Issuu

Think water, think WISA! T

Water& Sanitation

The official magazine of the Water Institute of Southern Africa T

Complete water resource urce and wast wastewater management

Africa

All about water

REGIONAL FOCUS Gauteng delivery gets going

IN N HE HE THE OT OT HOT AT AT SEAT

CRITICAL C CONSTRUCTION Central Cent Basin s AMD treatment takes shape treatm

You simply need to know and understand your craft. The quality of service you provide will speak for itself. Aurecon associate, Teboho Mofokeng

P18

July/August 2013 • ISSN 1990-8857 • Cover price R40.00 • Vol 8 No. 4

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CONTE C ONTE ENTS NTS S

Volume 8. No.4

ON THE COVER

Water Solutions Southern Africa (WSSA) discusses the leading role it plays in both the public and private sectors.

Roodeplaat Water Treatment Works

COVER STORY WSSA: Sustainable service solutions

WISA President’s message

Limpopo branch launched

Board banter

HOT SEAT Aurecon associate Teboho Mofokeng discusses the intricacies of being a dynamic woman in a male dominated industry

WISA Limpopo branch launched

Expanding capabilities at Percy Stewart WWTW

Is desalination the sustainable solution?

REGIONAL FOCUS ¦ Gauteng Roodeplaat WTW – a positive development Expanding capabilities at Percy Stewart WWTW Meyerton WWTW exceeds expectations Panfontein site capacity boosted Moroleta Spruit Outfall Sewer capacity doubled

28 32 34 37 38

TRENCHLESS NEWS Two decades of trenchless technology Fast and efficient directional drilling SASTT reaches 21 Preservation through innovation Western Aqueduct back on track

46 49 50 51 53

FEATURE DESALINATION Transnet gets new plant

Is desalination the sustainable solution?

New Lamberts Bay seawater desalination plant

MINE WATER Central Basin’s AMD treatment plant takes shape

METERING TECHNOLOGY The real cost of metering The water pressure is on

65 66

REGULARS Editor’s comment

Infrastructurene.ws

Industry news

JULY/AUGUST 2013

A clear impact, from

wastewater reclamation to water treatment for manufacturing.

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Publisher Elizabeth Shorten Editor Chantelle Mattheus Head of design Frédérick Danton Senior designer Hayley Mendelow Designer Kirsty Galloway Chief sub-editor Claire Nozaïc Sub-editor Patience Gumbo Contributors Laura Cornish Marketing & online manager Martin Hiller van Rensburg Production manager Antois-Leigh Botma Production coordinator Jacqueline Modise Distribution manager Nomsa Masina Distribution coordinator Asha Pursotham Financial manager Andrew Lobban Administration Tonya Hebenton Printers United Litho Johannesburg +27 (0)11 402 0571 Advertising sales Avé Delport Tel: +27 (0)11 467 6224 • Cell: +27 (0)83 302 1342 Fax: 086 502 1216 E-mail: avedel@lantic.net

EDITOR’S COMMENT FEATURE

Aspiring to inspire

S I WRITE THIS column, there are a number of recent incidents and headlines in both the local and mainstream media that are ﬁghting to come to the fore on this platform, such as the construction ﬁrms settling their collusive tendering cases with approximately R1.5 billion in penalties, as well as the

future of those ﬁrms that didn t settle. Additionally, there is the ongoing saga of the poo protesters in the Western Cape

Publisher

who resorted to dumping human waste at the entrance to Cape Town International Airport on 25 June 2013. Physical address: No 4, 5th Avenue Rivonia 2056 Postal address: PO Box 92026, Norwood 2117, South Africa Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 E-mail: chantelle@3smedia.co.za MEDIA

Alternately, there are the reports on former president Nelson Mandela s ill health after being admitted to a Pretoria hospital. At the time of going to print, the South African anti-apartheid revolutionary and politician had reportedly been in a critical condition for the past three days. Our thoughts are with him and his family at this time.

Major delivery projects... have been successfully completed or are very near to being successfully completed

All articles in Water&Sanitation Africa are copyright

All of the above will most assuredly impact not only the consciousness of the South African public, but also the context in which the public interpret the idea of service

protected and may not be reproduced either in whole

delivery from here on out. I, however, would like to focus on aspects that can ‒ and

or in part without the prior written permission of the

do ‒ have a positive impact every day on how the average citizen deﬁnes their ideal

publishers. The views of contributors do not necessarily

service delivery.

reflect those of the Water Institute of Southern Africa or the publishers.

I think this is highlighted in this edition by some of the major delivery projects we have focused on in the Gauteng region, which have been successfully completed or are

WISA CONTACTS:

very near to being successfully completed, thereby ensuring continued supply of not

HEAD OFFICE Tel: +27 (0)11 805 3537 Fax: +27 (0)11 315 1258 Physical address: 1st Floor, Building 5, Constantia Park, 546 16th Road, Randjiespark Ext 7, Midrand

only good drinking water, but also exceptional wastewater treatment to the communi-

BRANCHES

Percy Stewart Wastewater Treatment Works in Mogale City (page 32).

Eastern Cape Chairman: Hennie Greeﬀ Tel: +27(0)41 453 3102 Secretary/Treasurer: Chris Dickson Tel: +27(0)41 507 8200

www.ewisa.co.za

Free State Chairperson: D.R. Tlhomelang Tel: +27(0)51 403 0800 Secretary/ Treasurer: Riana Wessels Tel: +27(0)56-515-0375 KwaZulu-Natal Chairman: Chris Fennemore Tel: +27 (0)31 311 8734 Secretary/ Treasurer: Stephanie Walsh Tel: +27 (0)31 302-4077 Western Cape Chairman: Gareth McConkey Tel: +27(0) 21 712 4260 Secretary/ Treasurer: Eleonore Bondesio Tel: +27(0)21 872 0322 WISA mission statement m The Water Institute of Southern Africa provides a forum for exchange of information and views to improve water resource management in southern Africa.

Endorsed by

ties they service. These projects include the extension of the Meyerton WWTW through the construction of a new works parallel to the current one (page 34), the doubling of capacity for the Moreleta Spruit Outfall Sewer (page 38) and the 10 Mℓ expansion at the In addition, as we enter August, which is Women s Month, it would be remiss of me as a female editor not to take advantage of the opportunity to showcase women in the water industry that are excelling in their focus areas, such as Dr Inga Jacobs who is currently not only a board member of WISA, but also the president of the Southern African Young Water Professionals. See her interview and inspirational words on page 16. And finally, we showcase another exceptional project through the reporting of the Inside Mining editor, Laura Cornish, as she investigates the construction of a highdensity sludge treatment plant and pump system at the Central Basin s ERPM South Vertical Shaft near Germiston, which marks a major milestone in government s fight to prevent AMD entering the Vaal River. It seems as we have officially passed the halfway mark of 2013; the second half of the year holds much more in store ‒ and I can t wait for it to unfold.

Cover opportunity In each issue, Water&Sanitation Africa oﬀers companies the opportunity to get to the front of the line by placing a company, product or service on the front cover of the magazine. Buying this position will aﬀord the advertiser the cover story on pages 4 and 5 and maximum exposure. For more information on cover bookings contact Avé Delport on +27 (0)83 302 1342 or e-mail avedel@lantic.net

JULY/AUGUST 2013

COVER FEATURE STORY

WSSA

Sustainable service Water Solutions Southern Africa (WSSA) has taken the lead role in developing and implementing private sector participation within the water sector in Southern Africa, WSSAâ€™s director, Sylvia Tshivhunge, tells Chantelle Mattheus.

HIS HAS BEEN primarily though the company s municipal and industrial clients delegating the management, technical support, operational and maintenance responsibilities

for these water, effluent and wastewater services to a specialised company such as WSSA without relinquishing their rights of ownership of their assets or their contractual regulatory and monitoring responsibilities. WSSA has been specialising for over 26 years in the upgrading, optimisation, management, operation and maintenance of water and effluent systems throughout Southern Africa, covering not only the industrial sector but also the municipal environment, from large cities and towns through to municipal peri-urban and rural areas. We currently operate more than 650 facilities across eight of the nine provinces in South Africa and provide specialist services to industry and the water sector in Uganda, Zambia, Botswana, Mozambique, Qatar and Lebanon. Today, we provide over 426 000 m3/d of treat-

ed water and treat over 206 000 m3/d of effluent and wastewater through our management operation and maintenance contract frameworks, says Tshivhunge.

Holistic approach We provide our clients with complete peace of mind and hands-off solutions to the entire water cycle, continues Tshivhunge, adding that this is achieved through their independence from specific technologies and chemical suppliers, as well as their integrated life cycle cost approach. Clients are ensured of the most appropriate technology at optimum costs. As a professional service provider with extensive hands-on experience, we approach projects from a holistic perspective to minimise capital and operating costs of final water systems. WSSA s process involves assessing clients requirements, designing and developing customised service delivery solutions, including, where applicable, the process route, laboratory or pilot plant test work, selection of the best-suited technology from the market place for and on behalf of the client, project-managing the procurement, installation and commissioning, and then taking over the operation, maintenance and technical support of the plant. Our Total Water Management approach allows us to create value in a sustainable way for our clients using the TCO (Total Cost of Ownership) approach, injecting sustainability factors going beyond the traditional concept planning, design, construction and commissioning of water systems by including their subsequent management, operations and maintenance, explains Tshivhunge, adding that this ensures not only sound

JULY/AUGUST 2013

COVER FEATURE STORY

solutions asset management and maintenance to extend the life cycle of water infrastructure, but also the ongoing improvement of its economics in the long run in relation to aspects such as energy, fuel and chemicals consumption, asset renewal, performance outputs, availability, environmental footprint and the latest technological developments.

Evolutionary management systems WSSA is also one of the few water service providers in Southern Africa that has ISO 9001, ISO 14001, as well as OHSAS 18001 certifications throughout its operations nationally, with all three integrated into a single management system. These certifications provide assurance to clients embarking on service delivery partnerships with WSSA that they will receive the best value proposal for their water and wastewater services. In addition, a customer feedback system is in place through regular customer surveys conducted by the company s quality managers, and legal compliance audits are done to ensure that clients assets and plants are compliant with changing legislations. Our ISO management system is evolutionary and heavily relies on continuous improvement as stakeholders needs ‒ namely clients, customers,

“Our ISO management system is eevolutionary and heavily relies on continuous improvement as stakeholders’ a needs”

operational and process expertise through numerous contract frameworks and appointments. A prime example is where we are the sole water and sanitation service provider to over 3.8 million people in three key district municipalities, with 16 local municipalities, covering an area of 36 000 km2. This also includes the major city in the region, with its industrial and export hub, she states.

Contract intricacies WSSA also does operations and maintenance contracts, where it takes over the responsibil-

communities, employees, authorities, regulators and shareholders ‒ evolve. She adds that measure-

ity for the management, operation and routine main-

ment, analysis and iteration are key components of

tenance of the bulk water and wastewater treatment

such improvement, the latter being rolled out through

systems, as well as the associated water and sewer

detailed measurable action plans.

reticulation systems where required. In these contracts, we generally provide the management, supervision, op-

Municipal sector in focus

erating personnel and routine maintenance on a fixed

As a water services operator in the municipal sector

monthly charge, with chemicals, consumables, energy,

specifically, the organisation provides water service authorities with the full spectrum of water services with the view to continuously improve and sustain water and wastewater service delivery to communities and consumers. Our services cover the whole water cycle from bulk drinking water production, water and wastewater distribution, wastewater treatment and customer management for urban and rural communities.

Varied clients and sectors WSSA also presently provides services to several provincial and regional government or parastatal departments, providing the towns and communities in their areas with an extensive range of technical, construction,

In each issue, Water&Sanitation Africa offers advertisers the opportunity to promote their company s products and services to an appropriate audience by booking the prime position of the front cover, which includes a feature article. The magazine offers advertisers an ideal platform to ensure maximum exposure of their brand. Please call Avé Delport on +27 (0)11 467 6224/ +27 (0)83 302 1342 to secure your booking.

JULY/AUGUST 2013

COVER STORY

WSSA

repairs and replacement being carried out on a quota-

provision of SETA accredited training programmes in

tion, cost plus or day work basis, says Tshivhunge.

water and wastewater process control, not only within

Other options include leasing contracts where the tra-

its operations, but also as a service to its clients.

ditional O&M model is replaced with longer term leas-

We carry out skills gap evaluations throughout

ing or hybrid leasing contracts (5 to 15 years). Within

organisations and then design and implement tailored

this framework, in addition to management, operation

training and skills development programmess for their

and maintenance services, WSSA also takes over the re-

employees, taking into account recognition of prior

sponsibility and cost for the preventative maintenance,

learning. Tshivhunge adds that these programmes are

repairs and, in cases, the replacement of system assets.

aligned with the local training initiatives, accreditation

WSSA also has a wide range of existing contracts for municipal and industrial water and wastewater systems

programmes, subsidies and tax relief initiatives, to ensure not only compliance, but also to minimise costs.

where they are responsible for the management, opera-

These programmes address not only operational

tion, maintenance, repair and replacement of the water

processes, but also practical plumbing and pipe laying

and wastewater treatment systems and associated bulk

skills, technical support services, health and safety,

distribution, pump station and reservoir systems, charg-

and other water-related services. These are often

ing a fixed monthly fee. In addition to the O&M cost,

linked to change management initiatives aimed at

this fee covers the cost of chemicals, energy, repairs and

motivating and transforming the staff into an effec-

prescribed asset replacement. In these contracts, there

tive business unit. Equally as important, we provide

is normally a fixed monthly charge and often a volume

on-site management, supervision and trainers to

based charge, the latter based on the total volume of

manage the system over an initial period, while local

water and wastewater treated, explains Tshivhunge.

skills are recruited, trained and mentored to take over these responsibilities.

Technical and operational support WSSA s technical and operational support services

Extensive network

within the municipal water and wastewater sector in-

WSSA has a wide network of consultants, contractors

clude asset management, network management, water

and specialist service providers who can be mobilised

demand, conservation and loss management, crises

as required to meet specific requirements. We place

interventions, benchmarking, quality monitoring and

particular emphasis in our international operations on

laboratory services, customer management services,

expanding this network to include the local support

capital works programmes, rural water and sanitation

structures and specialists within our host countries.

services, water utility support and training.

This will also be consistent with our preference and support to be given to local suppliers

With regards to network management

specifically,

WSSA

and service providers as part of our local

manages,

operates and maintains over 26 000 km of bulk water transmission systems, together with their associated weirs, intake towers, pump stations, water towers and reservoirs. She adds that in most of these contracts WSSA is fully responsible for the maintenance and repair of the pipelines and associated fittings, valves

â€œWe are the sole water and sanitation service provider to over 3.8 million people in three key district municipalities, with 16 local municipalities, covering an area of 36 000 km2â€?

and meters, and has mobile repair teams and standby resources to ensure 24/7 response to any eventuality. Where the distribution of water to the end consumers is included in contracts, we manage the metering operation as well. On many of our contracts we take the full cost and risk of all repairs, replacement and water losses within the distribution system, either on a fixed charge or rate per cubic metre of individual metered consumption, incentivising us to maintain the plant at maximum state of repair and efficiency, as all system losses would be for our own account.

Closing the gap WSSA is doing what it can to assist in the provision of water professionals to the industry through the

JULY/AUGUST 2013

economic

development

objectives,

says Tshivhunge. She believes that this will also include maintaining

strong

communication

and cooperation links with other water service providers as well as other service providers, often valuable allies, when faced with common challenges in the water sector.

TRC/0103/E

PRESIDENT FEATURE ’S MESSAGE

YOUTH DEVELOPMENT

The key to growth ‘A nation that does not invest in its youth does not invest in its future’ – OR Tambo.

OUTH AFRICA, like many other developing

develop and prosper as fully engaged, responsive and

countries, is faced with a number of socio-

productive citizens.

economic issues that are indicative of a country

Some words describing our youth in general are:

striving to move into the mainstream alongside

young, gifted, creative, turbulent, energetic, confused,

first world countries. In some areas the country is doing

dynamic, innovative, capable, strong, fast, techno-boffs,

extremely well and in others we have to put more effort

inexperienced,

‒ no one said it was going to be easy, but we have to

getters, determined, impatient, expressive, impulsive,

keep at it. It is also an undeniable fact that the progress of a country lies in the education and empowerment of its youth. It is essential that the true value that the youth represents be unlocked and harnessed to its full po-

new

generation,

go-

new thinkers, anxious, sharp... the list continues. These attributes are or will be dependent on the environment these youth find themselves in, and we in the water sector have an opportunity to make a difference in their lives. We can play a

tential to enable us to achieve the desired progress as a

very constructive role by creating platforms for interact-

nation and in this context youth are defined as persons

ing with them and there are some great examples of the

up to the age of 35.

achievements made in this regard.

The month of June is dedicated to our youth and we

For us in WISA it is awesome to experience the enthu-

need to celebrate them, their goals, their aspirations

siasm projected by our own young water professionals

and their achievements. We are mindful of the happen-

who continue to make their presence felt throughout

ings of the past and reflect upon it as a reference point

the water sector both nationally and internationally.

in our lives to remind us of the continuous importance

Other institutions have similar structures that provide

of building positive relationships with our youth. There

opportunities that draw on the positive attributes of

is an urgent need for us to do so because we need to

the youth and, in so doing, shifting their organisation s

walk this journey with them to give them an under-

profile to higher levels.

standing of leadership, an invaluable skill that they ll

There are many learners who have made conscious

require as they plan their journey into the future. A

decisions about their career streams and have enrolled

positive injection into their spheres of thinking will see

in maths and science courses with the intention of

us building a great nation with an inspired, focused and

becoming engineers, scientists, etc. It is of paramount

determined youth.

importance that we, in the water sector, ensure that we

The future of South Africa lies within its investment

have a strong support base to facilitate the intake and

in our youth and we must ensure that all young people

development of those youth with an interest in our sec-

access the opportunities that enable them to grow,

tor to enable them to play constructive roles within the

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quick-witted,

• Department of Water Aﬀairs • ERWAT • ESKOM Holdings • eThekwini Municipality • Festo • Golder Associates Africa • Grundfos Alldos • Huber Technology • Johannesburg Water • Magalies Water • Merck • Mhlathuze Water • NCP Chlorchem

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JULY/AUGUST 2013

• Sobek Engineering • Sulzer Pumps Wastewater SA • TCTA • Tecroveer • Umgeni Water • Veolia Water Solutions & Technologies SA • WAM Technology • Water Research Commission • Water & Sanitation Services SA • WEC Projects • Xylem • Zetachem • ZMG Watech

PRESIDENT ’S MESSAGE

YOUTH DEVELOPMENT

sector. Very importantly, they also need to be afforded

His achievement was acknowledged by the minister of

the opportunity through effective mentorship and

Water and Environmental Affairs, Edna Molewa, during

coaching programmes to take ownership and responsi-

the Department of Water Affairs 2013 Budget Vote.

bility of their careers and future.

I would like to acknowledge all other companies,

The above reaffirms the message of President Jacob

organisations and entities on the successful implemen-

Zuma on Commonwealth Day, 11 March 2013, where he

tation of their youth development programmes and

stated: Young people hold the key to society s future,

initiatives as well as those individuals who altruistically

their ambitions, goals and aspirations, and we can only

rendered their time to mentor these young profession-

prosper if there are dedicated efforts to invest in the

als and continually reinvest into the sector. We would

youth. In South Africa, we decided to focus on youth

like to request organisations and companies, more so

workers to close the gap and ensure that services to the

those with the required capacity, to assess their situa-

youth are prioritised.

tion and also introduce similar initiatives,

As WISA we are grateful to those companies that invest in youth development and our own Department of Water Affairs is setting the yardstick through its Learning Academy, which

“Yo oung peoplee ho old d the keyy to so ociety’ss fu uture, theeirr am mbitiionss, goals and d aspiiratiionss”

which could very successfully be aided by the SETA offerings. During July 2013, our vivacious South African Young Water Professionals division of WISA will be holding its national

currently has a total of 536 active bursary holders studying engineering, science and

conference in Stellenbosch, and we wish them a productive and successful event.

surveying. One such fine example of the effectiveness

In conclusion, I want to leave you with this thought:

of this programme is Xolani Mdletshe, who is now a registered professional engineer and a product of

The elevator to success is out of order. You ll have to use the stairs... one step at a time. ‒ Joe Girard

the Learning Academy, and has navigated a long and

Thank you.

challenging road from university, through to being ad-

mitted professionally in the engineering field. He is the

Ronald M Brown

first ever candidate from the academy to be registered.

President: Water Institute of Southern Africa (WISA)

JULY/AUGUST 2013

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WISA FEATURE NEWS

LIMPOPO BRANCH LAUNCHED

Doing things differently On 11 June 2013, WISA celebrated the official launch of the WISA Limpopo Branch, as well as the launch of the Young Water Professionals Chapter and the Process Controller Division for the province.

JULY/AUGUST 2013

WISA FEATURE NEWS

PEAKING AT THE LAUNCH held in June 2013,

make decisions in a timely

WISA president Ronald Brown emphasised the

manner and openness to all

importance of partnerships. Always ask not

feedback and suggestions.

what WISA can do for you, but what you can

do for WISA, said Brown, adding that the new branch

Branch basics

would provide the platform for the exchange of ideas

Speaking

between water professionals in the province, as well as

WISA acting chief executive

providing professional support.

Dot Zandberg noted that

the

launch,

this is the second WISA

Brown also heralded the launch of the branch as

branch

groundbreaking, reaffirming that WISA is here to stay .

launched

Each of us can add value to the branch. Our objec-

in recent times ‒ the last

tives and vision must be clear. We need to create quick

being the Namibia branch ‒ cementing the growth

wins and in tandem look into the medium- and longterm goals. He said a lack of skills and money should not be considered an insurmountable hurdle, adding that this is where the individual needed to step forward and take ownership of their environment as well as fully

ABOVE The president of WISA, Ronald Brown

momentum of the institute. With the addition of the Limpopo branch, WISA now has nine branches. Lepelle Northern Water sponsored the event celebrating the launch of the Limpopo Division. WISA also recently introduced a new division, the

appreciate the importance of relationships.

water reuse division, bringing the total number of divi-

Brown also highlighted the need for political support

sions to 14.

with regards to infrastructure projects and in the value

Zandberg also unpacked WISA s vision 2015.

of partnerships. Behind every project there must be the

The

political will, because if there is no support the project

current strategic scope of WISA is embedded in its

will ultimately fail.

vision defined as: To build expertise, share knowledge

According to Brown, the ingredients for a successful

and improve quality of life . WISA realises its current

partnership include a shared vision, ongoing commit-

business case mainly by delivering conferences, work-

ment and communication, strong leadership, the pres-

shops and related professional gatherings, information

ence of people with decision-making authority who can

transfer by means of newsletters, monthly journal and

JULY/AUGUST 2013

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WISA FEATURE NEWS

FROM LEFT WISA acting chief executive Dot Zandburg; the Limpopo branch’s interim committee; WISA director Gareth McConkey

Limpopo interim committee member Elias Nkuna also did a presentation on the role and focus of the process controllers division in the province, saying they needed to promote a

knowledge management, networking and capacity building,

culture of working rather than focusing on the salary, promote

said Zandberg.

career development, and share information and update each other on the latest technology. This also allows us to network

Process controllers in focus

with other provinces, said Nkuna.

Zandberg further added that the launch of the process controllers division specifically should serve as a further catalyst towards the

Excellent inspiration

professionalisation of process controllers in South Africa.

The WISA director of branches, Gareth McConkey, discussed

WISA s key strategic directions with regard to the professionali-

achieving excellence in wastewater management, saying that

sation of process controllers, according to Zandberg, include the

although the institute had the legislation and technology to

development of the process controllers within the current aca-

assist in winning the war it was not yet there.

demic environment from entry to exit level, as well as the devel-

People make the difference, said McConkey, adding that

opment of the process controllers beyond the current academic

excellence was more than merely complying with a minimum

environment, to narrow the skills gap between the professional

standard. It is achieving the best you can and then trying to

process controller and the professional process engineer .

do better ‒ and one should always be aiming for excellence. However, he noted that this commitment to excellence could not solely come from process controllers, no matter how excellent they may be . Commitment to excellence in organisations does not flow upstream, it starts at the top, he said.

Local support In working towards the establishment of the branch, the local chairperson of the interim committee, Paradise Shilowa, noted that the branch s mandate was to bring it home , announcing the branch s intention to vie for the hosting of WISA s biennual conference in 2016. The province ‒ as with the industry at large ‒ faces a number of challenges highlighted by different speakers on the day. According to the Department of Water Affairs representative at the launch, the challenges included not only having to develop infrastructure, but also ensuring effective operations and maintenance, as well as managing ageing infrastructure that needs refurbishment, and this all require professional engagement, which the branch will supply. Other

challenges

highlighted

representatives

from

water boards, past presidents of WISA, South African Local Government Association representatives and council members from local government included the need to change the mindset with regards to how process controllers are deﬁned, the idea of the operator versus the process controller, and challenges related to skills in the sector and to water services and sanitation provision to communities, especially in rural regions. The launch of a WISA branch in Limpopo was the first step to improving the state of water and wastewater infrastructure in the province, said Shilowa, adding that they would specifically like to make sure the province s performance in the Blue and Green Drop programmes improved. We need to support each other, cross-pollinate ideas and strategies, and in the very least our process controllers will improve, concluded Shilowa.

JULY/AUGUST 2013

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WISA FEATURE NEWS

BOARD MINEBANTER WATER

The value of mentoring â€œThe most important advice I can give is to find good mentors and be clear in what you would like to be mentored on.â€? This is the message WISA board member Dr Inga Jacobs has for women new to the water industry. S JACOBS EXPLAINS, she has

big role. I should say that I happened upon

working on water issues, there are few truly

had mostly male mentors to date

it. After working in and observing trends in

transdisciplinary research initiatives being

and they have had an enormous

the water sector for a few years, as a political

pursued, and the challenge of creating the

inďŹ‚uence in shaping who she is

scientist, I began to realise that new and

space for scientists, government oďŹƒcials and

today. I have tried to ensure that I also have

emerging challenges and complexities, such

other stakeholders to work together around

tens of professional mothers and big sisters

as climate change, eutrophication, acid mine

common areas of concern, remains diďŹƒcult.

to advise on the technical but also non-tech-

drainage, skills ďŹ‚ight and social inequality,

Additionally, young social scientists are

nical aspects of life as a water professional,

are demanding more integrated levels of

often unaware of how their skills can be ap-

says Jacobs.

ingenuity and expertise from a diverse set of

plied, and indeed, are needed in the sector,

disciplines, says Jacobs.

says Jacobs.

However, WISA is great in that respect, according to Jacobs. This is mainly because

She adds that this relates speciďŹ cally to ad-

it is a network of professionals that connects

dressing the governance challenges facing

The wave of the future

you with people you would never have built

the water sector, which necessitates exper-

Her mission then became to ďŹ nd ways to

strong working relationships with over time.

tise from a diverse set of transdisciplinary

make young South Africans aware of the

Jacobs has been involved in WISA since 2009

backgrounds. No amount of technical and

career opportunities in the water sector,

and was elected to the WISA Board in 2010

scientiďŹ c ingenuity is adequate if the solu-

and how they can apply their seemingly

in her capacity as president of the Southern

tions generated are not relevant, digestible

unrelated social science skills to addressing

African Young Water Professionals (SA YWP).

and acceptable to the speciďŹ c sociopolitical

very real problems in the sector. In 2010,

and socio-economic contexts of our time.

I co-founded the Young Scholars Forum in

Go with the ďŹ‚ow

According to Jacobs, given this realisation,

transboundary water governance, a collab-

Jacobs has been working in the water indus-

there is growing recognition of the need

orative and transdisciplinary exchange initi-

try speciďŹ cally since 2007. Here introduction

for more transdisciplinary responses to

ative for scholars interested in this ďŹ eld, and

to the industry, however, was never very

the challenges facing the water sector,

one which encourages the recognition and

straightforward, with circumstance playing a

but there are still very few social scientists

mutual respect of multiple perspectives.

JULY/AUGUST 2013

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WISA FEATURE NEWS She also from then on became very

and over-the-hill. At the same time, the

heavily involved with the YWP net-

lamentations about the lack of capacity or

work in Southern Africa and globally.

the lack of sustainable knowledge transfer

Currently, she serves as the Southern

in the workplace seems to produce few

African

chairperson,

practical solutions to address the immense

and has also served as YWP s global

challenges facing us as our technical work-

president

force retires, and our younger profession-

regional

vice

(2010-2012)

and

the

als job hop, she says.

International Water Association s Board

Jacobs believes that no amount of

of Directors.

training programmes will work if we don t

I have also recently begun to conduct research in the role of individuals in addressing complex water challenges facing the water sector and, speciﬁcally the role and responsibility of young water professionals in this regard. Voices ‒ young voices ‒ from Africa are sought to provide insights on the opportunities and challenges facing water sectors in a developing country context. African youth are dynamic enough to take change in their stride, while having the mentorship of distinguished water professionals for guidance. We are the ones faced with the consequences of the

Dr Inga Jacobs (middle) receive their awards from Dr Mandla Msibi, director: Research and Innovation at Tshwane University of Technology (left) and WISA president, Brown

adopt a mindset of learning from each other, with the understanding that we can learn from other generations, even younger ones. With regard to the representation of women in the water industry speciﬁcally, Jacobs states that while she thinks that traditionally they have not been represented, this is slowly changing. South Africa has also been at the forefront in advocating for the inclusivity of women and women s needs and interests. Government has passed legislation to formalise its commitments toward achieving gender equality in South Africa, thereby creating a

environmental threats, and we are passionate about im-

public space where women s voices have a platform,

proving the situation. More than this, we aim to improve

says Jacobs, adding that drawing on these national objec-

the way things are done in a fun and positive way, while

tives the water sector has prioritised gender mainstream-

still maintaining economic relevance and excellence,

ing, and has seen a signiﬁcant number of women enter

continues Jacobs, adding that young water professionals

the industry and take up senior leadership positions. Women in the water sector have held, and con-

are strategically positioned to conduct multi-, or

DR JACOBS’ KEY MESSAGES

even transdisciplinary environmental investigations because they are not, as yet, constrained by the boundaries of their discipline or sector.

Continuing challenges? As a young water professional, I ﬁnd it strange that in a country like ours with such a rich cultural her-

tinue to hold, the highest oﬃces, including those of minister of Water Aﬀairs, deputy minister, senior

Yes I can Be useful Be the best I can be Learn from others (younger and older) Commit to the road Expect the unexpected Don’t jump jobs too often

advisors, and numerous other high-proﬁle and decision-making positions. The sector has been successful in achieving gender parity in many of its institutions, and the success achieved by the Department of Water Aﬀairs (DWA) in this regard

itage that acknowledges the importance of elders

is exemplary. However, the degree to which this

in virtually every culture, this sentiment rarely translates

transformation at higher levels translates into better water

into the South African workplace. In our world of rapid

access for women in communities or an improved service

change, the role of elders has diminished to irrelevant

remains to be seen.

JULY/AUGUST 2013

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HOT FEATURE SEAT

AURECON AR

Inspiring, innovative Although the water industry is still a maleA dominated field, this dynamic is changing as more women, like Aurecon associate Teboho Mofokeng, prove their worth on larger scale projects.

Teboho Mofokeng is part of the team set to roll out the upgrade of the Sebokeng Wastewater Treatment Works

JULY/AUGUST 2013

HOT FEATURE SEAT

and intelligent S IT DIFFICULT? Yes, but isn t anything worth doing

I think, nowadays, businesses in general ‒ including

diﬃcult? she answers when asked about the chal-

Aurecon ‒ are more geared towards uplifting women.

lenges inherent in being a woman in a man s world .

She is quick to note, however, that this perspective is

One of the challenges, according to Mofokeng, is that

been largely based on her observation of the private

the technical capability of the female engineer is generally

business sector. I don t think it is as challenging for

underestimated. But at the end of the day, the moment

females now as it was a couple of decades ago. Conditions

people realise that you can contribute and add value to

are deﬁnitely better as a result of employers making a

their project, it doesn t really matter whether you are fe-

real eﬀort to ensure women are well-represented in the

male or male ‒ gender ceases to be of relevance.

engineering sphere.

She adds that being male or female doesn t impact on

A changing dynamic globally

getting the job done ‒ speciﬁcally in the engineering sphere. We deal with technical matters and providing innovative solutions. This is where your thinking capability as an individual comes into play and that has nothing to do with gender, says Mofokeng. Mofokeng oﬀers this advice to other women in her position: You simply need to know and understand your

It is crucial that every individual within the industry keep abreast of the most recent research studies and technologies

Mofokeng adds that it is crucial that every individual within the industry keeps abreast of the most recent research studies and technologies. Thanks to technology and enhanced communication tools, the world is literally seamless and it is no longer about being on separate continents or separated by distance ‒ people are looking to partner and leverage oﬀ

craft. The quality of service you provide will speak for itself and more than that there will be no

each other s experience and expertise.

need to prove yourself. In my experience of dealing with

As evidence of this growing phenomenon, she high-

our clients (most of whom are from the government sec-

lights initiatives by government to twin with water boards

tor), I ve learned to be diplomatic and to listen attentively

from other cities. This is a very positive direction to be

in order to provide solutions that are practical and also

moving in as there can be a sharing of information and

meet the client s needs.

expertise from others that have travelled further down the

The Sebokeng upgrade will increase the WWTW’s capacity from its current 100 Mℓ/d to 200 Mℓ/d

JULY/AUGUST 2013

HOT FEATURE SEAT

WISA NEWS

AURECON

road. This helps to improve our skills base in South Africa

I would like to be involved in upskilling plant opera-

and in time we can help improve the skills base at other

tors. I am passionate about teaching and passing on

water boards.

my knowledge. Operator

Local progress When it comes to ascertaining whether our local water industry is progressing on the whole, Mofokeng s answer is encouraging: I think there are various entities and associations which are supporting the drive to help government maintain infrastructure and upskill people operating the water and wastewater treatment plants. She adds that engineers have a responsibility to provide sustainable solutions. However, proper operation and maintenance of treatment plants is essential to ensure that the infrastructure serves its design lifespan.

CAREER HIGHLIGHTS

knowledge

in some cases is limited

Mofokeng’s most exciting project to date – and the one she terms the ‘highlight’ of her career – is the Sebokeng Wastewater Treatment Works (WWTW). “We’ve only recently designed the project and construction hasn’t started yet,” explains explains Mofokeng. Aurecon is involved in the upgrade of this works to increase its capacity from the current 100 Mℓ/d to 200 Mℓ/d average dry weather flow (ADWF). “Its upgraded capacity will place it as one of the largest wastewater treatment works in South Africa,” says Mofokeng. The newly upgraded capacity will be double what it was before. “It’s a really big works, and designing something on such a big scale has given me invaluable exposure. On the Sebokeng project, I am involved in process design, project co-ordination and client liaison. My involvement has allowed me to understand the needs of the client to better serve these needs. Key focus areas on the Sebokeng WWTW upgrade have been the possible impact on the environment and the impact on the community – how we can get the community involved and, at the end, how we can upskill people who have been involved in the project at construction and design levels,” says Mofokeng. “On this project, we will assist the client with the operation of the extended works for a period of three months after the new works has been commissioned. This will provide us the opportunity to share the process knowledge with the plant operators.”

switching

buttons

on and oﬀ. This limits the capacity to ensure that plants are operated optimally. that

She

cautions

knowledge-sharing

needs to be strategic and purposeful. It is essential that operators have an understanding

the

treatment process as this will enable them to react with competence when trouble shooting. I believe that

everyone

involved

from operations, to maintenance and asset management has a vital role to play in the supply of safe

drinking water. All should be sensitised to the eﬀect their role has on society. According to Mofokeng, despite an emphasis on further education in the industry, more can be done to sensitise school children on the real cost of water and sanitation. While water and sanitation is a basic right it does come at cost, which includes capital, operation and maintenance. We can all contribute to help decrease the cost where possible. Mofokeng believes that this type of education will instil a greater respect for the end product and processes involved, and as a result, people will hopefully do better because they know better.

Aurecon inﬂuential in growth Mofokeng s role at Aurecon and the opportunities the Nevertheless, she admits that there are challenges facing all parties involved ‒ not least of which is the succession issue. Many experienced personnel managing and operating the South African plants have retired or are close to retirement and there needs to be succession plans

The upgrade of the Sebokeng WWTW is still in the design stage

group has aﬀorded her have played a huge part in her growth, both individually and as a water engineer. I believe we have som e of the most experienced water engineers on our team in South Africa. I have learnt so much from them, says Mofokeng.

in place. It is crucial to ensure that treatment plants,

She adds that Aurecon has allowed her to grow her

small or big, are operated by personnel that have an

leadership abilities by assisting her to become well-

understanding of the treatment processes used and fully

versed in how to deal with valued clients. The company

appreciate the consequences of not meeting the statutory

has in place wonderful programmes that help individuals

eﬄuent requirements.

to skill themselves on the softer issues of engineering,

Various water institutions and role players in the water and sanitation industry are working on ways to address

because we all deal with people at the end of the day, she states.

the challenges that the industry currently faces. I am

In conclusion, Mofokeng believes that business is about

hopeful that we will reap the beneﬁts in the coming

building relationships based and trust and integrity while

years and will progress from the current status quo,

providing excellent service. The growth of the global

states Mofokeng.

population and the consequent strain it places on water resources and sanitation infrastructure means that there

Education is essential

is a need for innovative thinkers to provide future solu-

Mofokeng is a strong proponent of not only education ‒

tions and engineering services. I believe that women

but the strategic upskilling of key personnel. Eventually,

can equally contribute to this need. JULY/AUGUST 2013

The top infrastructure and service delivery stories making the news

Deputy minister engages farmers in Breede Water Management Area

Water infrastructure requires R670 billion investment IN UNPACKING the necessity of building infrastructure to consolidate the gains of

of BOCMA and a capaci-

the past two decades

ty-building programme was

Minister of Water

designed to prepare a group Rejoice Mabudafhasi, deputy minister of Water and Environmental Affairs

of champions. According to the deputy

Affairs, Edna Molewa, has indicated that the capital investment in

minister: While the eﬀorts of

new water and sanitation infrastructure for the entire value

the BOCMA are appreciated,

chain, which includes the refurbishment of existing infrastruc-

“WATER RESOURCES

we must ensure that we do

ture, is projected to require an estimated R670 billion over the

management can ultimately

not lose sight of the bigger

next 10 years.

only be successful if and when

goal of ensuring that we

the public is fully on board. It is

combine all our resources and

minister on the occasion of the presentation of the Department of

important that great emphasis

provide hands-on support

Water Aﬀairs budget in Parliament on 21 May 2013.

be placed on creating aware-

to resource-poor farmers;

ness on water resources issues

there is a positive correlation

total allocation due to increased allocations for infrastructure

and especially to assist in the

between access to water and

development, the total allocation now only stands at R10.2 billion

development particularly of

rural development, poverty

for 2013/14, R12.4 billion for 2014/2015 and R15.5 billion for

water-wise youth and women.

eradication and food security.

2015/2016. The announcement of the Strategic Integrated

This is equivalent to a R67 billion investment per year, said the

Although she noted signiﬁcant increases in the current

This was the message from

The paucity of water on the

Projects (SIP) by the president in 2012 formed the foundation of

the deputy minister of Water

other hand, the key ingredient

an equity-based future that we envisage in the coming decade.

and Environmental Aﬀairs,

for food production, is one of

Rejoice Mabudafhasi, on 30

the major causes of famine,

development of a comprehensive investment framework, which

May 2013 on the occasion

especially in rural areas of

will inform budgeting and integrated planning based on a life

of the Breede Overberg

South Africa where people

cycle approach that includes planning and construction costs,

Catchment Management

depend heavily on primary

operation and maintenance, ﬁnancing costs and the costs of

Agency (BOCMA) emerging

food production for their liveli-

sustainable water management, said Molewa.

farmers/resource poor farmers

hoods, said Mabudafhasi. She

water transformation dialogue

added that the inextricable link

R67 billion per year is available from current sources. These in-

at Merwida Country Manor,

between food and water secu-

vestments will have to be funded from on-budget and oﬀ-budget

Rawsonville, in Worcester. The

rity had also been emphasised

sources through the private sector.

aim of the dialogue was to

during the Budget Vote earlier

promote active stakeholder

this month.

participation in the man-

A long-term goal within the

To facilitate eﬀective and timely investment, I have initiated the

According to the minister, currently only R30 billion (45%) of the

More women in the water industry

agement of water resources,

BOCMA process, according

as well as acknowledge the

to Mabudafhasi, is to develop

important role resource poor

the technical competence

THE ROLE OF women in water resource management is

farmers play in the economy

of emerging farmers capac-

and food security.

ity to fulﬁl water resources

changing, as is the focus of their interaction within the water industry, according to the deputy minister of Water and Environmental Affairs, Rejoice Mabudafhasi.

The BOCMA is a water management institution that

Elgin Road excavation work-

management functions and to ensure the sustainability

We brought rural women on board to prove that water

was established in terms of

of emerging farmers. The

resource management is not for engineers and scientists only.

Section 78 of the National

eventual impact will be a more

People with indigenous knowledge have a key role to play,

Water Act 36 of 1998 and is op-

sustainable approach to the

hence the conceptualisation and implementation of the Adopt

erational in the Breede Water

management, allocation and

a River Project, said Mabudafhasi in her address during the

Management Area (WMA) in

development of the water

Department of Water Aﬀairs Budget Vote on 21 May 2013.

the Western Cape. The BOCMA

resources in the catchment.

has a stakeholder-based

The BOCMA s planned capacity

project, 24 rivers were cleaned and 1 148 job opportunities

governing board that includes

building campaign aims to

created for local women. About 44 of these women have also

an emerging farmers repre-

be inclusive, interactive and

been awarded bursaries to study further at universities and

sentative. Public participation

dynamic, based on contextual

FET colleges to, as the deputy minister, says: Tell a story that

is therefore an integral part

problem solving.

begins with I was a river cleaner and now I am a scientist .

During the 2012/13 ﬁnancial year, through this speciﬁc

JULY/AUGUST 2013

INFRASTRUC TURENE.WS FEATURE

“No Drop” programme in pipeline

the SWPN-SA National Impact Projects, along with other initiatives that, for example, address

2013 Summit at the Cape Town

Water Resources Group, with the

the treatment and reuse of

International Conference Centre

vision of engaging all stakehold-

water from mining operations.

on. The programme has been

ers, enhancing collaboration

Here the SWPN-SA is looking at

developed in light of President

and create partnerships in an

one speciﬁc catchment where

Jacob Zuma challenging South

eﬀort to support South Africa

estimates indicate that mine

Africans to reduce water loss by

secure its water future and close

water is expected to contribute

half in 2014 and the Department

the projected 17% water gap

11% in fulﬁlling future water

of Water Aﬀairs introducing the

in 2030.

requirements. The focus is on

is developing a No Drop

Edna Molewa, minister of Water Affairs

HE STRATEGIC Water

Partners Network ‒ South Africa (SWPN-SA)

War on Leaks Project.

A cornerstone of the SWPN-

According to Molewa, as part

deﬁning institutional and pric-

SA is developing innovative

ing models that would make

of this package, the network is

solutions that leverage the

it worthwhile for government

programme, building on

developing a tool to support

strength and expertise of the

and mines to work together

the successful Department

municipalities as they take

Department of Water Aﬀairs, the

and expand the treatment and

of Water Aﬀairs Green and

on the challenge to reduce

private sector, civil society and

reuse of mine water.

Blue Drop programmes, to

water leakage in the systems.

expert organisations. By consol-

assist municipalities to assess

I will continue to champion

When rolled out, the research

idating resources and technical

the SWPN-SA within South

and improve their water

suggests we will be able to save

capacity, we can create shared

Africa and also to share our

use eﬃciency.

619 million cubic metres, closing

value for all stakeholders. It is

experience and learning with

the country s water gap by 3.5%

through this mentality that this

new country partnerships. I

by 2025.

partnership is yielding early and

invite all of you here today to

tangible results, said Molewa.

also join me in our eﬀorts to

This was announced by the minister of Water Aﬀairs, Edna Molewa, at the recent water

The SWPN-SA is an initiative

session held at the World

that was announced by Molewa

Economic Forum (WEF) Africa

two years ago with the 2030

She highlighted the No Drop programme as one of

close South Africa s water gap, concluded Molewa.

JULY/AUGUST 2013

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INDUSTRY NEWS

MANUFACTURING

A new local licensing agreement

ULZER PUMPS and Mather & Platt have together

Productivity gains at DFC VENG MANUFACTURING DFC has further upgraded

factory facilities to maintain a competitive advantage in quality and productivity. An automated welding line has been installed at the

announced a licensing agreement allowing the man-

company s Vent-O-Mat valve plant to improve the execution of

ufacture, sale and servicing of Mather & Platt products

welding sequences on stainless steel components used in the

and parts by Sulzer Pumps South Africa.

manufacture of guides and airtight thin-walled ﬂoats. Vent-O-

The agreement, signed in January 2013, will facilitate cus-

Mat, one of the world s leading valve ranges for the protection

tomer access to the Mather & Platt centrifugal pump range via

of pipelines against surge, air build-up and vacuum, frequently

both companies, allowing purchase of these pumps as well as

makes use of components in either 304 or 316 stainless steel, a

access to spare parts and service.

material on which automated welding delivers superior results.

The confusion over the link between Sulzer and Mather &

The new welding line, which will also automate the attaching of

Platt, now clarified by the licensing agreement, had its origins

stainless steel ﬂanges to

in the 19th century, when English company Mather & Platt

Vent-O-Mat valve barrels,

developed and improved upon the 1875 invention of the

centres on a Fanuc robot

Reynolds turbine centrifugal pump.

integrated with a Lincoln

A few years later, Mather & Platt entered into an agreement

400

amp

welding

ture a multi-stage turbine pump based on the invention, but

Binzel air-cooled welding

incorporating several improvements made by Sulzer.

guns, and incorporates a

The new design was an attractive one and a sharing of markets seemed commercially feasible, but Sulzer was able to supply the pumps at a lower cost than Mather & Platt, and the Over the ensuing century, the intellectual property rights to

machine

horizontal

DFC fluidised bed paint line productivity

and

manipulator

incorporated into a lathetype machine.

agreement to produce the same type of pump ended in 1904.

The automated welding line was commissioned in January 2013.

the Mather & Platt brand, products and spare parts changed

On order by Aveng Manufacturing DFC is a new paint plant,

hands several times, with independent pump develop-

which will be for Insamcor production only. This was scheduled for

ment by both Sulzer and by Mather & Platt leading to the

installation earlier this year and commissioning in early May.

confusion now amicably settled by the Southern African licensing agreement.

The latest factory upgrades and machine installations follow a major productivity improvement programme carried out between

The most recent sale, in 2009, of Mather & Platt by PSV

2006 and 2010. Phases 1 and 2 of this programme were complet-

Holdings to WPIL confirmed Mather & Platt South Africa

ed in 2007 after an investment of some R30 million and comprised

as the sole manufacturer, reconditioner and distributor of

the upgrading of technology and the optimisation of materials

Mather & Platt pumps throughout Central and Southern Africa.

ﬂow and individual workstations within all factories.

Sulzer South Africa is now the sole Mather & Platt licensee.

In 2010, the implementation of the Clockworks productivity pro-

Mather & Platt products, parts and service are now available

gramme was completed as the third phase, providing management

from both Mather & Platt and Sulzer.

with access to manufacturing process data and overall equipment eﬀectiveness by machine, product type and operator.

automatic

with Swiss rival Sulzer that both companies would manufac-

JULY/AUGUST 2013

ENDRESS+HAUSER

INDUSTRY NEWS

A good year Endress+Hauser has achieved record-high figures in net sales, employment, profits and equity. Despite ongoing global economic uncertainty, the measurement specialist group, which has headquarters in Reinach, Switzerland, and operates worldwide, expects this positive trend from 2012 to continue this year. PEAKING AT THE presentation of the ﬁnancial

results on 28 May 2013 in Basel, Switzerland, the group CEO, Klaus Endress, said: 2012 was not an easy year . In some markets, sales dropped, but

in many the group recorded growth. In the end, we only just missed our ambitious targets. Undeniably, a little luck played a role. The company remained largely unaffected by currency influences; developments in the foreign exchange rate even slightly supported the business. But above all, Endress+Hauser made the best possible use of the opportunities that the past year offered ‒ despite all the risks. The company increased net sales by 11% to almost €1.7 billion (R22.41 billion). Despite higher depreciation and amortization, the operating profit (EBIT) almost kept pace, increasing by 10% and ultimately reaching €273 million. Owing to a higher tax rate, net income rose by only 3% to €183 million, which is nevertheless a new record.

Development across a wide base

The executive board of the Endress+Hauser group (from left): Dr Gerhard Jost (production), Matthias Altendorf (innovation), Pieter de Koning (logistics, IT and organisation), Nikolaus Krüger (sales and marketing), Roland Kienzler (HR), Michael Ziesemer (COO), Dr Heiner Zehntner (legal), Dr Luc Schultheiss (CFO) and Klaus Endress (CEO)

Ambitious targets for 2013 Endress+Hauser has set itself ambitious targets for 2013. Net sales are expected to grow by 10% to almost €1.9 billion. For operating profit and net income, the company expects a moderate decrease. This is where investments in buildings and plants, software and IT of a record-high €160 million come to bear, as well as increased expenditure in research and development. A total of 550 additional jobs are to be created by the end of 2013. At present, Ziesemer confirmed that figures are slightly

below

budget . Whereas sales in China are again showing strong growth, the development on the US market lags behind expectations. Endress+Hauser has more than doubled its net sales in only eight years. The opportunities for us have grown, along with the risks, emphasised Endress. In order to make the company ﬁt for future challenges, sales support has been reorganised at group level. We don t expect 2013 to be an easy year, stressed Endress. The problems that have made our world so

Endress+Hauser showed growth across all regions, with

insecure and changeable still exist. This was one of

exceptionally good developments in the Americas. In

the reasons why the change at the top of the compa-

the US, this was the third good year in succession for us,

ny was announced so early. Endress will move to the

explained COO Michael Ziesemer. Low energy prices have

Supervisory Board in 2014 where he will succeed Klaus

sparked reindustrialisation in the US. In contrast, business

Riemenschneider as president; his successor as CEO will

in China showed disappointing development. This was, as

be Matthias Altendorf, currently MD of the group s largest

Ziesemer explained, an unusual experience after years

production centre in Maulburg, Germany. Endress said:

of dynamic development. Key drivers behind our growth

We have taken signiﬁcant steps in terms of organisation,

are megatrends such as energy, resources and eﬃciency,

strategy and personnel to set the course that will lead the

food, water and demography, emphasised Ziesemer.

company towards a successful future. JULY/AUGUST 2013

INDUSTRY NEWS

NEW APPOINTMENTS

Two new ‘water champions’ join water industry role player In a recent edition of Water&Sanitation Africa, the MD of Rheochem, Jacqui Swart, was interviewed on the occasion of the company’s 20th anniversary. Since then, Rheochem has employed two new senior technical people, the purpose being to provide wider coverage of the northern parts of South Africa, which will include an increased marketing effort and allied technical support.

HLAMULO HLUNGWANI joins Rheochem

Engineering in 2005 and is currently studying towards a

with a strong background in various aspects

National Diploma in Safety Management.

of water treatment, encompassing potable,

Nkosi s

academic

together

with

experience in chemical production, the laboratory

confident young lady, Hlungwani is ideally suited to the

and industrial effluent treatment, will prove useful

challenge of her new position of area manager as she

to Rheochem. His extensive knowledge of SHEQ

holds a National Diploma in Analytical Chemistry as well

is going to complement Rheochem s existing in-

as another in Marketing Management and Consumer

ternal and external (customer) safety, health and

Behaviour. She is currently studying towards a Bachelor

environmental programmes.

of Business Administration degree.

Hlungani and Nkosi are a dynamic duo and will un-

Benny Nkosi, with his pleasant, friendly nature and calm assurance, is also expected to be an asset to Rheochem. He obtained a National Diploma in Chemical

doubtedly add further diversity to Rheochem s team. We

wish

them

well

their

new

positions,

concludes Swart.

Water&Sanitation Africa caught up with the newcomers recently and interviewed them.

to be service driven. More stringent SHEQ requirements

and engineering with problem

on service and providing

also require customers to very

solving, marketing and sales ‒ I

solutions. The company prides

carefully consider their choice

really missed being hands on

itself on everyone within the

of suppliers. Most customers are

and part of the process of

organisation going out of their

now more discerning, ensuring

providing solutions.

way to oﬀer excellent service

that they form partnerships

and always striving to satisfy

with suppliers that have the

customers. It is still a very

resources and commitment to

personalised service that is

support their own quality and

oﬀered and that is what is key

safety initiatives. Rheochem

to Rheochem s success ‒ having

is large enough to have the

the correct attitude.

necessary resources yet small

In a recent interview with Jacqui Swart, she mentioned that the water treatment industry is extremely dynamic. Would you agree and why? I do agree. In terms

enough to still personalise

passion for water treatment

What would A passion for the number you say has of suppliers changed most water treatment has increased brought me back in the water considerably treatment to the industry in the past 5 chemical to 10 years, so an organisation market since you entered that wants to remain successful it over ﬁve years ago? The

brought me back to the

must separate itself from the

introduction of the Blue and

for what is a virtually new area

industry. Supply of water

rest by ﬁnding a niche in the

Green Drop certiﬁcation by the

for Rheochem, I have a huge

treatment chemicals is so

market in which it excels. I

Department of Water Aﬀairs

task ahead of me, which I have

far removed from straight

believe Rheochem has found

has created further focus on the

accepted with enthusiasm.

selling ‒ it combines chemistry

that niche through an emphasis

need for the supply of chemicals

Watch this space.

of chemicals,

NHLMULO HLUNGWANI You brieﬂy left the water treatment industry. What caused you to return? A

qualifications,

industrial and mining experience. A bubbly,

JULY/AUGUST 2013

service and is totally committed to doing things correctly so that the service provided genuinely goes well beyond the sale .

What is your personal goal in terms of your new position? As an area manager

BENNY NKOSI

internally to the company, but to add another positive dimension

You have a strong background in terms of health and safety. What do you think will add to Rheochem s existing capabilities in the ﬁeld?

to what we oﬀer entities that

One of my ﬁrst projects

a mining laboratory, I had

is a thorough review of

experience in a chemical

Rheochem s SHEQ policies and

manufacturing plant, which was

deal with Rheochem.

What attracted you to the water treatment industry? Besides having worked in

procedures. This will start with identifying the gaps and improving the existing health and safety systems at Rheochem,

followed more

Of particular interest to me is the design, building and commissioning of water treatment and processes and systems

but, due to

recently by a position in which eﬄuent treatment was one of my responsibilities. All of this touched on aspects of what the water treatment industry is about. Of

the nature of the business, it

course, my primary qualiﬁcation

will fully integrate with what

also created an awareness and

is happening in our ﬁeld of

knowledge of this speciﬁc ﬁeld

operations, adding value

of chemistry and engineering.

to customers, for example

Of particular interest to me

by provision of structured

is the design, building and

training in the handling of

commissioning of water

chemicals, assigning clear

treatment and processes and

SHEQ responsibilities to

systems. I believe there is scope

service technicians and area

for Rheochem to expand into

managers, and identifying

this area, particularly for solid/

risks in the workplace, which

liquid separation of industrial

in many cases is actually on

eﬄuents, a ﬁeld in which the

our customers sites. This adds

company has considerable

further beneﬁt to our customer

practical experience. There is

service. SHEQ measuring and

so much scope and this is very

monitoring will be key features

attractive to me in terms of

not only of what we do

expanding my career. JULY/AUGUST 2013

REGIONAL FOCUS

GAUTENG

A positive development The Roodeplaat Water Treatment Works, constructed as part of the larger Roodeplaat Bulk Water Supply Project, is now one of the most advanced water treatment facilities in South Africa and certainly a flagship plant for the City of Tshwane and Bigen Africa, Ian Pollard, Bigen Africa project manager, tells Chantelle Mattheus.

HIS CAN BE attributed to the fact that the City of Tshwane decided to implement the advanced processes of ozonation and granular activated carbon (GAC) filtration

processes proactively, in anticipation of expected future deterioration in raw water quality. The use of ozone in municipal water treatment is certainly not a new process, but it is not deemed conventional in South Africa. The Roodeplaat plant is currently one of the most advanced plants in terms of process configuration in the country and probably in Africa, explains Pollard. The 60 Mâ„“/d Roodeplaat Water Treatment Works (WTW) was commissioned in 2005 as part of the larger Roodeplaat Bulk Water Supply Project to augment water supply to the rapidly expanding northern areas of the City of Tshwane from feasible local sources in lieu of extending its existing supply scheme from Rand Water (and thus effectively from Lesotho Highlands schemes). The Roodeplaat Dam, situated approximately 20 km north-east of the Pretoria CBD, was identified as a feasible local source and a licence to abstract raw water from this dam was issued by the

JULY/AUGUST 2013

REGIONAL FOCUS

(then) Department of Water Affairs and Forestry to the City of Tshwane thereby approving the implementation of Phase 1 of a 60 Mâ„“/d bulk water supply scheme. The Roodeplaat Dam is currently classified as highly eutrophied as a result of the influx of treated effluent from two large wastewater treatment facilities situated in the dam s catchment also owned and operated by the City of Tshwane. Apart from excessive algal growth, which is a direct consequence of eutrophication and relatively easy to remove (via flotation, for instance), removal of associated algal toxins, complex dissolved manganese and iron, organic constituents responsible for taste and odour-causing compounds and chlorine-resistant pathogens are more difficult and require a series of treatment steps, many of which are viewed as advanced processes. Although all the treatment processes were included during initial planning of the treatment facility necessary to treat the Roodeplaat water to acceptable potable standards, the City of Tshwane decided to implement the envisaged future advanced processes (in the form of ozonation and GAC) proactively in anticipation of expected further deterioration in raw water quality, says Pollard. He adds that the Temba Roodeplaat Consulting

ABOVE & OPPOSITE TOP The Roodeplaat Dam is currently classified as highly eutrophied

properties, GAC is also an excellent medium for the

OPPOSITE BOTTOM The installation of the GAC filters

oxidation of dissolved organic constituents, improved

development and proliferation of bacteria that remove organic compounds, many of which are responsible for potentially unacceptable tastes and odours in the final water. At Roodeplaat, ozone will mainly be used for the GAC adsorption of organic compounds, disinfection of chlorine resistant pathogens and, to a lesser extent, the removal of complex iron and manganese.

Consortium, of which Bigen Africa is the lead consultant,

The project was implemented through two contracts,

was subsequently appointed to design the new pro-

one for the civil works and another for the supply and

cesses, and a pilot plant was installed at the Roodeplaat

installation of mechanical and electrical equipment.

WTW and operated for approximately three months

The ozone generation equipment was the single-most

to determine various site-specific design parameters,

expensive component of the mechanical works and was

which were ultimately used for the detail design and

imported from Switzerland. The civil works was com-

specification of the new processes, according to Pollard.

pleted in December 2011, while the commissioning of the mechanical and electrical works were completed in

Ozone in focus

December 2012.

Ozone is a strong oxidant and disinfectant with a variety of applications in water treatment. Unfortunately, ozone

Project breakdown

as a highly reactive gas cannot be stored in containers

The scope of works basically entailed the construction

and thus needs to be generated at the point of use by

of two new unit treatment processes, the first being

passing high voltage electrical current through an oxy-

an on-site ozone generation and dosing plant, explains

gen-rich environment. The electrical current splits the

Pollard.

oxygen (O2) molecule into two O-atoms and a small por-

LOX storage facility, a state-of-the-art 37 kg/h ozone

tion (e.g. 6 to 12% by weight) of the O-atoms combine

generation system comprising three ozone generators

The main components of the plant are an

with O2 molecules to form O3 i.e. ozone. The amount of ozone generated is dependent on various factors, one of which being the concentration of oxygen in the feed gas to the generator. Three types of feed gases are normally used for large-scale generation of ozone, namely pure oxygen from commercially-supplied liquid oxygen (LOX), pure oxygen produced on-site from air through a process called pressure swing absorption (PSA) or normal air, which is approximately 22% oxygen. For the system installed at Roodeplaat, ozone will be generated from LOX. According to Pollard, the use of ozone in conjunction with GAC filtration offers a number of benefits. Apart from its strong disinfection power, ozone has the ability to alter the molecular structure of complex organic compounds making these more amicable to biological degradation and removal. In addition to its adsorbent JULY/AUGUST 2013

Africa â€™s leader in natural resource and development solutions

from

Ozonia

The second unit process was the GAC filter gallery comprising 20 filter bays filled with GAC media

Switzerland, a re-

there have been reports of water quality problems

inforced concrete main ozone dosing chamber and two

in the supply region of the plant in the

intermediary dosing stations at the head

past and hopefully the inclusion of the

of the works and upstream of the sand

new processes will go a long way to fur-

filters.

ther enhance the quality of water distrib-

The second unit process was the GAC

uted to the consumer and build trust in

filter gallery comprising 20 filter bays filled

the local municipality as the water services

with GAC media to provide approximately

provider for the region, says Pollard.

12 minutes retention time at maximum

As such, one of the highlights for him

Two different types

was the colour of the water that turned

of GAC were installed to compare the

from having a slight greenish tint (still

full-scale performance and longevity of re-

within SANS 241 limits) to that having a

agglomerated GAC versus direct activated

deep blue colour after passing through

carbon, says Pollard.

the GAC filters. This is further enhanced by

hydraulic loading.

He adds that the project has been

the fact that the client also reported full

completed â€’ the GAC filters have been

compliance in terms of the targeted water

fully operational since July 2012 while

quality during the past couple of months,

the ozone generation system was com-

he adds. The parameters are now consist-

missioned

ently on the low end of the scale rather

between

September

and

December 2012.

than just below the upper limits.

Challenges on-site

a number of reasons, not least of which

Planning and integration between the civil

are working with advanced processes

and mechanical contractors and works

that are not common and overcoming

proved especially challenging according

the technical challenges in determining

to Pollard, as these components were

the optimum solution. In this instance,

handled under separate contracts

we did a pilot study where we ran a small

For him, the project has been special for

This was exacerbated by having to

ozone and GAC pilot plant to test the re-

undertake construction of the new pro-

sponse of the water prior to finalising the

cesses, with the plant remaining fully

designs. This added almost six months to

operational except for a couple of planned

the design period, but proved worthwhile

short shutdowns for critical tie-ins.

as various site-specific parameters were

However, these challenges were not insurmountable and, as Pollard notes, were overcome through various combined integration

and

scheduling

meetings.

Proper scheduling of works during shutdowns to ensure that maximum amount

Tel: + 27(0) 11 441 1111 www.srk.co.za

of work could be executed during each of the shutdown periods was also utilised, continues Pollard.

determined and used to optimise the design, says Pollard. The workmanship on the ozone generators is also really a highlight; it is extremely good, concludes Pollard.

CONTRACTORS

Civil contractor: Superway Construction Mechanical/electrical contractor: PDE JV comprising PCI Africa, Electron and Dip Civils

SUPPLIERS From green to blue Although

the

plant

has

consistently

produced SANS 241 compliant water,

Ozone equipment: Ozonia GAC: Cactus Carbon and UDEC Pumps: KSB/ABS Liquid oxygen: Afrox JULY/AUGUST 2013

REGIONAL FOCUS

GAUTENG

Expanding capabilities The 10 Mℓ/d expansion at the Percy Stewart Wastewater Treatment Works will not only increase raw sewage processing capabilities, but for the first time there will be PLCs and a SCADA system installed on-site, says Royal HaskoningDHV’s Michelle Vogts, project manager: civils, and Kegean Reddy, project manager: C&I. FTER

COMPLAINTS

the

Department

of Water Aﬀairs about the Percy Stewart Wastewater Treatment Works (WWTW) efﬂuent not meeting the legal requirements,

Mogale City Local Municipality (MCLM) appointed Royal HaskoningDHV (then SSI) in February 2008 to investigate and report on the shortcomings of the plant. According to Vogts, a scientiﬁc study concluded that the

plant required urgent maintenance and also recommended that the WWTW s capacity be increased with a 10 Mℓ/d extension to handle the current and future ﬂows. The plant was refurbished in May 2008 and the design of the extensions for the additional 10 Mℓ/d started in 2009.

Setting the scene Percy Stewart WWTW is on the edge of expansive urban

contractor having handed over newly built structures to

areas, overlooking valleys of natural terrain and farmland.

the mechanical and electrical contractor for wiring and

The WWTW is also located on a steep hill, with a 46 m

equipment ﬁtting.

height diﬀerence from the inlet works to the last manhole,

Vogts adds that apart from

before the final effluent is piped to the river. The old works consisted of trickling filters and a 10 Mℓ/d biological nutrient removal (BNR) activated sludge system. The waste sludge is anaerobically digested and used for irrigation on the instant lawn farm next to the works, using centre pivots, says Vogts, adding that the instant lawn farm also receives a limited annual volume of trickling

the 10 Mℓ/d BNR reactor with

The required increase in capacity of the second 10 Ml/d BNR is nearing completion

ﬁlter eﬄuent, according to the WWTW s licence.

and two ﬁnal clariﬁers (secondary settling tanks (SSTs)), the

extension

involved

building a fat trap for the Gelita eﬄuent, a new larger inlet works, balancing tank

The maintenance phase included repairing the trickling

and a new larger chlorine contact tank (CCT), as well as

ﬁlters rotating arms and pipework. The old BNR also

associated pump stations and electrical substations, with

required maintenance ‒ ﬁxing aerators and replacing

back up generators in the event of a power failure.

rusted penstocks and valves. Motor control centres and

The main power supply to the plant was also augment-

certain existing instrumentation were also ﬂagged for

ed. The new inlet works, balancing tank and PST were

upgrade/refurbishment as part of this appointment,

placed near the existing inlet works and the PST of the ex-

continues Vogts.

isting BNR. These three primary treatment components,

Currently, the required increase in capacity of the second 10 Mℓ/d BNR is nearing completion, with the civil

it s primary settling tank (PST)

next to the existing 10 Mℓ/d BNR s PST, were founded on rock. JULY/AUGUST 2013

REGIONAL FOCUS

Electrical additions

Automation solution

Royal HaskoningDHV was also appointed as

The

two

Both Reddy and Vogt agree that the expan-

electrical and C&I consultant for the design,

Schneider Modicon M340 PLCs and an

sion at Peter Stewart WWTW will not only

installation,

perfor-

Adroit SCADA. There is a PLC for the inlet

increase the client s raw sewage processing

mance testing of electrical and instrumen-

works (head of works and PSTs) and a PLC

capabilities to meet the current demand,

tation equipment, for the upgraded plant,

for the bioreactor. Each PLC will be ﬁtted in a

but for the ﬁrst time there will be PLCs and

explains Reddy.

PLC panel with a Schneider Magalies human

a SCADA system installed on-site, which

machine interface on the front of the panel

would substantially assist in day-to-day op-

for local control of plant areas.

erations and maintenance.

commissioning

and

The existing site had no SCADA (supervisory control and data acquisition) or PLCs (pro-

ﬁnal

conﬁguration

Beneﬁcial monitoring includes

grammable logic controllers) installed. Royal

The SCADA is situated in the control

The operating and managing staﬀ will

HaskoningDHV s approach in this respect

room with view only capabilities ‒ a client

have a monitoring system for the plant,

was to gather information for the design

request ‒ in the belief that this would en-

which will reduce plant downtime and

from planned site visits, client interaction

courage the operators to walk through the

increase operator visibility into the water

and design meetings held by its engineers,

site should any corrective action need to be

treatment process, explains Reddy.

who then subsequently produced a compos-

taken, instead of just starting a drive from

According to the C&I project manager,

ite preliminary design, which was completed

the SCADA, for example, says Reddy, adding

added beneﬁts of the automated system will

and put out to tender by the ﬁrm.

that the possibility of changing this at a later

be increased plant uptime and reduced fault

stage still exists through PLC and SCADA

through enhanced fault ﬁnding and trouble-

software changes.

shooting capabilities.

Various control system architectures were evaluated during the master planning phase, and these included plant wide telemetry

A ﬁbre optic infrastructure solution was

The installation of a ﬁbre optic ring

communication, individual PLCs and remote

selected for its robustness and the footprint

network will provide for a more ﬂexible

input/output systems for each plant area,

of the plant didn t warrant telemetry,

and

says Reddy.

adds Reddy.

cludes Reddy.

robust

networking

solution,

con-

JULY/AUGUST 2013

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www.rhdhv.co.za www.royalhaskoningdhv.com

REGIONAL FOCUS

GAUTENG

Expansion design exceeds expectations The Meyerton WWTW was extended by constructing a new 15 Mℓ/d works that is designed to allow for an extension to 36 Mℓ/d in future – more than originally projected, due to a different approach to design, Barry van Es, senior associate at GIBB tells Chantelle Mattheus.

JULY/AUGUST 2013

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REGIONAL FOCUS HE DESIGN NOT only allows for

time the works received an average of

Project progress

an extension to 36 Mℓ/d in future,

about 12 Mℓ/d of wastewater from do-

Design of the 15 Mℓ/d extension is cur-

but is more than the originally

mestic, industrial and commercial sources

rently complete and awaiting environ-

projected capacity of 30 Mℓ/d

via two pump stations. The works was

mental approval before implementation.

due to a diﬀerent approach to the design,

designed and constructed in the 1970s and

Construction of the first phase of the pro-

which instead of duplication of the 15 Mℓ/d

was designed to treat 5 Mℓ/d, continues

ject ‒ consisting of the addition of the new

works, will consist of the addition of primary

Van Es, adding that it was subsequently

SST, hydraulic flow splitter, sludge recycle

sedimentation and an increase in aeration

extended in 2007 to a capacity of 10 Mℓ/d,

pump station and new chlorination system

capacity in the biological reactor, explains

which is less than the current discharge to

‒ was under way when Water&Sanitation

Van Es.

the works. As a result, the works remains

Africa interviewed Van Es and expected to

under pressure due to the lack of adequate

be completed by the end of June 2013.

As an initial phase of the project, one of the two new secondary sedimentation

treatment capacity.

For the first phase of the project, which

tanks (SST) is currently under construction,

The project was therefore initiated based

consists of the construction of a new

together with appurtenant structures such

on the ﬁndings of the Rand Water feasi-

SST as mentioned above, the main con-

as a sludge recycle pump station and a

bility study, which recommended that an

tractor is Lichenry/Mariri Joint Venture, which is local to the area. The primary

hydraulic ﬂow splitter. This was done to relieve pressure on the sedimentation tank of the existing works, which is in a poor

OPPOSITE AND BELOW The new sedimentation tank under construction

subcontractors are Khayalami Projects for concrete work and Millennium Pumps,

condition and requires main-

which provides mechanical and

tenance. However, because

electrical services.

the old works has only a

According to Van Es, the con-

single SST, this refurbishment

tractor s positive attitude and

can only be done once the

the high degree of cooperation

new sedimentation tank is

between the main contractor

operational, says Van Es.

and subcontractors, as well as with the construction monitor-

Basic background The

WWTW

ing staff on-site, contributed to is

good progress and a minimum

the largest of three works

of delays in the execution of

managed by the Midvaal

the project.

Local

Meyerton

Municipality.

The

The next phase will follow

ﬁnal eﬄuent from this works

as soon as approval from the

discharges into the Fourie Spruit, which is a tributary of the Klip River.

environmental

authorities

additional works with a treatment capacity

received, which is expected soon,

The Klip River discharges into the Vaal River

of 15 Mℓ/d be constructed and that this be

Van Es, adding that although as yet there

at the barrage.

designed in such a way that it would be

is no construction programme for the next

possible to increase its capacity by another

part of the project, a construction period

15 Mℓ/d in future.

of two years will be allowed. It is expected

In a Rand Water feasibility study report of October 2010, it was stated that at the

JULY/AUGUST 2013

says

REGIONAL FOCUS

GAUTENG interconnection between the biological reactor and the new SST, the aerated balancing tank at the inlet to the works was ﬁrst drawn down completely, so that storage capacity would be created. In addition, the water level in the biological reactor was lowered and the last small compartment from where the ﬂow is discharged to the SST isolated and pumped out. Van Es adds that as soon as this had been completed the pipe was cut (excavation had been done some time before to expose the pipe over

that the new 15 Mℓ/d works will be completed in 2015.

“The extension of the works will allow for further growth and development”

the length required to execute the work) and the water that was contained in the pipe was pumped out of the working area. The existing pipe consists of a combination of a 450 mm diameter steel pipe and an old 450 mm diameter ﬁbre-cement pipe; a new

Challenging context

400 mm steel pipe was inserted inside the cut

According to Van Es, the greatest challenge on-site to date has been

ends, and the surrounding gap ﬁlled with a quick-setting epoxy.

connecting a pipe between the existing biological reactor and the

The epoxy was inserted after the rest of the pipework and valves

existing SST, as this involved the cutting of the pipe and the instal-

were installed to ensure correct alignment. After the epoxy had set

lation of three gate valves and a tee that will allow the ﬂow from the

the ﬂow between the reactor and the existing SST was resumed.

biological reactor to be diverted to the new SST. This had to be done

No leaks were found and the operation had required a nine-hour

quickly, as the works could not be shut down.

interruption in ﬂow between the reactor and the SST. The balanc-

Van Es explains that the connection is required to allow ﬂow to be diverted from the existing SST to the new SST, which will make it possible to make repairs to the existing tank. To install the

ing tank was able to contain the incoming flow for that period and no overflows occurred, states Van Es. The works is not set to use any particular new technologies or processes, which eliminates a larger number of possible challenges both during the construction and operation phases. The processes used are very similar to the existing and this was done firstly because the required effluent quality can be achieved without the need for more complex processes and, secondly, to maintain the

thuthuka group limited

operating and maintenance staﬀ s familiarity with the process and the equipment installed, says Van Es.

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Positive project There are a number of positive aspects to the project, not least of which Van Es notes as his highlight of the project, namely that the project provides the opportunity to increase wastewater treatment capacity through the design and construction of a new section of

Lead anode plant for Kamoto Copper mine, DR Congo.

the works, with up to date technology while maintaining the simplicity of operation of the old works. As part of the improvement, a new head of works (HOW), which will be equipped with mechanical screens and vortex degritters, has been designed. This will replace the existing HOW with its hand-raked screens and velocity-controlled grit channels, which are awkward to clean and maintain, and unpopular with staﬀ. This will improve working conditions at the works signiﬁcantly, states

CCD Thickeners for SNC Lavalin, Madagascar

Van Es. Another aspect is the positive impact the expansion is set to have on service delivery in the region. The existing works is overloaded and this has aﬀected the ability of the municipality to approve residential development, as the sewage generated in such developments will add to the load on the works.

35-million litre reservoir, North West Province, South Africa

He adds that people generally do not spend much time thinking about sewage treatment. They ﬂush and forget , and in this case it

Contact: tel: +27 (0)11 468 5956 e-mail: tomm@thuthukagroup.com / www.thuthukagroup.com Adding value to your African project

V Squared V2/11696 Jun2012

is not likely to be diﬀerent. Although the beneﬁt to the communi-

TGL has projects in: Zambia, Madagascar, D.R. Congo, Botswana, Malawi, Zimbabwe, Nigeria, Ghana, Namibia, Mauritius, Mozambique

ty may therefore not be obvious in a general sense, the extension of the works will allow for further growth and development in the municipal area, while also ensuring that the treated eﬄuent discharged to the environment is of an appropriate and legally acceptable quality.

JULY/AUGUST 2013

Panfontein site capacity boosted

ISING TO THE CHALLENGES of assisting client Rand

Water to urgently boost its capacity, contractor Liviero has fast tracked the first delivery target in its R231 million contract at the Panfontein water treat-

ment residue disposal site near Vereeniging. CEO Neil Cloete explains that Liviero commenced its contract for the expansion of the sludge disposal site at Panfontein ‒ along with modifications to the supernatant pipeline ‒ in August last year. Our client is in desperate need of additional capacity due to the fact that all the existing drying ponds are filled to maximum capacity. Between 500 and 1 300 t of dry sludge is produced each day during Rand Water s purification process. This is removed from the sedimentation tanks at Zuikerbosch and Vereeniging in thin slurry containing 3% mass by volume of dry sludge. This sludge is pumped to Rand Water s sludge disposal site at Panfontein. Here it is dosed with an organic flocculent in gravity thickening plants to aid the separation of the solids from the liquid. The thickened sludge is pumped onto drying beds where it is dried by evaporation and the clear supernatant fluid is drawn off and returned to the purification system. Liviero s project at Panfontein entails removing existing sludge and drainage pipes and installing new sludge pipes and water guns, as well as a new drainage system, including concrete channels and sand flumes. Associated steel sludge delivery pipelines, sub-surface drains and fittings will also be installed. In addition, the contractor will raise the pond walls by 4 m in a total of 20 drying ponds. The ponds will be lined with 1.5 mm HDPE lining. The sub-surface drains will drain into a trapezoidal concrete channel, which is 1 km long. Liviero s contract at Panfontein has been, quite literally, slippery work, Cloete reports. This is because work is taking place in the old sludge ponds, which get easily saturated during even light rainfall, resulting in slippery surfaces. Liviero mitigated this by creating access roads with imported G7 fill and creating sufficient drainage to prevent water from pooling. We also installed 90% of the sub-surface drains early in the project to drain the saturated existing ponds, Cloete adds. This contract is on schedule for completion in August 2014. JULY/AUGUST 2013

REGIONAL FOCUS

GAUTENG

Moreleta Spruit Outfall Sewer: HE CITY com-

missioned major

a mul-

ti-phase project

to upgrade the existing Moreleta Spruit Outfall

Rapid urbanisation in the City of Tshwane put the sewer system in the eastern suburbs under considerable pressure.

later stage. The

construction

was originally scheduled in four phases: Phases 1A and 1B

Sewer System to meet

as well as 2A have

current

demands

been completed. The

expansion

scope of Phase 2A

Walter

and B entailed the

and

future

requirements.

Aust, Associate: Water

construction

Engineering at Aurecon,

9.2 km of a concrete

and

outfall sewer pipe-

Johan

Deputy

Wessels,

Director

Replacement

line with diameters

and

ranging

between

Upgrading at the City of

600 and 1 350 mm.

Tshwane, tell Chantelle

The works include 11

Mattheus that innovative

pipe jacks, totalling

engineering

solutions

almost 1 000 m in

and genuine concern for

length, in congested

the needs of residents

site conditions ‒ an

and the environment are

immense

overcoming challenging

taking for even the

site

most

conditions

and

laying a successful founin the area. As a result of signiﬁcant population

under-

experienced

of teams.

dation for future growth

CONSTRUCTION TIMETABLE Activity

Project breakdown

Phase 2B

Aurecon has been involved with this project,

Contract documentation

Complete

areas in the City of Tshwane over

Pegging/surveying of proposed route

Complete

since its ﬁrst implementation in 2004. For

recent years, existing infrastructure

Contractor appointed

VF Munisi Civils

Phase 2B, Aurecon was appointed as lead

‒ including the outfall sewers in vari-

Contract commencement date

22 July 2011

consultant to execute certain stages of the

Construction commencement

September 2011

Contract duration

30 months

Percentage of work completed

Percentage of time expired

Projected completion date

22 January 2014

growth and expansion of business

ous parts of the city ‒ is progressively subject to increased pressure. One of the areas that is particularly impacted is the Moreleta Spruit sewer drainage area.

providing a comprehensive range of services,

project, namely the feasibility study, planning and preliminary design, environmental impact assessment, geotechnical investigation, detail design, tender documentation and adjudication. Aurecon is also responsible for site super-

The parallel line solution

vision together with occupational health and safety monitoring and regulation.

To provide for the expansion and densiﬁcation of urban

Phase 2B is currently under construction, with Aust and

development in the east of Pretoria, the Water and

Wessels estimating 83% of the work to have been com-

Sanitation division of the City of Tshwane identiﬁed the

pleted, even though only 70% of the scheduled timeline

need to upgrade the existing outfall sewer system to

has elapsed. The contractor appointed is VF Munisi Civils

provide more capacity for current demands and future

and the contract duration is set for 30 months, with con-

expansion requirements. It was decided to construct a

struction having commenced in September 2011.

parallel outfall sewer line to augment the existing line,

The ﬁnal construction value of Phase 2B is projected

rather than replace it with a new line catering for the total

at R45 million and is earmarked for completion in

required capacity.

February 2014.

This, in essence, will double the capacity of the Moreleta

During the planning phase, information was sourced

Spruit Outfall Sewer as there will be a duplicate outfall

from existing master planning studies. Aurecon also

sewer system. The new pipeline is mainly located on the opposite side of the river from the existing outfall sewer, says Wessels. This will enable the existing river crossings to be connected to the new pipeline. Where possible and practical, the existing river crossings will be retained to allow cross-connection between the existing and new pipeline to assist with refurbishment work that might

be undertaken at a

consulted with City of Tshwane Metropolitan Municipality

ABOVE Deflected socket pipes are used on both phases to construct long radius curves along the route

City Planners and Plan Associates to ensure that the latest available development planning was incorporated into the calculation of the projected future sewage flows from the Moreleta catchment area. It was confirmed that the 2025 planning figures used would be representative of the ultimate development condition.

JULY/AUGUST 2013

REGIONAL FOCUS

capacity being doubled The pipeline follows a route that passes through a varie-

existing bulk services continues to prove demanding. The

ty of land use areas, varying from open veld and rock out-

rehabilitation of the construction footprint, adjacent to

crops to urban and residential areas in close proximity to

the Moreleta Spruit was also exacting in its own right as it

existing buildings and numerous forms of overhead and

required careful planning and judicious decision-making.

underground infrastructure. The geotechnical investiga-

However, the greatest challenges have arisen from the

tions also revealed that an extensive volume of hard rock

diﬃcult construction circumstances experienced during

would be encountered and that groundwater seepage

regular ﬂooding situations, especially during periods of

could be expected along most of the route.

extreme rainfall.

Consequently, the contractors had to be informed that

The team is also well aware of the diﬃculties lying ahead

the works required diﬃcult and challenging mitigation

of them, having identiﬁed them well in advance. These

measures in terms of the following:

include attempting to successfully complete six pipe jack

• accommodation of spoil material

operations on gradients. In addition, the team knows it

• management of groundwater and seepage into trenches

will have to deal with construction footprints of less than

• shoring of trenches

10 m over more than 10% of the route and constructing

• removal and reinstatement of fences and barricades on the pipeline route • special conditions of work near Transnet Pipeline services • potential ﬂooding of works adjacent to the Moreleta Spruit, particularly during rainy seasons.

Highs and lows To date, the team has achieved excellent progress in spite of encountering innumerable challenges,

the outfall sewer through the

The greatest challenges have arisen from the difficult construction circumstances

com-

Faerie Glen Nature Reserve under very strict environmental monitoring. While rehabilitation of the construction footprint on an ongoing basis is an ever-present challenge, there are some interesting engineering highlights. For Aust, one of these this was

ments Aust. These included excavating up to 10.5 m

the construction undertaken in the Lynwood Area.

into solid rock faces close to the river embankments and

Innovative solutions

construction footprints of less than 10 m. An example of the problems associated with narrow footprints is the Willows Substation section. The substation s perimeter fences had to be temporarily relocated and reinstated afterwards to accommodate the construction of the outfall sewer. This required the isolation of the premises from the construction works under specialist supervision from the Energy and Electricity division. The outfall sewer was successfully constructed through the substation premises, and rehabilitation of the premises is complete. In general, the installation of the outfall sewer in close proximity to private property, perimeter fences and

BELOW LEFT Concrete outfall sewer pipeline with diameters ranging between 1 350 mm and 600 mm BELOW RIGHT Krings boxes permitted the execution of the works in a safe and risk free manner

Due to the meandering of the Spruit, the new outfall frequently had to be installed in a very narrow footprint. To circumvent the problem in one especially diﬃcult area, the project manager and the Aurecon management team decided to deviate a section of the existing outfall to make way for the installation of the new outfall, explains Aust. This involved the excavation of the pipe trench by means of Krings boxes, a specialist shoring system imported from France. The task was to excavate to a depth of 5 m, in a 10-m footprint between an 800 mm bulk water main and the 825 mm existing outfall sewer, and beneath overhead

JULY/AUGUST 2013

REGIONAL FOCUS

power

lines.

The

specially

im-

The Phase 2B contractor

ported Krings boxes allowed the

has

execution of the works in a safe and

resources to the Faerie Glen

risk-free manner.

Nature Reserve to increase

Some of the other interesting

deﬂected socket pipes to construct

additional

the progress in the reserve.

technologies and processes implemented on-site include the use of

allocated

Rehabilitation works, includ-

Construction during regular flooding

ing grassing, hydroseeding and planting of trees are a priority and will commence as soon as all

long radius curves along the route,

the construction activities in the area have been completed. The re-

as well as the supply of calcium aluminate cement sacriﬁcial layer

habilitation will be environmentally closely monitored, with activity,

concrete pipes by Southern Pipeline Contractors.

including the control of alien vegetation, continuing for a one-year maintenance period following completion of construction work.

A caring approach

Rehabilitation on pipeline projects can normally only be assessed

The environmental management and rehabilitation of impacted

properly over a period of two to three rainy seasons. On virtually

areas form an important part of the project. The environmental

the total length of Phase 1 of the project, the pipeline route can,

approval for the project was obtained, with the Record of Decision

after two to three years, no longer be diﬀerentiated from the

issued on 20 February 2007 and the Water Use Licence granted on

surrounding veld.

24 February 2010. The detailed Environmental Management Plan

Some environmental and conservation aspects that are achieving

conforms to both authorisations and is applied and monitored

very positive results include the careful monitoring of footprint

strictly to mitigate the environmental impact of the works.

width and tree preservation.

Open spaces in the eastern suburbs of Pretoria have become a scarce commodity, one of the aims of the project is, as far as possi-

Addressing residents concerns

ble, to leave an even cleaner and greener landscape behind once

At the request of a concerned resident, some temporary ropes

construction and rehabilitation have been completed. As a result,

were strung in the trees for the beneﬁt of a local bush baby colony.

the Phase 2B pipeline route was locally rerouted to avoid existing

The concern was that the necessary removal of a portion of a line

trees. More suitable indigenous trees are planted to replace those

of trees crossing the trench would destroy some of the habitat of

that had to be removed during construction.

the colony, even if only temporarily. Although the trees will be replaced, the ropes provide a solution to the problem, says Wessels.

A phased approach to commissioning With Phase 1 completed, it is now possible to commission the new outfall sewer between the Derdepoort ﬂow dividing structure (FDS) and FDS1, situated at Watermeyer Street.

Specialists in the manufacturing of domestic and industrial water storage

In addition, the Phase 2 upgrading has been divided into an extra phase to accommodate budgetary constraints. Phase 2A is complete and was recently commissioned, while the construction of Phase 2B commenced in October 2011. Phase 3 will commence after Phase 2B has been completed. The objectives of Phase 3 are to upgrade, renew, rehabilitate and refurbish the existing collector sewers, which have structural defects and/or damage, and to renew pipe sections already identiﬁed by the consultant, using traditional methods or new trenchless

Water

techniques. This will provide a system with greater capacity to meet current needs as well as future expansion requirements, given the signiﬁcant growth in urban development in the east and

Storage

south ofthe Moreleta drainage area, says Wessels.

Lessons learnt A valuable lesson learnt by the team was the enhanced coopera-

MEYERTON 0861STRUCT (787828) Fax: 016 362 3608 rodney@structa.co.za www.structa.co.za

tion from keeping the residents impacted by the project properly informed. Public participation in the form of newsletters proved very successful and a good community liaison oﬃcer formed an integral part of the communication line. In closing, Aust, Wessels and the project team would like to thank the public for their continued support, patience and understanding during the construction and augmentation of the new Moreleta Outfall Sewer. Despite all the challenges, such as seasonal ﬂooding, the phases have been constructed and completed on time, within the approved contract values and yearly budget. A notable achievement on a very demanding project.

JULY/AUGUST 2013

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PROFILE

JOHANNESBURG WATER

Providing water, providing life A world-class African water and sanitation utility JWâ€™s vision is to become the leading brand in the delivery of water services in South Africa through the provision of access to good quality and affordable water and sanitation services to the residents of Johannesburg in a financially sustainable, customer-focused and responsive manner. Hazard assessment, also practised by JW,

pollutants. These are compounds that are

involves regular evaluation of the existing

being used in new manufacturing pro-

monitoring programme by studying past

cesses and may be present in very small

data. It then becomes possible to adjust

concentrations. Infrastructure replacement

OHANNESBURG HAS always en-

the monitoring programme, ensuring that

is also critical as it becomes increasingly

joyed water of the highest quality.

it remains relevant. The Water Safety Plan

diďŹƒcult to maintain water quality when, for

Johannesburg Water (JW) sees the

is revised regularly to ensure its ongoing

example, pipe bursts are prevalent.

Water quality

maintenance of this track record as a pro-

relevance.

Continuous testing is also critical in

cess. Changes to the way that the entity

The biggest challenge, however, is to

ensuring water quality as this is the final

approaches water quality are evolutionary

ensure that water usage is optimised.

defence in the protection of the water

rather than project-based.

The demand for water continues to rise in

supply. Equally, the infrastructure must

At the time that JW was established in

what is a water-scarce region and exces-

be maintained as a poorly maintained

2001, the water quality monitoring pro-

sive usage plus above-normal unmetered

network increases the risk that the water

gramme was expanded considerably to

consumption

supply may be contaminated.

ensure all parts of the city were included.

burden on water sources. Maintaining

The Blue and Green Drop initiatives have

This

substantial

high water quality standards will become

galvanised many players in the industry.

monitoring in informal areas. The more

increasingly expensive and, in fact, im-

More than just regulatory assessments,

recent adoption of the Water Safety Plan

practical in the face of unnecessarily high

they have become coveted awards and

concept has reinforced the benefits of the

water demand.

have played an important role in changing

programme

includes

place

unsustainable

monitoring programme. Incident response

Therefore, JW believes that optimised

management has been formalised and is

water consumption will become ever more

revised in the light of experience gained

critical moving forward. The protection of

JW has, since the inception of these

from incidents that have occurred.

the water sources is also very important

awards, performed excellently. It has risen

the mindset from predominantly monitoring to total quality management.

JW has embraced the concept of the

as this will ensure that treatment costs are

to the challenge of increasingly compre-

Water Safety Plan, the heart of which is

minimised. Water sources need to be pro-

hensive requirements that have marked

the identification and mitigation of risks.

tected from contamination by emerging

the assessments since their inception.

Bushkoppie WWTW sludge handling facility

JULY/AUGUST 2013

PROFILE

Northern WWTW sludge handling facility

Olifantsvlei WWTW Expansion Project

3. Northern WWTW sludge

Infrastructure

handling facility The project entails the replacement of four

1. Olifantsvlei WWTW Expansion Project

2. Bushkoppie WWTW Sludge

belt presses at the Northern WWTW. The ex-

Construction of Module 3, Unit 3, at the

handling Facility

isting installed dewatering belt press units at

Olifantsvlei Wastewater Treatment Works

The Bushkoppie WWTW currently has

JW s Northern WWTW are the original units

‒ the objective of this expansion is to in-

no sludge handling capabilities. Sludge

commissioned at the works and are consid-

crease the liquid treatment capacity of the

is currently pumped to Olifantsvlei and

ered to be obsolete. Technology employed

works from 200 Mℓ/d to 250 Mℓ/d.

Goudkoppies WWTWs for dewatering

for dewatering of sludge has advanced

and composting.

to include four enclosed belt press units,

major

This method involves high pumping

therefore limiting odours and aerosols and

equipment related to this project, such

costs and frequent pump down times.

ensuring an improved conditioned solids

as the activated sludge reactor. The total

This project entails the construction of

content emanating from the unit process

budget for the expansion, including all

a new sludge handling facility and the

to ensure a sustained and improved sludge

contract amounts, escalation, contingen-

installation of six belt presses.

dewatering capacity at the Northern WWTW.

The scope of works includes all the main infrastructure

components

and

cies and professional fees, is approximately

The project s total budget, including all

Construction started on 20 April 2011

R166.8 million. At the time of going to

contract amounts, escalation, contingen-

and the approved completion date was

print, R133 million had been spent and the

cies and professional fees, and estimate

15 January 2013. Some challenges during

overall project construction completion

for electrical contractor, is approximately

the roll-out of the project included delays

was at 78%.

R255 million for the new sludge handling

due to access issues, shutdowns, additional

Olifantsvlei Works has a catchment area

facility and R69 million for the installation

scope and faulty existing equipment.

that includes the western areas of Soweto,

of the belt presses ‒ a total amount of

Lenasia and the southern and south-east-

R324 million.

The project was also mainly mechanical so no local labour was used. The total budget

Construction started on 3 May 2011

for the project, including contract amount,

the

and the completion date is estimated to

escalation, contingencies and professional

equivalents

be 30 June 2014. At the time of going to

fees, was approximately R36 million, with

that can be treated by the works by

print, overall project construction com-

the expenditure to date totalling approxi-

approximately 50 000.

pletion was estimated at 68%. The instal-

mately R34 million.

ern areas of Johannesburg. The

new

number

module

will

household

increase

Construction commenced on 26 October

lation of belt presses is 100% complete

The impact of the project can primarily be

2010, and the expected completion date

and in defects liability. The completion

measured through the already established

was 26 June 2013. The benefits of the

certificate for this portion was issued on

beneﬁts of the project, such as the fact that

project are numerous though, such as en-

28 September 2012.

the new belt press dewatering units will

suring ongoing liquid treatment capacity

The benefits of the project far outweigh

produce a manageable sludge that is more

of the works, reduced likelihood of sewage

any challenges faced in its construction.

conducive to the composting process, there-

spillages into the river (and as a result,

The new sludge handling facility will

by substantially assisting JW in complying

greater environmental protection) and

produce a manageable sludge that is

with sludge disposal standards as stipulated

lower operational running costs for the

conducive to the composting process

for the works. Additionally, this project also

works due to not requiring supplementary

and will assist JW in complying with

ensures there won t be any sludge backlog.

chemical addition to the final effluent. In

sludge disposal standards as stipulated

The overall project construction comple-

addition, the project ensures sustaining

for the works. The replacement of aera-

tion was estimated to be at 98%, with the

and supplying the future development

tion project was awarded in March 2013

practical completion certiﬁcate having been

within the catchment area.

but is yet to commence.

issued on 7 December 2012.

JULY/AUGUST 2013

PROFILE

JOHANNESBURG WATER projects that will have the highest impact and contribution in order to reach the target of Project 15% by 2014: • Pressure management An eﬀective way to control the amount of water lost in

Water conservation and demand management strategy

a system, pressure management can be implemented without

compromising

the levels of service at the target or critical points. The aim of the programme is to reduce excess night-time

water pressures in order to decrease background (small) leaks and to limit unnecessary pipe bursts. Elimination of pipe bursts

INCE 2007, various interventions

Project 15% will ensure water security in

improves quality of life to households in

that seek to promote eﬃcient use of

the City of Johannesburg; suﬃcient ﬁnancial

that there is a continuous supply and water

water and reduction of water losses

resources are an integral part of achieving

becomes available all the time. A small

the set target.

reduction in pressure can mean a signiﬁcant

have been undertaken, and reasonable strides have been made. To date, approx-

South Africa is one of the most water

imately 40 000 Mℓ of water savings have

stressed countries in the world, and it needs

been realised.

improved management of its limited water

• Water mains replacements The City of

Due to the need to increase the levels of

resources. WC/WDM has been recognised

Johannesburg has approximately 11 400

water savings and manage the water demand

as one of the most important principles

km of water reticulation mains with great

eﬀectively, JW has embarked on a process to

that will ensure sustainable, eﬃcient and

variability in the condition of the pipe.

accelerate its comprehensive water conserva-

eﬀective service delivery. The options for

In order to create an objective pipe re-

tion/water demand management (WC/WDM)

further expansion of water supply by the

placement priority list, JW commissioned

in order to streamline the key WC/WDM

development of new physical infrastructure

a desktop study under contract JW6113

interventions that will have the maximum

are limited and have huge cost implications.

to come up with a generic prioritisation of

contribution to achieving the target of saving

It is therefore imperative to eﬀectively

suburbs under the pipe replacement pro-

of 110 000 Mℓ of water by 2014.

manage the increasing demand for water

gramme. A priority list was then compiled

This strategy seeks to demonstrate the key

in order to achieve a sustainable long-term

for implementation during the 2012/13

interventions that need to be implement-

balance between water availability and

and 2013/14 ﬁnancial years. In addition to

ed in the 2012/13 and 2013/14 ﬁnancial

water requirements.

water savings realised, the programme will

years, in order to achieve the desired water

The City of Johannesburg accounts for 40%

minimise water supply interruptions caused

savings. The Department of Water Aﬀairs

volumes of water consumption out of the

by frequent bursts of aged pipe networks,

(DWA) introduced Project 15% to steer

Upper Vaal River Catchment, extracted by

thus ensuring that households have access

up WC/WDM interventions implement-

Rand Water, thus making water conservation

to clean and safe water all the time.

ed by various municipalities in the Vaal

and water demand management an increas-

Catchment, to ensure a coordinated ap-

ingly important aspect. This led to JW devel-

• Active leak detection

proach in achieving potential water savings

oping a comprehensive WC/WDM, which

control is carried out in an eﬀort to identify

of 15% within the catchment. It is also im-

was approved in 2007, to manage the future

all unreported leaks as well as invisible leaks.

perative to note that the ability to achieve

water demand of the City of Johannesburg

To prioritise the leak detection activities,

and achieve water savings of 90 000 Mℓ over

areas with high minimum night ﬂow (MNF)

a 10-year period, from 2007 to 2017.

are identiﬁed through ﬂow loggings on a

Active leakage

Since the approval of JW WC/WDM

monthly basis. The night ﬂow is considered

strategy in 2007, the company has realised

to be high when the ratio between the

water savings of about 40 000 Mℓ to date.

minimum ﬂow and the average ﬂow into

The calculation of these savings is based

the district metered area is higher than 30%.

on a 4% projected growth in demand. This

JW has dedicated leak detection teams

accelerated strategy supports the adoption

that survey the water reticulation mains to

of Project 15% and is focused towards the

identify and report all visible and invisible

achievement of 450 050 Mℓ annual demand

leaks. These teams cover approximately

target by June 2014. The current water

90% of the total water reticulation per year.

demand of 526 539 Mℓ (May 2011 to April

Leaks are then reported to the relevant

2012) indicates that a further 77 000 Mℓ of

maintenance depots for repair.

water savings must be achieved to reach the set target.

The programme contributes towards water savings, which will ultimately ensure that

The following WC/WDM interventions have been identiﬁed and prioritised as key

reduction in real losses through leaks.

JULY/AUGUST 2013

water is conserved for future generations and households of the city.

The mine shaft is over 1 500 m deep and the pumps, which are 15 m high (four storeys) and weigh 25 t, must be lowered 200 m down the shaft without being dropped

SASTT contact details: Web: www.sastt.org.za President: Michael king Tel: (021) 417 2900 Fax: (021) 417 2999 E-mail: mike.king@smec.com Honorary director: Joop van Wamelen Tel: (012) 567 4026 Fax: 086 668 4026 E-mail: director@sastt.org.za

JULY/AUGUST 2013

TRENCHLESS NEWS

20TH ANNIVERSARY

Two decades of trenchless technology Trenchless Technologies is celebrating its 20th anniversary in the directional drilling and pipe rehabilitation industry this year, indicating a certain tenacious faith, Trenchless Technologies’ Sam Efrat tells Chantelle Mattheus. NE NEEDS TO be extremely tenacious and

have a great deal of faith in order to overcome

TOP (main pic) Rock hammer

which allowed the company to undertake a full range

the many challenges one is faced with over the

of horizontal boring for pipes from 25 to 160 mm, pipe

years. Trenchless Technologies is in business

bursting from 110 to 315 mm as well as pipe ramming

because, from inception, we managed to ﬁll a need in

up to 400 mm. We made good progress in pipe bursting

the market to provide viable solutions and alternatives to

(and to a lesser extent sliplining) for various municipalities

conventional open-cut pipe laying, says Efrat.

that could see the beneﬁt of not digging up their streets and pavements as well as the cost savings achieved, and

Trenchless Technologies was registered in 1991 and in May 1993 commenced operations with a 3 t truck, a

our main focus for many years remained pipe bursting,

compressor, two earth piercing tools and some R80 000 in

he states.

capital. We began operating out of a studio at the back

He adds that in time, as technology improved, the com-

of my house in Berea, Johannesburg, with ﬁve employees.

pany became more versatile and oﬀered a wider range of

Today, we have over a 100 employees, many of whom have been with us for 10 to 20 years, through thick and thin , explains Efrat.

Growth & gains The continued growth of the organisation can be attributed to the fact that it immediately ﬁlled a need in the market for boring small diameter holes beneath the roadway to install electrical conduits and water piping, using earth piercing or moling tools and pipe ramming. In 1994, Trenchless Technologies acquired the Terra Hammer agency for Southern Africa and purchased a

range of percussive hammers from 65 to 210 diameter,

BELOW FROM LEFT SPR EX (Expanda) set up and installation of winding cage into manhole

more tailored solutions. In 1997, we acquired the ﬁrst of

1050 SPR RO (Rotoloc) installed through manholes

also looking at fold and form solutions to further expand

SPR EX (Expanda) cage being lowered into manhole

four horizontal directional drills and in 2004 undertook our ﬁrst CIPP (cured-in-place-pipe) project, followed in 2006 by SPR EX (Expanda) and SPR PE (Ribline) spiral wound piping and in 2011 SPE RO (Rotoloc). At present, we are our range of services. According to Efrat, some 400 km of trenchless work has been undertaken to date. Since inception, we have experienced an average 20% year-on-year growth and expect this trend to continue, fuelled by the impending investment in water infrastructure needed to secure Southern

JULY/AUGUST 2013

300 000 metres of

TRENCHLESS PIPE Successfully Installed

RENOVATE EXISTING PIPES BY: Pipe Bursti0) Sliplining CIPP UV Cure CIPP Ambient Cure Ribloc Expanda Ribloc Ribline Ribloc Rotoloc Pipe Eating INSTALLATION OF NEW PIPES BY: Horizontal Directional Drilling Guided Rock Drilling Bores of 1200mm Lengths up to 400 metres Microtunnelling

Countrywide 08600 66 344 +0(1u64'0%*.'55T%1T<# 999T64'0%*.'55T%1T<#

TRENCHLESS NEWS Africa s water resources, as well as the continued ﬁbre

position and lowering of the encapsulation body work

optic network roll-outs.

such that the remodelled drill resembled a tank with a

He anticipates that the trenchless rehabilitation market is

height of only 1.8 m.

going to grow exponentially from a R500 million per year

• Some 65 installations took place in clay, while the

industry to a R5 billion per year one. We also expect the

remainder were in rock. This necessitated the use of per-

horizontal directional drilling (HDD) industry to continue to

cussive hammer and rock reamers to expand the holes to

grow in parallel to the ﬁbre optic network roll-

the required diameters.

HIGHLIGHTS OF THE LAST 20 YEARS

out; this will continue for several years with the last mile and ﬁbre to the home and business .

• Lateral support ground anchors were encoun-

techniques ‒ spiral wound expanded to a

“We have completed over one hundred successful contracts for many satisfied clients, without a single dispute. We are also extremely proud of the awards we have achieved over the years,” says Efrat. These awards include: • 2000 SAICE Pretoria Branch Award for Technical Excellence: together with the City of Tshwane and consultant Bigen Africa, for the rehabilitation of sewers in Mamelodi. Pipe bursting – midblocks • 2007 (SASTT) Award of Excellence: for the Rehabilitation of Sewer Pipes in Klipspruit Basin together with Johannesburg Water and consultant Vela VKE. Pipe bursting, CIPP and directional drilling • 2009 (SASTT) Award of Excellence: for the ABSA Bank Energy Centre Sleeves Reticulation Project installed by directional drilling • 2010 CIDB Construction Summit Award: for outstanding performance in South Africa’s construction industry • 2012 (ISTT) International Project Award: for the rehabilitation of two parallel sewer pipes in Port Elizabeth’s CBD.

close ﬁt, spiral wound in-place, ambient CIPP,

CURRENT PROJECTS

Achieving success The organisation s greatest achievement to date, project-wise, has been the Port Elizabeth Goes Trenchless project, which won the ISTT Project Award for 2012. This is the highest accolade available in the international trenchless industry, chosen from projects nominated from 30 affiliated trenchless societies worldwide, explains Efrat. The project entailed the rehabilitation of two parallel sewers located in the heart of Port Elizabeth s CBD and was originally designed to use the spiral wound technique throughout; however, the team soon discovered that site conditions also required CIPP and pipe bursting at certain locations. Altogether, we used five different trenchless

UV CIPP and pipe bursting ‒ to successfully complete the project. This project is an excellent example of using trenchless technology options to address unanticipated site conditions, allowing the project to be completed successfully without

presence and position were not predictable, and resulted in drilling equipment becoming entangled in several instances. Drilling tools were pulled, pushed and rotated until they became free or broke the ground anchoring cables. • In order to gain access to the drill face coring to remove concrete, lateral walls from 300 to 500 mm thick were required.

A ﬂuid landscape Over the past 20 years that the organisation has been active, the trenchless context in the local water landscape has changed signiﬁcantly, says Efrat. In the beginning, trenchless technology was looked upon mainly as a novelty to be used only where open cut needed to be avoided. Today, it has become common for most road crossings for new installations as well as for pipe replacement in most major municipalities.

• Mossel Bay Golf Estate – Pipe bursting 110 corrugated plastic pipe to install 160 HDPE • Polokwane AC water pipe replacement involving pipe bursting • Umjindi AC pipe replacement using pipe bursting • Winchester Hills AC pipe replacement utilising pipe bursting.

The change from boring and pipe ramming to HDD was a huge jump in technology, allowing a far more controlled and successful installation for new pipes and conduits in a range of ground conditions. The success of this technology has allowed HDD to become the prevalent methodology, explains Efrat.

excavation and surface disruption, says Efrat. A project that has been by far the most challenging ‒

Similarly, the advent of CIPP, spiral wound lining and

and interesting ‒ to date for Efrat and his team is the ABSA

HDPE fold and form, and reduction technologies allows

Bank Energy Centre Sleeves Reticulation. This required

lining of pipes from manhole to manhole without any additional excavation greatly expands the range of techniques

the installation of 85 sleeves using HDPE pipe from 110 to 710 mm, up to 16 m deep, to connect several of ABSA Bank s CBD buildings with gas, electricity, fibre optic, chilled and hot water. According to Efrat, challenges faced included: • The basement floors were designed to support the weight of a typical sedan vehicle. Consequently, propping was required from the floor below to add support to all areas over which the HDD drill needed to travel into the required position within basements. • A floor-to-floor height restriction, requiring that all equipment be less than 2.1 m in height. Consequently, the Terra-Jet 7520 was refitted by removing the operator cabin, rebuilding the hydraulic oil tank at a lower

tered during drilling in dozens of locations. Their

BELOW FROM LEFT SPR RO (Rotoloc) Installation in 10150 concrete pipe

and solutions available.

ABSA - Ground anchor in rocky bore hole

prevented the introduction and wide scale use of many of

Parktown Reservoir ButtWelding 560 HDPE PE 100 PN 10 Prior to Sliplining

Necessity, is the mother of invention; when a huge trenchless market exists, the techniques will follow, says Efrat. For many years, there was very little maintenance and investment in municipal infrastructure and this has largely the more recent trenchless techniques and advances. However, over the past few years many trenchless contractors ‒ us included ‒ have geared themselves up with the most up-to-date technology so as to be ready for the very large impending and anticipated government investment in water infrastructure, even though today this market does not exist.

JULY/AUGUST 2013

TRENCHLESS NEWS

PRODUCT RANGE

Fast and efficient directional drilling SBORN IS THE oﬃcial OEM sup-

built quality of these machines, he adds.

plier in Southern Africa of auger

Like all of the top-quality machines in

borers and horizontal directional

Osborn s equipment oﬀering, these hori-

drills (HDDs) manufactured by

zontal directional drills and auger borers

American Augers at the company s facility in

are supported by the company s compre-

West Salem, Ohio. The application of these

hensive, national after-sales network, which

products ranges from the installation of

oﬀers 24/7 service, back-up and spares.

utilities, water, gas, sewerage and communications to drainage.

Piping installation investigated

Product sales manager Peet Venter notes

Venter says that that American Augers

that since being launched, the equipment

auger boring machines are designed for

has received a rousing reception from the

the fast, eﬃcient installation of wider di-

South African market. The equipment meets

ameter pipes from 450 to 3 500 mm. They

the underground construction needs of cus-

eliminate the safety risks associated with

that are in keeping with the manufacturers

tomers involved in construction, the pipeline

traditional tunneling methods like pipe jack-

commitment to minimising their impact on

industry and the installation of infrastructure.

ing and are more eﬃcient by utilizing the

the environment. Venter explains that this

We at Osborn are proud to be able to pro-

quick tram mode that is unique to American

has been achieved by reducing noise and

Augers equipment, he stresses.

emissions outputs, and he highlights the fact

mote these machines as part of our product

American Augers’ auger borer

oﬀering. He says that Osborn s after-sales

In its quest for top-quality performance,

that this trenchless technology equipment re-

support, including its ﬁeld service, are critical

American Augers has also maintained a

quires little or no open cutting, which has very

factors in securing orders. Combined, with

focus on the environment, and these drills

minimal impacts on natural surfaces, features

the customer recognising the outstanding

and auger borers boast several features

and habitats.

JULY/AUGUST 2013

TRENCHLESS NEWS

21ST ANNIVERSARY

SASTT reaches 21 The Southern African Society for Trenchless Technology (SASTT) is now 21 years old, and with age has come a certain maturity for the society, SASTT’s honorary director, Joop van Wamelen, tells Chantelle Mattheus.

He adds that the SASTT is working towards building capacity to provide technical training in trenchless technology for engineers, technicians and students. Highlights to come in this period are also no less than the last, indicates Van Wamelen, with the SASTT to be represented at the international board meeting of

VER THE PAST YEAR, I have had the feeling, subjective as it may be, that the society is beginning to reach a signiﬁcant measure of maturity. This is reﬂected by the number of

technical enquiries we receive from local authorities and professional engineers as well as the growth in membership over the last year, says Van Wamelen. There have been several highlights for the SASTT over these 21 years, but undoubtedly the highlight that will stay with Van Wamelen for a long time is that a corporate member of SASTT, namely Trenchless

Technologies,

leading

BOTTOM Port Elizabeth goes trenchless A. Phase 1 (before) 450 cast iron pipe before cleaning B. Phase 1 (after) 450 cast iron pipe after cleaning

the ISTT and the International No-Dig Conference and Exhibition in Sydney, Australia, in September this year. In addition, SASTT is working with the ISTT towards holding the second ISTT Masterclass and No-Dig South Africa Conference and Exhibition in mid-2014.

Context and challenges According to Van Wamelen, like all civil engineering work, the local trenchless technology market has been ﬁckle. Nevertheless, trenchless construction, rehabilitation and upgrading projects are on the

go all over the country ‒ and not only in the metropolitan municipalities.

team of companies, was awarded the International Society for Trenchless

However, the challenges remain ‒

Technology (ISTT) 2012 ISTT No-Dig

and there are many, according to Van

Award for the project entitled Port

Wamelen. He says one challenge that

Elizabeth goes trenchless .

SASTT can proactively do something once

about though is the fact that due to a

again, SASTT awarded its own SASTT

quirk of South African public tendering

Award for Excellence for 2012 to an

legislation, a good deal of trenchless

exceedingly diﬃcult project known as

work is being awarded to what he

Another

highlight

that,

Upgrading and Replacement of Sewers in Alexandra Township (Phase 3), states

terms incompetent tenderers .

When

these

tenderers

not

manage to subcontract the work to a

Van Wamelen.

competent company, they often make

Focus forward

a mess of things. This gives trenchless

My focus is directed by the board of

technology a bad name ‒ and is bad for

SASTT. This is a team of seven profes-

the client s budget, says Van Wamelen,

sionals who share an unshakable ded-

adding that the SASTT has approached

ication to the promotion of trenchless

the Construction Industry Development

technology, explains Van Wamelen.

Board (CIDB) to convince the board to

As such, the focus for the 2013/14

introduce trenchless technology as one

period remains for the SASTT on build-

of the designated categories of special-

ing and strengthening aﬃliations or alliances with other professional organisations, such as the current ones with Engineering Council of South Africa and the Institute of Municipal Engineering of Southern Africa. The SASTT is also in the middle of a programme of developing SASTT

A highlight for Van Wamelen was Trenchless Technologies being awarded the International Society for Trenchless Technology 2012 ISTT No-Dig Award

standard speciﬁcations for trenchless

ist work in order to counteract this. The potential for trenchless technologies to positively impact the local water context is gigantic and therefore needs to be properly utilised and taken advantage of, he continues. It is no secret that Southern Africa is losing an unconscionable portion of its potable water due to leakage from

technology. These speciﬁcations are being drafted with

the reticulation networks. Trenchless techniques can ﬁnd

an eye on constraints such as the technical skills of site

and ﬁx those leaks very competitively, safely, eﬀectively

operatives schooled and trained in the third world, con-

and eﬃciently. It just requires the political will to start

tinues Van Wamelen.

doing something about it, concludes Van Wamelen. JULY/AUGUST 2013

TRENCHLESS NEWS

WETLANDS CONSERVATION

Preservation through innovation A sensitive wetland project necessitated a solution with a minimal site footprint and little or no excavation – the perfect opportunity to utilise trenchless alternatives.

URRENT LEGISLATION limits the

directional drilling, the no-dig option, was

degradation of environmentally

accepted by the client ‒ largely persuaded

sensitive areas due to construction

by the projects environmental team. The

activities. With the introduction

400 mm diameter pipeline section installed

of no-dig construction techniques, project

under the wetland area measured 160 m. A

managers have the opportunity to explore

second pipeline was also installed under an

alternative construction methods that have

ABOVE LEFT View of wetland area where 160 m of 400 mm diameter pipe was installed using Horizontal Directional Drilling ABOVE RIGHT View of the drill rig being positioned on site

to install bores of up to 450 m in length and

Town commissioned the installation of

Alternative construction methods... address the environmental constraints faced by conventional construction processes

a new, much-needed 400 mm diameter

existing waterway, with the pipeline measur-

eﬄuent main in the Strand area. A section

ing 24 m. The drilling project was completed

The no-dig solution proved far superior

of this pipeline traversed a catchment area

within a week ‒ despite heavy rains in the

when compared to the open-cut option due

for stormwater run-oﬀ, which, over time,

area. The combined resistance of the weight

to its smaller site footprint, shorter project

had formed a wetland. TT Innovations was

and friction of the HDPE pipeline measured

duration and signiﬁcantly reduced environ-

contracted to provide trenchless alternatives

well within the drill rig s 16 tonne pull-back

mental impact, states TT Innovations Neil

to the conventional dig and lay. Horizontal

capability. This particular rig has the capacity

van Rooyen.

a minimal site footprint, require little or no excavation and ultimately address the environmental constraints faced by conventional construction processes. This was the case when the City of Cape

has previously installed pipelines as large as 800 mm in diameter. In a similar project, this drill rig and crew installed a 200 m long pipe measuring 315 mm in diameter under a river. Generally, most of the longer drill installations cross under protected areas such as rivers and wetlands.

JULY/AUGUST 2013

Trenchless Technology Specialist

Our range of services include: • Pipe Bursting • Horizontal Directional Drilling • Pipe Rehabilitation

• Pipe Ramming • CCTV Inspection • Dewatering

• HDPE Welding • Deep Excavation and Shoring • Underground Service Detection

• Slip Lining

• Industrial Pipe Cleaning

• Close-ﬁt lining: COMPACT PIPE

For more information you can contact us: +27 (0)21 761 3474 F +27 (0)21 797 1151 E info@tt-innovations.co.za www.tt-innovations.co.za

TRENCHLESS FEATURE NEWS

eTHEKWINI

Western Aqueduct back on track The multimillion-rand Western Aqueduct project is back on track following this weekâ€™s announcement that Cycad Pipelines has been selected as the successful contractor for the initial 7 km sector of the water pipeline between Inchanga Station and Alverstone Neck. Construction commenced in the first half of 2013. HE ENTIRE 55 KM second phase

intended to be constructed as a single, large

the pre-qualiďŹ ed contractors making up the

Western

contract but has been dogged by delays. The

two panels.

Inchanga

second sector, covering the stretch between

Further delays to this project will have

Station and ends at Ntuzuma,

Alverstone Neck and Ashley Drive in Kloof

detrimental consequences for Durban as

has been released for tendering purposes.

current water supply infrastructure is unable

the

much

Aqueduct

needed

begins

and includes two branch pipelines to Tshelimnyama and Mount Moriah. It is ex-

The eThekwini Municipality called for ex-

to cope with the forecast future water de-

pected to signiďŹ cantly strengthen the capac-

pressions of interest last year and 16 contrac-

mand. In addition to large commercial and

ity of bulk water supply to the western re-

tors were selected for two diďŹ€erent panels:

industrial projects on the drawing board, the

gions of eThekwini, injecting up to 400 Mâ„“/d

one comprising companies qualiďŹ ed to deal

city s population is expected to increase by

and it will ultimately boost much needed

with large diameter pipes and

at least 20% by 2030, Macleod warns.

water supplies to the north of Durban.

capable of working with pipes of a smaller

Commissioned in June 2011, the ďŹ rst phase

and

diameter. Cycad Pipelines won this tender

of the Western Aqueduct covered 19 km

Sanitation (EWS), Neil Macleod, says EWS

on a competitive bid against the other

from Umlaas Road to Inchanga Station.

has unbundled the 55 km pipeline project

pre-qualiďŹ ed contractors in the large diam-

Lessons learnt from that project will further

into six individual projects that will be rolled

eter pipe category. The rest of the contracts

reďŹ ne the environmental rehabilitation for

out over a seven-year period. It was initially

will be competitively tendered between

the second phase, he states.

The

head

eThekwini

Water

the other

JULY/AUGUST 2013

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FEATURE

DESALINATION

Transnet gets new plant desalination,

clean-in-place

system, an energy recovery system and storage tanks. As a result of the nutrient-rich Atlantic waters, we ve had to install a pipeline pigging system to flush barnacles and other marine organisms from the 1.1 km intake pipeline, says Olivier. To minimise the plant s effects on surrounding seawater salinity, Veolia has also built a highly efficient brine disposal system. A key element of the plant s design is the energy recovery system. Olivier explains:

Higher pressure,

and thus more power, is needed to reject the salt in the desalination process.

Based

specialised

technology that has only become viable recently through advanced engineering, the recovery system directs unused energy from the reverse osmosis process to the beginning of the process, resulting in lower power consumption overall.

In 2008, Transnet awarded the Veolia Water subsidiary, Veolia Water Solutions & Technologies South Africa, a contract to design, build and commission a new reverse osmosis desalination plant at its iron ore terminal situated at the Port of Saldanha.

Veolia has further been contracted to operate and maintain the plant during its ﬁrst 12 months with the help of a plant supervisor, lab technician and two operators. Veolia is responsible for generating and implementing the maintenance plan, schedules and work charts, says Olivier.

Desalinating seawater with new-generation technology The plant has been designed to cope with red tide ‒ a frequent occurrence on the west coast of South Africa

ITH CONSTRUCTION and a performance

triggered by explosive growths of phytoplankton.

test completed in August 2012, Transnet

Phytoplankton, and its residues, can cause serious RO

now has access to its own constant supply

membrane fouling if not removed before the desalina-

of high-quality water for use in dust sup-

tion process, says Olivier. The other risk to the plant

pression and a range of other tasks.

includes oil and hydrocarbons from ships in the harbour.

Initially, the plant would have consisted of only one desalination unit capable of handling 1 200 m³/d of water, but Transnet has elected to double the plant s capacity. This is in reaction to the parastatal s intention to further reduce its dependency on municipal water and is in accordance with future expansion projects, says Cobus Olivier, engineering manager at Veolia Water Solutions & Technologies South Africa (Paarl). The reverse osmosis (RO) plant, part of a turnkey project executed by Veolia s Design & Build division based in Paarl, now consists of two units ‒ taking its capacity to 2 400 m³/d. The plant has the capacity to be upgraded to 3 600 m³/d by adding a third RO unit. It consists of an open seawater intake system, a pretreatment system to limit the eﬀects of red tide and hydrocarbons, seawater reverse osmosis units for

If not removed, these substances blind the RO mem-

TOP Saldanha desalination plant: The reverse osmosis skids, shown here as the long, white tubes, feature an overall treatment capacity of 2 400 m³/d, helping Transnet to become more independent from fresh municipal water sources

brane surface, rendering them significantly less effective for desalination. The recent performance tests in Small Bay, Saldanha Bay, have proved Veolia s conservative pretreatment designs to be effective in protecting the membranes from these fouling elements. Locally, Veolia has designed, built and commissioned desalination plants in Plettenberg Bay, Mossel Bay, Bushmans River Mouth, Knysna and Cannon Rocks, and was also recently awarded a contract for a new plant in Lamberts Bay. Desalination plants fall within the company s global SVR (service, value and responsibility) strategy that sees increased value for Veolia s customers, and improved social and environmental responsibility through increased service capability.

JULY/AUGUST 2013

FEATURE FEATURE

DESALINATION

Is desalination the sustainable solution? Nearly 40% of the world’s population suffers from a shortage of water. By 2050, this number could reach four billion. Australia, Spain, Mexico, California and the Arab Peninsula have already opted for the desalination of brackish or seawater to meet their needs; but can this option be viewed as sustainable?

CCORDING TO LEADING desalination spe-

raw water quality, examines the environmental impacts

cialist Degrémont, not only is it sustainable,

and deﬁnes the appropriate line technology, ensuring the

but it is also the answer to the rising need for

sustainability of the solution. The solution is also suited

domestic and industrial water, given that 97%

to all contexts, such as being used in coastal areas to treat

of the available water on earth is salty.

seawater or inland to treat brackish water. The freshwater

Desalination consists of extracting the salt from salty or brackish water to make it suitable for drinking or usable by industry or for irrigation. In 10 years, production costs have been divided by a factor of two, thanks to the eﬀorts of the water treatment industry and the manufacturers of membranes and equipment such as pumps, turbines and pressure exchangers, says Degrémont s marketing manager for Southern Africa, Francine Dubreuil.

production is also automatically adjustable according to

“Special design of the water intakes ensures no impact on the aquatic environment”

seasonal variations. This is particularly pertinent when considering that 42 of the 70 cities with more than one million inhabitants globally without direct access to additional freshwater resources are located on the coast.

Distillation is the oldest technology used; however, reverse osmosis ‒ a membrane-based separation process

Economics versus ecology

that enables more than 99.9% of the salts present in the

Ultimately, when discussing the sustainability of a solu-

water to be captured ‒ is the most recent technique.

tion, the ecological aspects or environment needs to be a primary priority. This has not always been considered

Degrémont is recognised as the pioneer of desalination through reverse osmosis since the first installation on Houat Island in France, in 1969. Currently, the company has 250 references worldwide, serving 10 million inhabitants with two million cubic metres produced. Some 500 000 m³/d of water is produced by plants operated by Degrémont. The flexible solution offered by Degrémont is not only tailor-made to each project, but the team analyses the

TOP Sea intake tunnel, Melbourne BELOW Melbourne, Australia’s biggest desalination plant

a major attribute of desalination solutions; however, the environment is protected with Degrémont s solution, she says. Special design of the raw water intake and eﬃcient pre-treatment ensures no impact on the aquatic environment and treatment of washing water before discharge, and diﬀusion of brine allows this to be accomplished without disrupting the aquatic equilibrium. In addition, energy needs can be met from renewable energy sources such as wind, tidal or solar power. However, the implications on the cost also need to be sustainable. Costs are controlled with a combination of standardised processes.

Greater yield is gained from

reverse osmosis units and membrane longevity owing to the efficiency of the purification treatment. There is also reduced consumption of external energy through the use of recovery systems. As a major environmental player, Degrémont not only offers its customers sustainable solutions, but whatever the customer s problem, Degrémont can propose the right technical and economic solution ‒ up to and including financing.

JULY/AUGUST 2013

FEATURE

www.degremont.com

SEA WATER: SOURCE OF

REUSE

Degrémont’s membrane ﬁltration technology is suitable for the whole range of treated wastewater uses, from agriculture and landscaping to industry and many others. Already valued by farmers and industries, the clean water produced by this demanding process makes a major contribution to water conservation and environmental protection.

DESALINATION Degremont draws its desalination experience from its portfolio of more than 250 reverse osmosis plants around the world. The process removes mineral salts by forcing water to cross a semipermeable membrane. With the growth in world demand for drinking water - and with 40% of the world’s population living within 100 km of the sea this technology offers a sustainable solution for the supply of potable water.

FOR THIS & OTHER DEGRÉMONT’S WATER TREATMENT PLANT EQUIPMENT, CONTACT : DUMI LUTHULI, Deputy Managing Director dumi.luthuli@degremont.co.za MORNAY DE VOS, Business Develop. Mg mornay.de.vos@degremont.co.za Tel: +27 (0) 11 807 1983 Fax: +27 (0) 10 591 5095 www.degremont.co.za

THE WATER TREATMENT PLANT SPECIALISTS

FEATURE FEATURE

DESALINATION

New Lamberts Bay seawater desalination plant The Cederberg Municipality has awarded a R17 million contract to the Veolia Water Solutions & Technologies subsidiary, Veolia Water Solutions & Technologies South Africa, to design, build and commission a 1.7 Mℓ/d seawater desalination plant in Lamberts Bay. the

shore

‒

Muisbosskerm.

This will provide a relatively clean source of feed water to the pretreatment phase, says Olivier. Pretreatment involve

will passing

seawater through a number of dual media pressure ﬁlters, which removes

particles

and

material

other

preparation

for

treatment by reverse osmosis (RO) membranes. During the RO phase, the salt water will be forced through semi-permeable membranes, retain

which

salts

allow

fresh

and water

to permeate. Once

ON-SITE INTRICACIES

HIS INFRASTRUCTURE upgrade will help alleviate growing pressure on the region s water system and improve availability of highquality water for the region s nearly 40 000

residents. A steady increase in water consumption by the town and surrounding farmers has resulted in an overall drop in groundwater levels, says Cobus Olivier, engineering manager at Veolia in Paarl. This new plant

Veolia Water Solutions & Technologies is building a 1.7 Mℓ/d seawater desalination plant in Lamberts Bay, which will alleviate growing pressures on the region’s water system. This building is where the equipment will be housed; the reservoir can be seen in the background and in the foreground (right) is the plinth being cast for the DMF (dual media filtration) filters

is part of the Cederberg Municipality s drive to correct this problem and improve water sustainability.

desalinated,

water

will

stabilised with limestone and CO2, and fed into the town s existing freshwater network, continues Olivier. Veolia s manufacturing subsidiary in Spain will supply the plant s standard compact seawater desalination skids. The details of the operation and maintenance contract is currently being ﬁnalised with the municipality, he concludes.

The Lamberts Bay contract falls on the success of six

A very tight budget requires Veolia to optimise stand-

seawater desalination plants installed by Veolia along

ard plant designs to maintain a high design and build

the Cape coastline since 2009 at Canon Rocks, Bushman s

quality. To ensure signiﬁcant energy savings and reduced

River Mouth, Knysna, Plettenberg Bay, Mossel Bay

carbon dioxide (CO2) emissions, the plant will be ﬁtted

and Saldanha.

with a state-of-the-art energy recovery system as part

Veolia Water Solutions & Technologies is the Veolia

of the plant s initial capital investment. Speciﬁcations

Water subsidiary specialised in technical solutions as well

also require the plant to accommodate a future upgrade

as design and build projects for water and wastewater

to 5 Mℓ/d.

treatment, for industrial and municipal clients. Veolia

Due for commissioning in October 2013, the plant will source seawater from boreholes drilled nearby

the

Water Solutions & Technologies recorded revenue of €2.4 billion (R32 billion) in 2012. JULY/AUGUST 2013

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FEATURE

MINE WATER

Central Basin’s AMD treatment plant takes shape It’s a race against time. The combined efforts of the Trans-Caledon Tunnel Authority (TCTA), main construction contractor Group Five and all subcontractors must ensure the new treatment plant at the Central Basin’s South West Vertical Shaft is operational before acid mine drainage decants to surface, finds Laura Cornish, editor of Inside Mining, Water&Sanitation Africa’s sister magazine.

JULY/AUGUST 2013

FEATURE HE ACID MINING drainage (AMD) dilemma, not a

For TCTA, allocation of suﬃcient funds to enable the

new concept to the South African public, reached

construction contract to be awarded, coupled with ob-

emergency status when gold mining-acidic

taining environmental authorisation where legislation has

water started decanting from a defunct shaft in

never made provision for this type of project, have been

the Western Basin in 2002, polluting nearby spruits and

signiﬁcant challenges Holden explains. Regardless, the

groundwater. Today, the emergency is reaching criti-

urgency of the project has necessitated

cal status as government ﬁghts to prevent a repeat at

TCTA bring its strengths to the table: fund-

the Central and Eastern Basins.

ing and implementing large-scale water

Every day the water level shared between the three

projects. Thanks to much negotiation and

Witwatersrand gold basins ‒ Eastern, Central, Western

compromise with ERPM, Central Rand Gold,

‒ is rising at a rate of about 300 mm/d, according to

the Department of Environmental Aﬀairs,

the Department of Water Aﬀairs (DWA) Inception

the DWA and all the interested and aﬀected

Report published in March 2012. Pumping stopped in

parties who participated in the scoping re-

the Western Basin in 1996, the Central Basin in 2008

port, the success of this project will become

and the Eastern Basin in 2011.

a reality.

Fortunately, the crisis on the Western Basin has

Group Five Civil Engineering was ap-

been curbed thanks to the upgrade of the existing

pointed the full R319 million treatment

Rand Uranium plant, which has been expanded from

plant construction contract, including civils,

12 Mℓ/d to 36 Mℓ/d. This has stopped and neutralised

earthworks, building, and mechanical and

the uncontrolled decant of water ﬂows. The severity of the situation has seen government take an active stance. In 2010, the government formed an inter-ministerial committee to evaluate technologies and methodologies to best solve the problem ‒ for the immediate future and the long-term future. TCTA, a special purpose vehicle established by the DWA, was appointed to implement the short-term intervention on its behalf.

The immediate priority: the Central Basin The Central Basin extends from Durban Roodepoort Deep (DRD) in the west to the East Rand Proprietary

Experts are predicting that water levels will reach the environment critical level around September/ October this year

Mines (ERPM) in the east. The mine lease areas in this

volume of AMD from the Central Basin is more than dou-

larger than the next biggest similar treatment plant in South Africa (at eMalahleni), with highly complex concrete structures, piping and electrical systems. Holden says the plant is designed to treat 57 Mℓ/d. At this stage the final treated effluent will still have a high sulphate content (approximately 200 mg/ℓ). This is no different to what was discharged by the mines up until to 2008 when pumping and treatment at this site ceased. The stream bed is already heavily polluted from old tailings and urban stormwater run-off.

basin extend over about 251 km2. Considering the amount of water necessary to treat the

electrical installation. It will be three times

Although this is not ideal, it is still a lot better than doing nothing until a long-term solution has been completed.

ble that of the Western Basin, prevention (of AMD reach-

The biggest impact caused as a result of the project is

ing the surface) is non-negotiable. Experts are predicting

the increase to the salinity of the water in the Middle Vaal

that water levels will reach the environment critical level

system, which necessitates the release of fresh water from

around September/October this year ‒ only 186 m below

the Vaal Dam to dilute it. This will result in a deﬁcit in the

the top of the shaft.

Upper Vaal system in 2015. What this means is that if there

If water rises above this level it could start having an im-

is a drought, water restrictions will need to be imposed.

pact on groundwater. The word could is used as no one

Wayne Poulsen, senior site agent for Group Five, ex-

can accurately predict the hydrogeological reaction as the

plains the basic treatment process: An extraction pump

water level in the mine void rises, explains TCTA business

station, including two huge dewatering pumps, will

analyst Richard Holden.

pump AMD from the existing ERPM shaft. The water will

Construction of a high-density sludge treatment plant

be pumped to two reactors, which combined have an 80

and pump system at the Central Basin s ERPM South

x 80 m concrete footprint and are 5 m deep. This water is

Vertical Shaft near Germiston commenced in February this

then pumped to a lime dosing plant, including silos and

year and marks another major milestone in government s

eight mixing tanks, each of which are 16 m in diameter

ﬁght to prevent AMD entering the Vaal river, which would

and 4 m high. Two thickeners, each 47 m in diameter, will

ultimately cause a shortage of water to consumers in

settle out the solids. The treated water will be discharged

Gauteng and the surrounding provinces. Without this

via pipelines to the nearby Elsburg Spruit and the sludge

project, the major impact will be on water security for an-

discharged via pipeline to an existing ERPM tailings facil-

yone who draws water directly or indirectly from the Vaal

ity. Group Five is further responsible for the construction

River system, Holden notes.

and delivery of all ancillary tanks and buildings as well as a

During the due diligence, various shafts were evaluated

full-scale laboratory.

and, given the cost to construct a new shaft, an existing

Ekurhuleni Metropolitan Municipality will supply the

defunct shaft was chosen. The plant will be situated at the

necessary clean water to site and power will be provided

existing South Vertical Shaft, which intersects the mining

via a high-power 4 km overhead line.

void of the central basin. The eastern side of the Central Basin also represents the lowest pumping head.

Our construction timeframe is less than a year, meaning not a day can be wasted. Trial commissioning will start JULY/AUGUST 2013

FEATURE

MINE WATER KEY ROLE PLAYERS

in November 2013, with trial operations running until 18

Department of Water Affairs

it must run permanently, 24/7. Our most critical challenge

Implementing agent

TCTA

throughout the project remains time; we have to meet

Design

Aecom

our critical deadlines. But we are conﬁdent of success; we

Main contractor

Group Five Civil Engineering

Gold, which graciously donated them to based at the Andritz facility in Germany and

Piping

Murray & Dickson Construction

Earthworks

Diesel Power

Mechanical

S.A.M.E

employment, enterprise development and skills training)

Electrical

Standard Electrical

ranked us highest .

Civil foundations

M3 Construction

Building and civil works

Enza Construction

April 2014, Howard Wakeﬁeld, senior contracts director for Group Five Civil Engineering, points out. We will hand the plant over to TCTA at complete readiness after which

started well and are making excellent progress. Wakeﬁeld believes that even though there were numerous tender bids put forward for the project, our combination of pricing, technical ability and compliance with TCTA s stipulated requirements for enterprise development and BEE (including mentorship, procurement,

Current project status Earthwork construction on-site is well under way, says

dropped. Ritz Pumps South Africa, with its German joint venture partner Andritz Ritz, has been contracted to supply two heavy-duty mining dewatering pumps to the project. They originally belonged to Central Rand TCTA for the project. The pumps are currently are due to undergo their second factory acceptance test. Following this, they will be shipped to South Africa where we will oversee their installation, says Chris Munnick, MD of Ritz Pumps SA. The beauty of our system is that our pump is assembled above ground and then free hung ‒ suspended from surface ‒ which means underground access to get to the

Chris Prinsloo, general manager of Diesel Power s Civils &

pump station, as is generally the case in

Bulk Earthworks Division. Primarily a mining contractor,

South Africa, is not needed, says Munnick. The pump

Diesel Power is focused on growing the civils arm of its business. The company is responsible for all project bulk earthworks, from excavation through to platform construction and backﬁlling. Prinsloo admits that their challenge, as with Group Five, is time. It is a tight programme and we need to hand over the platforms so the next leg of the project can start. We have also been experiencing a lot of rain. Regardless, our commitment to the project is unwavering, and we will meet our deadlines. The company has eight staﬀ members, 20 operators and

The mine shaft is over 1 500 m deep and the pumps, which are 15 m high (four storeys) and weigh 25 t, must be lowered 200 m down the shaft without being dropped

is simply suspended in the shaft opening with our ZSM system, which can withstand in excess of 1 600 t due to an axial non-positive and detachable pipe connection. Our technology enables us to free hang pumps up to 1 250 m with piping from 80 to 600 nominal bore and achieve heads of 1 500 m. We can also insert a pump in large borehole from the surface straight down into the water source, suspend and hang the pump into the water and pump out directly without having to go through the shaft with a complex piping system as is required

16 labourers dedicated to

for the traditional underground high-pressure pump

the job. The reactor plat-

station setup. The use of single-suction submersible motor pumps for

ed, the thickeners area is

pumping huge quantities or from great depths is associ-

70% complete, the dos-

ated with extreme loads on the unit, Munnick continues.

ing area is 60% complete

The higher the pump performance, the stronger the

and building platforms

axial thrust exerted on the pump, the motor and its thrust

are 80% complete, says

bearing. The consequences of this are overloading and

Prinsloo.

We have also

untimely shutdown. The solution is to double up, mean-

just started on building

ing greater durability. This is what our design is all about, a

15 m

form is already complet-

the internal roads and the retaining walls. This is such an exciting

double-suction pump that provides full compensation for axial thrust. In short, the heavy-duty pump is designed for longer life ‒ between 25 and 30 years.

project to be involved

While the plant has been designed using historical infor-

with; to be part of a

mation, ﬁnal qualities will only be known when pumping

project saving the envi-

commences and the water level stabilises at and around

ronment and preserving

the environment critical level, Holden points out.

water resources for future

Projects such as this are extremely complicated and

generations is a great mo-

do not naturally fall into the category of national water

tivator, Prinsloo states.

resource, water board or

CRITICAL FACTS Western Basin

Central Basin

Eastern Basin

Volume of AMD that needs to be treated

27 Mℓ/d

57 Mℓ/d

82 Mℓ/d

ities of all the project

Environmental critical level (ECL)

1 550 m AMSL (165 m BCL)

1 467 m AMSL (186 m BCL)

1 280 m AMSL (290 m BCL)

elements are enormous,

Current level

0.88 m BCL

256 m BCL

423 m BCL

Breach of ECL if pumping does not commence

Breached already. Objective is to draw the water down to ECL

Pumping ‒ a key critical project element The scale and complex-

including the dewatering pumps. The mine shaft is over 1 500 m deep and the pumps, which are 15 m high (four storeys) and weigh 25 t, must be

lowered 200 m down the shaft without being

Responsible government department

Location of treatment plant

Rand Uranium, Mogale City

municipal

responsibility.

They are a prime example of integrated water resource management and will shape projects to come as South Africa reaches the limit of its allocable water resources.

Sep/Oct 2013

Nov 2014

They need time to come together

South West Vertical Shaft, Germiston

AMSL = above mean sea level BCL = below collar level

JULY/AUGUST 2013

Grootvlei No 3 Shaft, Springs

they

are

ensure

that

environmentally

and ﬁnancially sustainable, Holden reiterates.

25 YEARS OF THE EXTRAORDINARY TCTA is a state-owned liability management entity responsible for bulk raw water infrastructure development

The TCTA is proud to contribute towards a system which aims to deliver a sustainable water supply across Southern Africa TCTA is also expected to play a key role in the funding of the Lesotho Highlands Water Project Phase 2, the implementation of which was announced in a joint statement issued in August 2011 by the Governments of Lesotho and the Republic of South Africa. The provision of water serves as a catalyst for sustainable economic development. The manner in which TCTA implements and manages its projects is governed by principles of transformation and sustainable development. We consider ourselves an instrument of social purpose, formed within society to accomplish social objectives. Consequetly, we are obliged to create new patterns, processes and strategies to tackle complex socio-ecological issues.

he Trans-Caledon Tunnel Authority(TCTA) specialist VNLOOV IURP VRXUFLQJ SURMHFW ÂżQDQFH WR planning, design and construction, place TCTA in the ideal position to facilitate development of bulk raw water infrastructure. From an initial single project, TCTA now manages a portfolio of nine. These are the Lesotho Highlands Water Project Phase 1; the Berg Water Project (Western Cape); the Vaal River Eastern Subsystem Augmentation Project (Mpumalanga); the Mooi-Mgeni Transfer Scheme Phase 2 (KZN Midlands); the Olifants River Water Resource Development Project Phase 2 (Limpopo); the MokoloCrocodile (West) Water Augmentation Project (Limpopo); the Komati Water Scheme Augmentation Project (Mpumalanga) and, more recently, the Acid Mine Drainage Project (Gauteng) and the Metsi Bophelo Borehole Project (across six provinces).

TCTA has committed itself to the progressive ideals and principles of sustainable development and their integration into various aspects of our business processes, giving us an opportunity to create value for all stakeholders, including social, economic and environmental facets. All the above services are in support of governmentâ€™s development agenda to make a better life for all. TCTA is committed to assisting government to achieve its socioeconomic objectives.

For more information on TCTA visit: www.tcta.co.za or Call +27 12 683 1200

25 anniversary advert may 2013 updated.indd 1

2013/05/28 10:17:33 AM

FEATURE

METERING TECHNOLOGY

The real cost of metering The decision to invest in good-quality water meters that are specifically designed and optimised for South African water conditions can significantly reduce non-revenue water and enhance and maximise authority’s revenue. CCORDING TO Mark Shamley, MD of Elster

the cheaper import caused the authority to lose R45.83

Kent Metering: Water losses in the distribution

per month per meter in lost revenue compared to the

system can be categorised into two types: the

local meter (using Johannesburg tariﬀs for 2012/13),

real losses from leakage or the apparent com-

yielding a payback on the original cost diﬀerence of

mercial losses that often result from inaccuracies in me-

the meters of only 0.7 months. This would equate to

tering, meter reading errors or even billing errors. These

R4.58 million lost revenue per month for the authority

losses can have a negative impact on the municipality s

should it have 100 000 of the cheaper imported meters

revenue, despite these apparent water losses being eas-

installed (or R55 million per annum ‒ the equivalent

ily reduced through choosing the best performing me-

of the total annual meter Capex of an average sized

ter that is suited for the speciﬁc local water conditions.

metro in South Africa).

Most domestic meters in South Africa are mechanical

Meters in South Africa are typically installed for

devices and performance degrades as a result of:

periods of 20 to 30 years, but due to local water con-

• volume of water ﬂowing through the meter

ditions, the optimal meter replacement period in South

• quality of water ﬂowing through the meter ‒ suspended

Africa is probably every 8 to 10 years, depending on the

solids (grit) in the water supply.

household s water consumption, the quality of water go-

Elster Kent KSM Volumetric water meter

Both factors cause the meter to under-read and hence the consumer pays a lower bill than the actual amount of water that has passed through the meter. Shamley says:

ing through it and the quality of the water meter. The Elster Kent KSM Volumetric meters are a ﬁne example of a good revenue meter that caters for African water

Some meters are designed for the

conditions. The unit provides optimum accuracy and

harsh water conditions experienced in South Africa and

performance at all times, even at the lowest ﬂow rate. The

throughout

Africa,

and

meter can be installed in

hence perform better by

any position, i.e horizon-

coping better with suslocal circumstances and thereby degrading at a slower pace than many of the imported meters. It is not wise to buy the cheapest meters as this could end up costing a municipality more in revenue than was saved initially over the meter s life cycle. It s not the cost of

which

ultimately

pipelines, maintaining op-

10 9 8 7 6 5 4 3 2 1 0 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10

timum performance with no loss of accuracy. The

Elster

revving vides life

a and

meter

Kent

low

revolutionary

grooved

piston long

pro-

working

ensures

that

stoppages

are

substantially

reduced,

durability enhanced and 10

100

the meter, but the cost of metering that s important,

tally, vertically or inclined

ACCURACY %

pended solids under these

Tests After 500 Hours with Grit in the Water 1.5 Qp Class C Meter

1000

takes

into consideration the cost of lost revenue due to a meter under-reading. He states that when meters are tested, the tests are performed under ideal conditions with clean water. Elster Kent meters are designed and optimised to be utilised in South African and African water conditions, unlike many of the imported meters. In the graph provided, results of accuracy tests with grit in the water show a comparison between the performance of a good revenue 1.5 Qp Class C Elster Kent Meter against a cheaper model imported from the East. The test results show that the cheaper imported meter under-read by as much as 9.95% than a good locally produced Elster Kent meter. In this speciﬁc example, the under-reading of

GRAPH 1 Lost revenue due to meter inaccuracy At 30m³/month consumer consumption A 9.95% measuring difference covers R30 difference in price between Elster Kent meter and cheap meters from the East in just 0.7 months

performance

improved

as a result of the unique-

FLOW RATE l/h

Good Revenue Meter

10000

Poor Revenue Meter

designed

grooved

piston within the meter measuring chamber. Another unique feature of the unit is the gear train that is mounted in a gearbox. This maintains optimum alignment of the gear and reduces friction. The compensating ramp is a unique way of allowing movement in the plastic body where there are pressure shocks. Shamley closes by saying: At the end of the day, the water meter is the cash till of the system. The cheapest meter is not necessarily the best revenue meter and, in the long run, procuring a good quality, good revenue meter can pay back in less than a month. The actual cost of metering should take into consideration the average cost of the meter, plus the cost of water that the meter doesn t measure.

JULY/AUGUST 2013

FEATURE

WATER METERING

The water pressure is on The next war will be over water, such is the shortage of this valuable asset. Advanced technologies offering greater accuracy and reliability in the management and monitoring of water therefore need to be embraced – sooner, rather than later. HE ESTIMATION is that one in six people glob-

correct. Generally, it has been found that consumers that

ally has no access to potable water. The situation

have access to accurate information on consumption will

in Africa is exacerbated by an exponential pop-

actively manage their demand and recognise the need to

ulation growth. These facts, coupled with South

pay for their consumption.

Africa s scarce and diminishing water supply, now make it

It should be noted that a smart meter in isolation

crucial that South African municipalities, consumers and

serves little purpose. Without a reliable data transmission

businesses start to seriously address water ineﬃciencies.

backbone and back-oﬃce management system, the information supplied by the meter is underutilised or wasted.

Ageing infrastructure

Therefore the necessary technical infrastructure required

Ageing water infrastructure needs to be upgraded or

to enable smart technology to operate optimally requires

replaced, and with utility companies desperately short of

local authorities and delegated utility management com-

skilled water practitioners, the time is right to consider the

panies to have the expertise to eﬀectively interpret and

pros of smart water metering ‒ a concept that oﬀers many

use the information gathered eﬀectively. There is a ten-

advantages. There is no economic sense in repairing or

dency to request smart meters in the belief that the device

recalibrating old water meters (frequently 15 or older)

itself will resolve water billing and management issues. It

when far more cost-eﬃcient and accurate technology is

is a prerequisite that adequate management expertise is

now available. In the ﬁrst instance, old water meters that

available (internally or outsourced) prior to embarking on

have been repaired are generally not compatible with

a smart meter upgrade, comments Bold.

new data transmission technologies ‒ a prerequisite for

Sensus regards itself as the smart water

eﬃcient reticulation management. Secondly, new gener-

company that provides real world, proven

ation meters have vastly improved measuring ranges and

solutions of high value metering, automated

superior accuracy, which render old meters ineﬃcient and

meter reading and advanced metering infra-

inaccurate. There are immense savings to be made from

structure system solutions for water. In 2012,

embracing smart technology in the water sector, says

Sensus conducted research into the eﬀective-

Basil Bold, MD of Sensus South Africa.

ness of smart water technology by a team of

He continues: It is generally accepted that, on aver-

internationally recognised consultants in over

age, more than 35% of all water fed into municipal

15 countries. The research included multiple

reticulation systems is unaccounted for i.e. lost

choice and open-ended questions to various

due to pipe bursts, leakages, reservoir overﬂows,

sized global water utilities. The resulting white pa-

theft, inaccurate metering and puriﬁcation losses.

per, Water 20/20: Bringing Smart Water Networks

into Focus, stated that smart water networks can

I believe the starting point to address these issues

oﬀer savings of up US$12.5 billion (R122.3 billion) per

is better measurement. Improved measurement oﬀers possibilities to identify and address major in-

year, globally, and that leaked water costs utilities an

eﬃciencies, develop new holistic water management

estimated $9.6 billion per year. The savings that result

strategies and educate the consumer with a view

from the utilisation of smart water technology can enable the utilities to reinvest some 5% back into their budget

to encouraging a culture of water conservation. The average consumer is probably more aware of the price of a litre of milk than how much their water bill is and why. Measurement is knowledge and the implementation of smart technology within our water sector is, I believe,

The new IPERL offers intelligent end-point data functionality

to improve water networks and help address the global water scarcity crisis. Sensus has recently introduced iPERL, a new state-ofthe-art water measuring technology that oﬀers intelligent

the way forward to addressing the country s critical

end-point data functionality and replaces traditional

water issues.

water meters. The iPERL delivers sustained accuracy and value with a performance that is unaﬀected by installation

A smart water meter

conditions. It is simple, reliable, accurate and long lasting,

A smart water meter typically oﬀers an intelligent inter-

with quick returns-on-investment and ﬂexibility for future

face to an electronic data communication system with

optimisation. The technology is environmentally friendly

the primary focus on accurate measurement for billing

and has the lowest environmental impact possible. It is

purposes, but also near-to-real time information on pos-

fully protected against all water network hazards and

sible leakage and consumption demand proﬁles. There is

manufactured from fully recyclable materials.

a perception that consumers are simply not willing to pay

To measure is to know; without this knowledge, the

for water usage and the only eﬀective method of extract-

current water wastage will continue to lead us into the

ing payment is by punitively cutting oﬀ supply. This is not

dire straits forecast, concludes Bold. JULY/AUGUST 2013

FEATURE

WATER METERING

Accurate environmentally friendly metering M More accurate metering over a wider measuring range – that’s th the key advantage of a new technology domestic water meter fro Sensus South Africa. from HE NEW VOLUMETRIC Class C

addition to a high-integrity inductive pulse

older generation products a mere facelift.

meter ‒ known as the 220C ‒ in-

capability. This allows the meter to be

Its new water meters embrace smart tech-

corporates

integrated into any remote meter-reading

nology, which is the only technology that

network, while ensuring the data integrity

currently oﬀers accurate data measurement

required for billing purposes.

and recording, and substantial medium- to

scious

environment-con-

advances

manufac-

turing materials in addition to improved communications technology.

An additional feature is the vertical con-

long-term savings for users. Replacing

The body of the 220C is of an ultra-strong,

ﬁguration of its piston axis assembly, which

old-style meters with a meter that has

composite engineering polymer. This is

improves its ability to handle dirt without

been merely restyled makes no practical or

an indication of the move away from high

stoppage ‒ this is crucial when water quality

economic sense.

carbon-footprint brass-bodied meters. It s

cannot be guaranteed or the meters are be-

half the weight of a brass-bodied meter of

ing installed into old reticulation networks

testing by the SABS and has been ap-

the same size.

where pipe bursts are frequent.

proved by the NRCS (National Regulator for

The meter s communications technology

Sensus invests substantially in research

incorporates a standard reed switch, in

and development and does not give its

The

meter

has

undergone

extensive

Compulsory Standards Speciﬁcations) to the more stringent Class C accuracy standard.

JULY/AUGUST 2013

WAYS TO RECEIVE 1. PRINT

Email your details to subs@3smedia.co.za to receive a copy of Water&Sanitation Africa every alternate month.

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PRODUC TS & SER VICES

PUMPS

Injecting fresh momentum The new Etanorm series impresses with operating reliability, energy efficiency and versatility.

Setting standards around the world The ﬁrst was the result of the demands made by the international market. Many users of KSB s products are global players who form part of an international network. They tend to favour standardised products, in particular where spare parts stocking is concerned. This was exactly the point that had posed a real challenge thus far. Irrespective

ORE POWER PER pump ‒ this is how one

of its design or features, the Etanorm has successfully

can summarise the principal characteristics

made a name for itself in almost every country in the

of the new Etanorm type series. When opti-

world. However, over the years, KSB had had to come up

mising this classic pump, the development

with numerous design variations to meet the needs of

engineers made it a point to go the extra mile. It took

particular countries, so that although the pumps were

numerous calculations, simulations and experiments un-

still similar at heart, the number of design diﬀerences had

til the experts were ﬁnally happy with the new Etanorm.

gradually increased. Not only did this mean that KSB had

The result is clear for all to see: the good old Etanorm new

to cope with an enormous complexity of having to pro-

style will more than meet customer expectations.

duce spare parts and accessories for every single pump

Role models tend to have a hard time; besides always giving their best performance, they also have to look for ways to improve further. The same is true of KSB s Eta family pumps. The type series goes back to 1936 and upwards of 1.5 million units have been sold to date. This makes it the most successful standardised water pump of the world. The pump s success is largely based on the wide variety of design variants and the broad range of

series. The users themselves were

The Etanorm has successfully made a name for itself in almost every country in the world

applications resulting from these. The Eta product range

ple sets of spare parts, for example, if they ordered pumps both in Europe and in Asia. To do away with this problem, KSB decided to standardise the Etanorm and to set the same quality standards at all production facilities in the world.

comprises conventionally sealed water pumps in a wide

The second impetus was given by ErP Directive (EU

variety of designs ranging from variable speed models to

Regulation 547/2012), also known as ecodesign directive.

the zero-leakage Etaseco. To further increase customer

Although many pumps today already meet requirements

beneﬁt, all pumps can be automated, for example by

that will not take eﬀect until 2015, it was still KSB s goal to

combining them with PumpDrive and a Hyamaster

become better still. KSB s trend-setting FluidFuture cam-

(speed control) or PumpMeter. In other words, the Eta

paign is the logical further development of this approach.

pump family has a solution to oﬀer for almost every

FluidFuture is the name of a concept consisting of all prod-

pumping problem.

ucts and services that together make for an energy-eﬃ-

The challenge facing the team of development

engineers

headed

KSB s

Dr Norbert Kastrup, product

development:

cient way to run a system. The concept is holistic in nature,

KSB has added several pump sizes to the selection chart of the type series

i.e. besides the pump itself, it also looks at the system as a whole through the eyes of a pump expert.

High energy eﬃciency To meet the objectives of high eﬃciency and low ener-

Single-stage Pumps, began

gy consumption, the pump s hydraulic system is key.

with quite a simple

Generally speaking, the old style Etanorm pumps were

question: do

also able to convince,

How

thanks to their opti-

inject

pump

known

mised

that

hydraulic

systems.

for

And

its low energy

the

consumption,

graduated se-

reliability

and

lection charts

durability

with

a l l o w e d

fresh

ﬁnely

engineers

momen-

ﬁnd

tum? After much

exactly

two

the right pump size

things that pro-

for the intended appli-

debate,

cation. But KSB decided

vided the impetus

to go a step further: Our

for a renewed technical over-

strength is that we precisely

haul and optimisation of

match the pump to the

the Etanorm.

also faced with having to stock multi-

JULY/AUGUST 2013

Hereâ€™s a big reason you can save even more energy. Etanorm is a classic that keeps getting more efficient. It meets the energy efficiency requirements of the ErP Directive for 2015 already today â€“ for three good reasons: optimised hydraulic components for pace-setting efficiency, individual impeller trimming, and ideally matching drives and automation components. Etanorm is available really fast, comes in numerous variations, and provides the unique reliability of a globally identical product. For more information, please visit www.etanorm.com / www.ksbpumps.co.za

Pumps Valves Service Q

PRODUC TS & SER VICES

PUMPS Kastrup s team also studied the details of the various operating conditions. Etanorm is a classic clean water pump that normally is not used in an abrasive environment. However, operators increasingly have to contend with solids, such as sand. We have taken this fact into account by making the shaft seal chamber more compatible with solids. And there is a wide variety of materials to match the pump to the ﬂuid to be handled. To cater to Asian markets, we have added bronze to our materials range for example, because it is the material of choice in India.

Fast service What we expect users to value most, however, is that the Etanorm is now manufactured at all production facilities around the world according to the same quality standards. Aside from EN flanges, the pumps are also available with ASME flanges. The user gets a pump that is specific requirements such that, for example, the energy consumption is minimised and the operating costs are reduced, Kastrup explains. In addition to the hydraulic system and the trimmed impeller, variable speed oper-

The first local order of pumps ready to leave the site

manufactured at all three production sites (Frankenthal, India and South Africa) according to the same quality and development speciﬁcations. This makes global procurement considerably easier and increases the availability of pumps and spare parts. For example, the Etanorm can

ation in connection with PumpDrive and a standard IE2

be easily installed in pipelines requiring an EN-type or

motor is equally instrumental in keeping energy costs,

ANSI-type ﬂange.

and hence the cost of operation, down. Combined with

Although quality standards are the same everywhere,

the innovative KSB SuPremE motor, eﬃciency level IE4

it is as important as ever that each pump is individually

with at least 15% less power loss can be achieved

tailored to match local conditions. Pumps and accessories

already today.

have to be capable of being adjusted to regional requirements quickly, easily and reliably. Thanks to KSB s close-

Reliability of operation

knit global sales and service networks, spare parts quickly

Plant operators are also interested in the reliability of their

reach their point of use. Servicing and maintenance of the

systems. For one, KSB has added several pump sizes to

new Etanorm are now also easier. Among others, this is

the selection chart of the type series. And by increasing

due to the enlarged seal chamber, which makes for bet-

the rigidity, the pump casings can now absorb higher

ter venting, and the bolted connection between casing

forces and moments imparted by the pipelines; this makes

cover and bearing bracket, which is a feature of all pump

for a further increase in reliability. This wasn t the only

sizes. Admittedly, this does not sound very spectacular

design change, however. The bearing bracket has been

at ﬁrst, but it is details like these that make maintenance

reinforced further to minimise the vibrations generated by

much easier in practice, Kastrup points out. As a further

the running pump. And even if operating conditions vary

improvement, the interface between casing cover and

and the ﬂuid pumped contains solids, the conﬁned casing

bearing bracket now features forcing screws. The reason

gasket and optimised casing cover ensure that operation

for this is that on grey cast iron pumps, in particular, the

is reliable. Moreover, the pump boasts excellent suction

connection between the two parts often was very diﬃcult

performance and virtually cavitation-free operation across

to loosen after a long period of operation. On the new

a wider operating range. This results in a low wear rate

design, the cover is easy to open, even after many years.

and exceptionally smooth operation.

Outlook

Highly versatile ‒ for every type of application

The term standardised in standardised water pump is

A total of 43 sizes are now available. From the point of

somewhat misleading. After all, the Etanorm is one of the

view of their hydraulic systems, several sizes remained

pumps with the greatest wealth of variants. No more

the same, but 23 sizes oﬀered scope for improvement,

than 1.4% of the pumps of this series sold in 2011 were

Kastrup says. We used the ﬁnite element method (FEM)

identical in design, indicates Kastrup by way of example.

and computational ﬂuid dynamics (CFD) for this. After

The wide range of sizes and materials guarantees that

optimising all hydraulic contours by means of CFD,

users get pumps that are ideally suited for their particular

the improvements were validated by testing them in

conditions of use. A pump with an impeller carefully

extensive test set-ups. Work on the hydraulic systems

trimmed to match the operating point also warrants low-

also resulted in several additional sizes for smaller ﬂow

wear operation. In addition, the user beneﬁts from the

rates, so that it is now easier to match the best eﬃciency

fact that the machines will be manufactured according

point when selecting a pump. In the past, the sizes with

to the same production and quality standards across the

a nominal impeller diameter of 315 were not suitable

world from the spring of 2013. The design optimisations

for two-pole operation, because that put too much of a

resulting from this development process provide impor-

strain on the pumps, he continues. This design variant is

tant impulses and make sure the Etanorm retains its role

now also available.

model status. JULY/AUGUST 2013

PRODUC TS & SER VICES

Technology backed by engineering experience Process plants are reliant on various technologies for successful production. Today’s reality is that these technologies are often forced to work under the harshest conditions. AST

YEAR,

Germiston-based

Ecochem Pumps was appointed as the exclusive distributor of the

Soméflu’s international distribution manager, Adrien Hourlier (left), with Ecochem Pumps’ general manager, Richard Rudling

Hourlier explained that almost any type of plant makes use of corrosive ﬂuids of one type or another, resulting in the Soméﬂu

Soméﬂu range of chemical trans-

Hourlier s visit to introduce him to existing

range of pumps having almost universal

fer pumps throughout South Africa and

customers, where he made presentations on

application. He said that internationally the

neighbouring countries. In late April, Adrien

the Soméﬂu product range.

company s main business is within chemical

Hourlier, Soméﬂu s international sales man-

and fertiliser manufacture, petrochemicals

ager, visited South Africa to provide support

Current trends

and the mines. Soméﬂu technology is also

and further strengthen the relationship.

During his visit, Hourlier and Ecochem

applied to water treatment, which Hourlier

Ecochem has, for many years, supplied the

Pumps general manager, Richard Rudling,

sees as an important growth path for the

market with Milton Roy s range of chemical

issued a statement outlining current industry

company in Africa.

dosing pumps. Although Milton Roy tech-

trends and Soméﬂu s plans for the future.

nology is not connected to the business of Soméﬂu,

both

com-

panies are French. In addition, the Soméﬂu chemical

transfer

pump is complementary to the Milton Roy chemical dosing pump in process operations. These

synergies

ABOUT THE SOMÉFLU PUMP Soméflu centrifugal pumps are designed for transferring corrosive, abrasive and hazardous fluids in mining, chemical, petrochemical, water treatment and other applications, managing the bulk transfer of chemicals from one point to another. The pumps, machined from a block of raw material, can handle a flow rate up to 1 500 m3/h and a 100 m head pressure.

are

Rudling added that Ecochem Pumps will

According to Hourlier,

also be looking at steel production for the

the market for chemical

Soméﬂu product, because of the French

transfer pumps is gener-

company s international experience in pick-

ally shrinking in terms of

ling applications and acid regeneration.

small orders, but growing for

larger

orders.

This

Plans for South Africa

is because of the trend

Ecochem Pumps recently received a signif-

towards the closure of

icant order for Soméﬂu pumps from a lead-

smaller plants in many in-

ing platinum mine in North West province.

dustries and their replace-

These pumps, already supplied and installed,

ment by larger plants with

are expected to be commissioned soon.

expected to help Soméﬂu with initial sales,

a greater throughput, which can then take

Besides mining, Rudling said that Ecochem

and Ecochem Pumps made use of the

advantage of economies of scale to deliver a

would be making a particular eﬀort to

installed Milton Roy product base during

lower cost of production per unit.

target new petrochemical and chemical

JULY/AUGUST 2013

PRODUC TS & SER VICES

PUMPS

manufacturing plants in South Africa and an-

New tools for design optimisation

ticipates capturing a respectable share of the business emanating from locally designed and managed projects. However, he added that the challenge with new plants will be to gain entry to those that are funded from abroad. In such cases, he

LOBAL SPECIALIST in energy management Schneider Electric provides

said that one could expect most of the prod-

comprehensive smart water solutions, dedicated tools that are now

ucts incorporated in the plant to be sourced

available to support consultants and engineering companies in the

from the country funding the project.

design, efficiency and optimisation of intelligent water architectures.

We will target replacement business in these overseas-funded projects,

Utilities need to optimise costs and eﬃciency, says Ravi Saman, water and waste-

Rudling

said. In some instances, the foreign products

water vertical manager at Schneider Electric South Africa. The design tools enable

that will be used are not built to last and

consultants to deliver comprehensive speciﬁcations for water utilities, reduce con-

represent a comparatively high lifetime

sultant project time and continuously improve customer experience. Many factors aﬀect the landscape of today s global water industry. Consultants and

cost of ownership. We will be ready to help when the plant operators discover this fact,

engineers are the backbone of the design and implementation of smart water solu-

he stated. Ecochem Pumps is particularly

tions, which enable utilities to improve visibility and fully control their operations.

strong in fault diagnosis, which was one of

Saman adds that integrated solutions not only provide enhanced process control,

the main reasons that we selected it as our

but by processing data in real time, utilities are able to take action quickly in order to

authorised distributor, Hourlier explained.

save water and energy, reduce maintenance costs, optimise compliance and security, and deliver increased customer satisfaction.

The company has 50 years experience in

Schneider Electric provides water utility consultants and engineers with dedicated

the chemical transfer business.

tools to help identify and analyse existing situations, as well as design and specify

Rudling commented: Soméﬂu was estab-

integrated solutions for smart water architectures.

lished in 1962, so its products are backed by expertise of more than 50 years. Of particular

The tools include ready-to-use speciﬁcations, white papers, system user guides

importance are the plastics that Soméﬂu has

that allow the prescription of advanced solutions based on EcoStruxure, Schneider

developed for use in the construction of its

Electric s innovative platform to build uniﬁed environments.

pumps. Soméﬂu has the only plastics in the

Eﬃciency, longevity and reliability of the utility s network of pipes, pumps, reservoirs

pump industry that are speciﬁcally designed

and valves are improved by better measuring, collecting and analysing data from a

to handle abrasion. Most competitors use

wide range of network events and making that information available in real time to

standard polypropylene and their products

operators. Such reliable information enables automated control and optimisation of

suﬀer from abrasive wear. Not only will the

complex processes and timely decision-making regarding areas that can beneﬁt from

Soméﬂu pump have an advantage in this

proactive measures or corrective actions, adds Saman. Incident management tools

market in terms of resistance to abrasion,

identify what area of the network needs to be isolated for repair or maintenance,

but it also has the advantage of the ultra-

which customers will be aﬀected and help crews to manage and optimise their time.

violet ray resistant pump casing, which

Schneider Electric oﬀers comprehensive smart water solutions that can be adapted

our competitors do not have. It can be left

to meet the needs of the customer, including hardware, software and services as

to bake in the Karoo sun and still last for

well as engineering and project management, energy performance and mainte-

many years. For these reasons, I expect the

nance plans.

Soméﬂu product to do well in this region.

INDEX TO ADVERTISERS Aquadam

Johannesburg Water

Structa Technology

ASW

Krohne South Africa

Trans-Caledon Tunnel Authority TCTA 63

KSB Pumps

Tenova Bateman

Mather+Platt

Thuthuka

Nalco Africa

IFC

Aurecon Degremont Dow Water & Process Solutions Echochem Pumps

Osborn Engineered Products

Elster Kent Metering

Rheochem

Royal HaskoningDHV

Endress+Hauser

Tracker Connect

Trenchless Technologies

TT Innovations

Veolia Water Solutions

Fiberpipe

Saint-Gobain

GIBB Engineering

SBS Water Systems

Vermeer Equipment Suppliers

52 21

Gast International SA

Schneider Electric

Videx Storage Tanks

Headstream Water Solutions

Sera Dose Tech

Water & Sanitation Services OFC & OBC

Itron

SRK Consulting Engineers

Zest WEG Group

JULY/AUGUST 2013

IBC

INNOVATIVE FEATURES COUPLED WITH EFFECTIVE TECHNOLOGY

WEG Automation incorporates innovative technology in motor control coupled with ease of human-machine interface. Engineered for an energy hungry world, WEG Automation offers optimum functionality including easy installation and operation.

0861 00 ZEST |

www.zest.co.za

LV Drives: 0 - 2850A Single Phase 220 V – 0.18 to 2.2 kW Three Phase 525 V – 1.5 to 1850 kW

Three Phase 380 V – 0.37 to 1750 kW Three Phase 690 V – 1.5 to 2000 kW

MV Drives: 85A - 1178A Three Phase 2.3 kV – 400 to 3730 kW Three Phase 4.16 kV – 400 to 6000 kW

Three Phase 3.3 kV – 400 to 6000 kW Three Phase 6.6 kV – 450 to 6000 kW

LV Soft Starters: 0 - 2424A Three Phase 380 V – 1.1 to 750 kW Three Phase 525 V – 1.5 to 1050 kW

Three Phase 380 V – 1.1 to 1250 kW * Three Phase 525 V – 1.5 to 1800 kW *

MV Soft Starters: 180A - 360A Three Phase 2.3 kV – 550 to 1100 kW Three Phase 4.16 kV – 1100 to 2250 kW

Three Phase 6.9 kV – 1900 to 3400 kW

Coralynne & Associates +27 (011) 422 1949

*(inside delta connection)