to remote sites; and all power generation and distribution equipment across Southern Africa. Thanks to its impressive multi-axle fleet, LS is capable of moving anything from 1 kg to 500 t anywhere in South Africa. The different types of transport services are categorised by the respective weight of the load. Where permits and escorts are needed for these operations, LS provides a turnkey solution to get the load to its destination. It operates from its main yard in Rosherville, but has a wide network of depots in Johannesburg, Polokwane,
Top 10 Among the 10 countries analysed in the ‘Africa Gearing Up’ report, South Africa and Egypt top the list on logistics performance
Durban, Richards Bay, Cape Town, Middelburg and East London. LS has an in-house technical support services team that ensures fleet integrity is maintained. All vehicles are monitored en route through constant satellite surveillance, 24 hours a day.
Waste management LS also specialises in the management, transportation and disposal of waste in a safe and environmentally responsible manner. This is an expanding area of the business and falls in line with the waste management needs of South Africa. As a patron member of the Institute of Waste Management of Southern Africa (IWMSA), LS is a registered asbestos contractor and dangerous goods transporter. Waste transported includes general waste, hazardous waste, compactable and non-compactable waste, medical waste, building rubble, conveyor belting, and wood.
Materials handling and consolidation In addition to transport services, LS offers the consolidation or breaking of bulk
Logistics Services’ current and previously satisfied clients include 20 of the largest role players in the South African economy
materials, not only for the full utilisation of loads, but to ensure cost efficiency, too. The division offers warehouse management services to its clients, which include: cataloguing, materials planning, project materials planning, inventory accounting, item control, receiving, storage, issuing, and in-store maintenance.
Tracking and tracing The use of technology for logistics support is a growing trend in the industry and LS uses this capability to provide a comprehensive logistics system solution. Designed to manage and support the logistics supply chain, the system offers clients a turnkey management dashboard to track products, load weights and journey stages. It also includes a track and trace system that deals with the tracing of trucks in transit. The advantage of using such a sophisticated, electronically based logistics support system is that it offers the division and its clients improved billing, scheduling and planning capabilities – ensuring LS’s future sustainability in a highly competitive economic environment.
Responsible waste management Logistics Services is a patron member of the Institute of Waste Management of Southern Africa (IWMSA), and a registered asbestos contractor and dangerous goods transporter
Eskom Rotek Industries 2018
if you can dream it, we can construct it excellence in execution
if you can dream it, we can construct it
excellence in execution
InterSystems || Profile Logistics Ash Products Services rotek | ERI
Why ash is big business
otek’s Bulk Material Services division specialises in the selling of coal combustible products such as ash, gypsum and salts. Cement is the key ingredient in the production of concrete, an essential building material for infrastructure development, second only to water in total volumes consumed annually. Coal combustion products, which are by-products generated from burning coal in coal-fired power plants, play an important role in concrete production. These by-products include fly ash, which can be used to replace or supplement cement in concrete, thereby making the concrete ‘stretch’ further and assisting with cost-cutting. Recycling coal combustion products in this way is beneficial to the environment. Close to 90% of the world’s cement is produced with the use of coal as the source of primary energy. It takes about 200 kg of coal to produce one tonne of cement and up to 400 kg of cement is needed to produce one cubic metre of concrete. But probably the most impressive statistic is that the world’s largest hydropower station is built from 20 million m3 of concrete, requiring a substantial 2 million tonnes of coal.
Why ash? Ash can be used as a key ingredient for various applications such as cement, tiles, plastic, paint, rubber, bricks and blocks, road construction, brake linings and mine backfilling
Eskom is home to 15 coal-fired power stations, which produce ash that is available for utilisation in different applications as long as environmental compliances are met
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5 types of ash Rotek offers 5 different types of ash, available at all coal-fired power stations:
Fly ash is the bulk of Rotek’s ash produced and is the fine, powder-like dust that is collected in the electrostatic precipitators or bag filters.
Coarse ash, also known as boiler bottoms ash, drops down from the furnace and is collected in the ash hopper at the bottom of the boiler.
Clinker ash is obtained from a chain grate boiler process that was used in the older power stations.
Mixed ash is the rejected or excess unclassified fly and boiler bottoms ash co-disposed at a common ash handling facility.
Cenospheres are formed during coal combustion in thermal power stations where glassy ash particulates are generated.
eAsh l i f o rProducts P | smetsy retnI | Srotek
of ash from Lethabo Power Station was exported to Lesotho for the Katse Dam project
2.4 million m 3
In order to comply with legislative processes and to promote fairness and transparency, ash is sold on a tender basis. Rotek will gladly meet with clients to understand their intentions and expectations for the use of ash, to advise on purchase requirements, and to explore future possibilities. Topics of discussion will include: • the type and volume (tonnes) of ash required • the approximate location of the ash and period of time the volume would be needed • the intended use of the ash • if samples are required, they could be collected at the agreed location • transformation objectives with a specific focus on local content.
The mighty Katse Dam was the focal point of the first phase of the Lesotho Highlands Water Project (LHWP). Requiring over 2.4 million m3 of fly ash concrete for construction, the 185 m high, double-curvature arch dam was the highest dam in Africa for over a decade. The main objectives of the LHWP were to supplement the water supply to South Africa and to provide Lesotho with hydroelectricity. When construction started in 1991, the LHWP was the largest and most complex construction project of its type in the world.
The amount of ash produced by Eskom per annum
A modern coal-fired power station can produce about 17 000 tonnes of ash per day, depending on the coal quality and heat content
million tonnes The approximate amount of ash that is sold per year, particularly to the cement industry
Coal ash is classified as hazardous waste under the National Environmental Management Act: Waste Act (NEMWA). This requires potential users of ash to apply for waste management licenses, supported by an environmental impact assessment or basic assessment or norms and standards. For further information on the waste management licence and the legislative act, visit the Department of Environmental Affairs’ website: www.environment.gov.za.
Eskom Rotek Industries 2018
InterSystems | Profile InterSystems | Profile Logistics Services Trans-Africa Projects | ERI | Profile
e r u t u f e h t g n i r e
rans-Africa Projects is uniquely and perfectly poised to serve the complex needs of the energy sector, as a result of its shareholders, leading global engineering and construction company Fluor, and Eskom – the largest utility on the African continent. The company is a 50/50 joint venture between Fluor and Eskom and was founded in 1995 on the back of the successful Cahora Basa Project, in Mozambique, to reconstruct and refurbish the high-voltage DC transmission line. The joint venture company has since grown to execute projects both nationally and internationally, and employs more than 150 people (primarily technical staff ). Its key focus is offering a full range of specialist and EPCM services in the power transmission and distribution market. The company was originally set up to do work outside of South Africa; however, in 2003, Trans-Africa Projects redirected its efforts to almost exclusively supporting Eskom with its expansion plans in South Africa. Today, Eskom accounts for the majority of work executed by Trans-Africa Projects. The company’s African and international projects have all been successfully managed from its head office in Midrand and, in the interest
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Trans-Africa Projects is a specialist consulting company with the capabilities to deliver on a range of projects, across a broad section of the energy sector.
of delivering a seamless regional experience, Trans-Africa Projects has established offices in Cape Town, Durban and Maputo, Mozambique.
Unparalleled intellectual property Trans-Africa Projects specialises in highvoltage transmission, sub-transmission, distribution and electrification projects, ranging from 11 kV to 765 kV. The company’s consulting and engineering, procurement and construction management expertise allows it to offer its clients comprehensive solutions that cover the full value chain from project design and management to commissioning supervision and maintenance support. According to Malambo Shakantu, managing director of Trans-Africa Projects, the company is able to offer a unique value proposition because of its association and access to both Eskom and Fluor’s intellectual property. “We have access to a worldwide network of specialists and the best intellectual property in the power transmission and distribution space, thanks to
our shareholders Fluor and Eskom. We’ve also established technology sharing agreements with international industry experts such as the State Grid Corporation of China, which has placed us at the forefront of the highvoltage industry and enables us to offer our customers a total solution,” Shakantu explains. Through its shareholder agreement with Eskom, Trans-Africa Projects has access to specialised Eskom resources. “Not many consulting firms can say they have access to this capability and we see it as an added benefit for our customers. Through it, we are able to offer our current and prospective customers costeffective design solutions that are truly unique and that we know will work,” Shakantu points out.
Partnering with customers While the technical and intellectual support of industry giants is a key differentiator for Trans-Africa Projects, its business philosophy – as it relates to its customers – is something that allows the company to really stand out from the crowd.
e l i f oProjects rP | s mets S r|e tERI nI Trans-Africa Logistics Services | yProfile
“Our client-centric business philosophy has two key aspects: first, we believe that the customer is our partner, and second, we are in the business of providing solutions. So while we might say that we offer transmission design and engineering services, we really believe in sitting down with the customer and working with them to understand their problem, so that we can find the best possible solution,” Shakantu notes. “The success of our clients is our success and some of our most notable achievements as Trans-Africa Projects have been assisting our customers to achieve outstanding cost savings,” he adds. Working in Africa, Shakantu notes that project funding and affordability are major challenges for many customers. As such, the company endeavours to find the most cost-effective way to complete a project, while ensuring it delivers. “Trans-Africa Projects has been at the forefront of delivering new transmission lines and substation solutions, and factors such as our unique tower and foundation designs and conductor selection have resulted in major cost and time savings for our clients on recent projects,” Shakantu explains. “Cost-saving comparisons for potential clients, such as a utility company in the Middle East, have demonstrated that transmission line costs and refining construction methodologies can lead to a cost saving of up to 40%. This is something we are able to achieve for our clients by partnering with them and working smartly,” he continues.
GLOBAL PRESENCE Trans-Africa Projects has completed projects in 13 countries across Africa, including Mauritius, and has delivered exceptional work for clients further afield, in countries such as: • Australia • China • India • Indonesia • Iraq • Mongolia • Papua New Guinea
Moving forward Looking ahead, Shakantu notes that Trans-Africa Projects is on a mission to maintain its position as one of the leaders in the transmission design and engineering sector, while delivering highquality solutions for its customers. “We are committed to serving our clients and providing returns to our shareholders. In order to do that, we need to continue working with our biggest client, Eskom, on projects in line with its expansion strategy, all while taking the time to nurture our company’s own expansion plans.” Shakantu says the company is looking to expand its presence to the Middle East by establishing an office in the region, as well as further up into Africa with an office in Kampala, Uganda. “We are also looking to expand our customer base by adding other clients outside of Eskom to the mix. This, we believe, will enhance our position to increase our value add to our shareholders, and touch a broader market with our unique offerings.” Shakantu says the company is also working to expand its incubation programme, which focuses on skills development within the sector. “Through the programme, we are supporting upcoming black-womanowned firms in the industry, and this is something we are really hoping to do more of going forward. “TAP continues to partner with various stakeholders in making a positive impact in communities in which it works. We believe that people are attracted to companies that provide technical complexity and have a deep caring for the environment and this is one of our cornerstones in building a platform where people can make that difference. “In a nutshell, our biggest goals for the coming years are to ensure that we deliver for our clients, for our shareholders and for our country,” Shakantu concludes.
other clients • Aveng EPC • BHP Billiton • Botswana Power Corporation • Building Energy (Italy) • Cahora Bassa (Mozambique) • Central Electricity Board (Mauritius) • Conco • Electricidade De Mozambique • eThekwini Municipality • Fluor • GDF Suez • Group Five • Igoda Projects • Kenmare Moma Mining (Mozambique) • Motraco (Mozambique) • Moyeng Energy • MuliloThermal (Botswana) • NamPower (Namibia) • National Electric Power Authority (Nigeria) • Oyu Tlgoi LLC (Mongolia) • Punkackyaya Power (Indonesia) • Scatec Solar Independent Power Producer • Sishen Mine • Swaziland Electricity Company • UraMin Namibia
+27 (0)11 205 9400 www.taprojects.co.za
Eskom Rotek Industries 2018
InterSystems | Profile Africa case study | ROTEK
A lesson from Africa
How Eskom Uganda is leading the way in the generation of reliable and affordable power for Uganda’s national development.
skom Uganda Limited (EUL) was incorporated on 22 November 2002 and was awarded a 20-year concession to operate and maintain two power stations in Uganda, namely the Nalubaale and Kiira Hydro Power Plants. EUL took over operations and maintenance of the complex from the Uganda Electricity Generation Company Limited (UEGCL) on 1 April 2003. EUL is a subsidiary company of Eskom Enterprises SOC Limited South Africa – the investment arm of Eskom Holdings SOC Limited. Over its 14 years of electricity generation in Uganda, Eskom has adopted prudent utility practices to ensure that it meets dispatch demands and generates enough electricity for the country. Eskom has assembled and developed competent staff in operations and maintenance, and has continued to excel in providing reliable and affordable electricity for national development at US$0.01 per unit.
Investments and milestones Eskom’s market share in terms of generating electricity into the national grid now stands at 40%. Eskom is currently the cheapest generator of electricity in Uganda. To date, Eskom has invested in excess of US$20 million in upgrading systems and equipment at the power plant.
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The 33 kV switchyard before refurbishment
Status after refurbishment
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Interbus transformer before refurbishment
New 60 MVA Interbus transformer after refurbishment
Graph 1 Plant availability performance for April 2003 - 2016 • Eskom intends to invest an additional US$25 million in the remaining period of the concession for upgrades and new systems in order to sustain plant availability. • Over the last 14 years of operation, Eskom has paid USh14.3 billion in corporation tax. • Recently, Eskom procured two new interbus transformers at a cost of US$2 million. These transformers are crucial in stabilising power supply to areas from Lugazi to the greater Busoga regions of Jinja, Iganga and Kamuli, through coupling the two substations. This, in turn, will promote industrial growth in the region.
Plant performance BEFORE
Unit 4 transformer before replacement
Status after transformer replacement
Eskom has consistently exceeded its target in terms of plant availability, which has been maintained above the power purchase agreement minimum target of 94% (see Graph 1). Eskom has made investments that have led to the efficient use of water to generate power. When Eskom took over the facility before implementation of the governor upgrade project, energy conversion efficiency was at 21.53 m3/kWh, which was quite poor. This meant that less energy was extracted from each cubic metre of water. This has since reduced to an average of 19.2 m3/kWh – meaning that more energy is extracted per cubic metre.
Creating energy efficiency awareness Drawing lessons from South Africa, Eskom has partnered with the Ugandan Ministry of Energy and Mineral Development to promote awareness by educating the public on the efficient use of energy.
Eskom Rotek Industries 2018
InterSystems Partnerships || Profile ROTEK
Understanding the needs of a dynamic organisation In business, success is dependent on the right partnerships coupled with best practice. South Africa’s growing role on the continent necessitates that local businesses behave as responsible corporate citizens when investing and operating in Africa.
ecognising shortcomings in an organisation’s culture is one of the strategic paths that leads to its success. Companies are finding it necessary to constantly evolve to keep up with technological advancements and embrace the digital age. In South Africa, the Fourth Industrial Revolution (FIR) is almost upon us, with the Department of Science and Technology and the Council for Scientific and Industrial Research (CSIR) already involved in cutting-edge
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research to prepare the country for Industry 4.0. While it may seem a long way off for most, the use of artificial intelligence is already common in our everyday lives and automation is increasingly dominating local workshops and factories. A new McKinsey Global Institute report found that realising automation’s full potential requires people and technology to work hand in hand. It further states that recent developments in robotics, artificial intelligence, and machine
learning have placed us on the cusp of a new automation age. Robots and computers can not only perform a range of routine physical work activities better and more cheaply than humans, but they are also increasingly capable of accomplishing activities that include cognitive capabilities once considered too difficult to automate successfully, such as making tactic judgments, sensing emotion, or even driving. Automation will change the daily work activities of everyone, from miners and landscapers to commercial
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Example of a standard business continuity life-cycle plan
bankers, fashion designers, welders, and CEOs. However, the big question remains: how soon before these automation technologies become a reality in the workplace?
Preparing for the future The FIR will influence most, if not all, economic sectors. From a technology perspective, South Africans will witness the integration of physical, digital and biological technologies. This shift is sure to cause disruption within many organisations, as workforces undergo change. It is also for this reason that many
companies are focusing on understanding the analytics of their people from the traditional information required by human resources to understanding behaviours and mindsets. Establishing and following through on strategies is also crucial in preparing for the future. Although the basic principles that make for a good strategy can sometimes be obscured, ultimately, strategy is a way of thinking and not a procedural exercise of a set of frameworks. Trained by the largest global management consultancy, the Top Consulting Group (TCG) currently
supports all divisions within Eskom. TCG’s expertise lies in organisational design; strategy development and implementation; productivity improvements; and operational optimisation while adopting a change management approach for sustainability. The group is passionate about solving complex challenges that matter to our clients, with the objective of developing a better South Africa. With a mandate to help Eskom and other state-owned enterprises in South Africa develop sustainable solutions to mission critical challenges, TCG is united and deeply committed to the organisation’s success, and offers post implementation support to previous projects, if required. Source: Mail & Guardian; McKinsey Global Institute
For more information on the
Tel: +27 (0)11 629 4442 or +27 (0)11 629 4000
services Eskom Rotek Industries
offers, contact the New Business
Lower Germiston Road, Rosherville, Johannesburg
Eskom Rotek Industries 2018
InterSystems | Profile Logistics Business Dovetail Services Solutions | ERI | Profile
Driving supply chain successes As a market leader that has been in operation for nearly 25 years, Dovetail Business Solutions is an obvious first choice for companies seeking logistics software solutions.
ovetail is a niche software provider to the transport and warehousing industry, and has, since inception, been selling transport and warehouse management software (WMS and TMS) to companies in South Africa and various other African states. Its services also extend to implementation and after-sales support. It has been doing all this for the past 25 years. For a company to be in business for what is effectively a quarter of a century and continue on an upward growth trajectory, it has to be doing something right. In this case, the longevity of the business can in part be attributed to the quality of the solutions Dovetail offers.
Robust solutions and systems Shermandra Singh, commercial director at Dovetail, explains, “Our solutions are robust and fit for purpose. They have been designed to handle complex operational processes while providing an easy-to-use end user experience.” Dovetail’s focus is on providing logistics companies with end-to-end WMS and TMS solutions that will have a marked impact on operational efficiencies and fuel costs, and optimise supply chain logistics. Coupled with strong systems, the company has a wealth of supply chain IP – whether among the executive team or the
consultants who implement and support Dovetail’s solutions on the ground. The company strives to be the best in the business in Africa when it comes to logistics software solutions and makes a concerted effort to work with like-minded clients. Commenting on Dovetail’s growth path, Singh expands, “Our future growth is linked to continually increasing our South African client base while expanding the use of our solutions across Africa. We have had immense success in various African countries over the past four years and will continue to build on this.”
A mobile, automated future Effective supply chains underpin almost all modern commercial activity and the logistics industry is certainly in a strong position; however, in order to remain at the leading edge, businesses need to adapt to and drive the rapid evolution of mobile technologies and automation. One of the biggest advancements with regard to tech in Africa has been the adoption of mobile technologies. And with the increasing affordability of smartphones, Africans have greater access to the internet as well as exposure to international demands, standards and trends, including automation. Mobile technologies have made significant improvements in creating supply chain visibility and, in the logistics and transport sector, many
countries in Africa are also moving towards automation. Africa is still a number of steps away from completely automating warehouses and supply chains, yet transport, courier and warehousing companies are realising the importance of automated data processes. “They are slowly but surely starting to implement logistics software solutions that can automate information processes,” adds Singh. “With the rise of e-commerce, consumers are also increasingly using mobile technologies to buy and compare products and prices at the click of a button, further stressing the need for supply chains to become stronger, more effective and more transparent and to use mobile technologies for streamlined service delivery,” Singh asserts. Mobile technologies help delivery companies to become more streamlined while creating a more transparent delivery process for the end consumer in the form ETAs and delivery notifications. The growing expectations of modern users and businesses make it all the more necessary for companies to keep up with tech developments. As a leading niche software service provider that understands its clients and the sector, Dovetail Business Solutions is the perfect partner to logistics operations looking to move forward in this ever-changing world.
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Taking you forward with global software solutions
Dovetailsâ€™s logistics software provides solutions to the transport and warehouse industries and has been serving the key logistics companies in Africa for almost 25 years. The Transport and 3PL Warehouse Software has more than 30 000 users across Africa from Courier to Road Freight to Warehousing
Market Leaders in Transport and Warehouse software
Web: www.dovetail.co.za Tel: +27 11 540 9300
Khushbu Thakur Regional Application Specialist
Quicker and easier transformer testing than ever before … … was our vision for our new powerful and lightweight test set. TESTRANO 600 is the world’s first portable, three-phase test system which supports all of the common electrical tests done on power transformers. With just one setup for multiple tests, TESTRANO 600 significantly reduces the wiring effort and testing time. Its specially designed power amplifiers ensure a new level of accuracy. And the multi-touch color display enables smart and comfortable operation. www.omicronenergy.com/newTESTRANO600
Alectrix (Pty) Ltd, South Africa email@example.com www.alectrix.co.za
At Eskom Rotek Industries, their heritage is in their inheritance. They have a history that spans more than 100 years, and are proud of the...