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ENDORSED BY SAPMA, SAPSDA, SAVAMA AND VAMCOSA

SKF pumps up the volume

MAY/JUN 2021

Pumping for prosperity


We offer valves for precision processes - and demandingapplications Our valves fulfill the highest of standards and are designed for many years of safe and reliable operation. Our service specialists regularly check, monitor and maintain all relevant system components - depending on what has been agreed. Our modular framework agreements offer you individual service and spare parts concepts. And we even go one step further. We additionally check systems for efficiency in order to reduce operating costs and increase productivity. For example, with the SES System Efficiency Service.

ZTS GATE VALVE

GATE VALVE AKG-A/AKGS-A

STAALWEDGE GATE VALVE AKDS/AKD

NORI 500

Contact our dedicated Valves Sales Engineers for all your Valve requirements Tel: 011-876-5600 • Email: info-za@ksb.com KSB Pumps and Valves (Pty) Ltd www.ksb.com/ksb-za Your B-BBEE Partner

BOA - H


CONTENT COVER STORY Local manufacturer gearing up for growth

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PIPES ALLU Transformer TS Drum improves profitability in pipeline applications by 80%

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PUMPS Slurrysucker succeeds where old methods fail

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SKF pumps up the volume in lubrication management

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Abrasive solids handling made simple with the new Warman submersible pump

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Bravo pump pushes out contenders in dense slurry work

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Pumping for prosperity

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VALVES What is backflow and how must we protect against it? Festo at the heart of absolute automation thanks to its intuitive industry solutions

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Benefits of rubber check valves for processing harsh fluids

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Fugitive emissions addressing the challenge

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Additive manufacturing importance to valve manufacturers

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Standing the test of time

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WATER Wastewater treatment plant cuts energy use by 20% with a new biological treatment system

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Cut planned infrastructure budget by addressing billions of litres of wasted water

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PRODUCTS & SERVICES Polymers for more reliable seals in cryogenic conditions

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INDUSTRY NEWS Additive manufacturing make way for the future New Cloud-Based, Remote Performance Monitoring and Alert System for AODD Pumps

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BUYERS GUIDE

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On the cover LVSA Group (PTY) LTD +27 (0) 11 680 2005 sales@lvsa.co.za www.lvsagroup.co.za

Pumps & Valves Africa

Managing Editor: Surita Marx Tel: +27 (0) 87 153-1217 Cell: +27 (0) 83 281-5761 Email: info@pumpsandvalves.co.za Web: www.pumpsandvalves.co.za Sales: Elma Heuer Email: Elma@pumpsandvalves.co.za Production Manager: Xane Roestroff Email: adverts@pumpsandvalves.co.za

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Air & Vacuum Technologies 9 Bilfinger 15 Bray 23 Golf Day 42 Integrated Pump Rental 37 Integrated Pump Technology 41 KEW Foundries 29 LVSA Group OFC,OBC KSB IFC Pleix-Quip Africa CS Stelkon 33 Steloy Foundries 31 Stewarts & Lloyds 7 Totally Concrete IBC Ukuthela Foundry Projects 35 Vega Controls 13 Xylem 11

Disclaimer:

Opinions in this Publication are those of the authors and do not necessarily reflect those of this publication, its editorial board, its editor or its Publishers SAPMA or VAMCOSA The mention of specific products in articles and advertisements does not imply that they are endorsed or recommended by this Publication or its publishers in preference to others of a similar nature, which are not mentioned or advertised. Reliance on any information contained in this journal is at your own risk. While every effort is made to ensure the accuracy of editorial board makes no representations or warranties, express or implied, as to the correctness or suitability contained and/or the products advertised in this publication. The Publisher shall not be liable for any damages or loss, howsoever arising, incurred by readers of this publication or any other person/s. The Publisher disclaims all responsibility and liability for any damages, includes pure economic loss and any consequential damages, resulting from the use of services or products advertised in this publication. Readers of this publication indemnify and hold harmless the publisher, its officers, employees, and servants for any demand action, application or other proceedings made by any third party and arising out or in connection with the use of any services and/or products or the reliance on any information contained in this publication.

Pipes, Pumps and Valves Africa - May/Jun 2021

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COVER STORY

Local manufacturer gearing up for growth Becoming South Africa’s leading valve manufacturer, serving both the local and African requirements and meeting the local content policy set by the Department of Trade, Industry and Competition (the dtic) is a top priority for the LVSA Group. Pipes, Pumps and Valves Africa met up with CEO, Sagren Pillay, to talk about how the company is preparing itself for market expansion and growth. There is much to be said for local manufacturing especially with today’s global market demanding ever-shorter lead times. Customers want quality products delivered yesterday. Manufacturing locally in the current climate is by no means easy and is not an undertaking for the fainthearted. There is no denying, however, that local manufacturing is a fundamental driver of GDP growth and associated with direct employment for the youth. Much has been achieved by the LVSA Group that opted to start manufacturing a range of valves for the local market in 2019. “We have a background in manufacturing having birthed out of Thermal Valve Manufacturers (TVM), at the time one of

the country’s top valve manufacturers,” explains Pillay. An opportunity with well-known petrochemical companies, however, led to the development of a purely import and distribution company, the LVSA Group. “At the time it made sense to import products from overseas markets as it delivered quality valves at competitive prices. Our focus was on the petrochemical industry and we built up a range of clients in this sector.” Pillay, however, never lost sight of the potential or importance of manufacturing – a vision he was determined to fulfil. After many years of research and development on the manufacturing of valves for refineries, power, mining and water industries, they are proud to announce that the


Delivering quality products According to Pillay, South Africa needs a burgeoning manufacturing sector. “Government is leading the way with its Local Production and Content initiative, which flows from the government’s policy framework that includes the National Development Plan, the New Growth path, the Industrial Policy and Action Plan and the Preferential Public Procurement Finance Act, among others.” For Pillay, companies such as the LVSA Group must heed this call from the government and manufacture locally. Furthermore, if companies manufacture locally then business, government and state-owned enterprises can all procure these locally manufactured goods with obvious benefits for national competitiveness and economic growth. Pillay says were in the past South African manufacturing had to face serious challenges such as global competition, cheap imports, local costs and low productivity, it is no longer always the case. “To manufacture in South Africa has always carried a high cost due to the pricing of raw materials. For the longest time, it did not make sense for the LVSA Group to position itself as a manufacturer as multinational companies – and even the state-owned enterprises (SOEs) were not going to pay 200% more for a product just because it was made locally.” Pillays says there has been much change internationally in the valve manufacturing sector making it far more feasible for the group to open its manufacturing facility locally. “International foundries have been closing down due to ignition and environmental issues. Especially in China, this has been the case. This has impacted significantly on lead times and it can now take up to 32 weeks before a product is delivered locally from the international manufacturer.” Also, prices have been on the increase and the cheap imports were fast becoming not so cheap anymore. “In China, for example, many of the rebates that manufacturers were getting have been done away with and we are seeing the cost of imports increase by as much as 28%.” Having set themselves the goal of becoming 100% local much progress has been made over the past two and a half years. “For the past eight months we have not imported any products and our foundry is up and running delivering tailor-made solutions to our customers.” With the factory been built in Durban on 24000m2 land and 12000M2 under roof, offices and warehouses in Johannesburg and Cape Town as

well as an in Mozambique, the company is well placed to serve the local market. “We have worked hard to get the necessary quality systems and processes in place. Our first step was to engage with the foundry. Getting the quality and costing model for the foundry working was a priority as the price of products remains a critical element to success. This was a process and did take some time.” The next step was to ensure all the necessary approvals were in place including the SABS, ISO and API approvals. “We are in the process of getting our products certified by the South Africa Bureau of Standards (SABS) and the American Petroleum Institute (API). Our application to API has been accepted and we are hoping to have the approval by the end of August. Benefits to local manufacturing There are several benefits to local manufacturing, says Pillay. “First and foremost is the lead time as we can manufacture and deliver locally between eight to 12 weeks and the future will even be shorter. From a cost perspective, we are also far more competitive now with our prices. Reduced shipping costs,utlesting our local metals and manufacturing time are directly translating into less cost.” Furthermore, he says, the experts are available on location as opposed to engineers and other experts having to come from international shores to address problems or issues. “This means less downtime and far more fluid operations for our customers.” According to Pillay, there is also a benefit in that there is far more control over the supply chain than when importing valves. we now have control right from the foundry to the machining and assembly “We can expedite orders and deliver critical supplies far quicker than when purchasing internationally.” He says successful manufacturing is dependent on getting the pricing right, having the right mix of people on board and the necessary skills in place. “From a skills perspective, we have brought out a range of design engineers and production heads from India for five years to train our local youth and transfer the necessary skills. We have also developed a course on valve manufacturing and are awaiting Merseta approval on the course. Sectors being focused on are water and sanitation, power generation, refinery and the mining industry. “We also continue to focus on our current industries where we have a strong presence such as the petrochemical industries.” Pillay says there is no doubt that the value of local manufacturing is increasingly being realized. “The outbreak of Covid-19 has only highlighted the importance of having a strong local manufacturing capability. We calling on local industries to support the locally manufactured products manufactured in South Africa. We are very happy so far with the feedback we are getting from the local market who are keen on local products.”

LVSA Group (PTY) LTD, +27 (0) 11 680 2005, sales@lvsa.co.za, www.lvsagroup.co.za

COVER STORY

LVSA Group will be one of the first to 100% manufacture a range of valves in South Africa.


ALLU Transformer TS Drum improves profitability in pipeline applications by 80%

PIPES PIPES

The ALLU Transformer TS Drum Assembly is an effective tool for pipeline padding and backfilling applications. By allowing the material to be screened on-site and then backfilled directly into a trench, it eliminates the need for dedicated stationary screening or purchase of fine soil, saving time and money. ALLU D-Series attachments work with wheel loaders, excavators, skid steers or backhoes to screen, crush, pulverize, aerate, blend, mix, separate, feed and load materials all in one stage — increasing the profitability and efficiency of pipeline construction operations. The core of the ALLU TS Drum Assembly technology is the configuration of the screening blades that spin between the screening combs. The end product size is defined by the space between the combs, and different fragment sizes can be achieved simply by repositioning the combs. Because the screening combs carry most of the material weight, the drums and bearings experience less impact and load. The design of the assembly ensures the machine works well in wet and dry materials without any clogging.

A case study with one pipeline contractor recently realized 80 percent savings per cubic yard using an ALLU D-Series attachment with TS drum assembly — the ALLU DH 3-12 TS16 — on a standard excavator. In looking at several options, this contractor realized that traditional screening had a low productivity rate and large particle soil and stones could easily fall into the trench, whilst purchasing fine soil is also a high cost. The pipeline contractor opted for crushing and screening with ALLU DH3-12 TS16, which demonstrated a lower cost than the other options and an 80% saving per cubic yard. Also giving them total flexibility as its available with two different blade types: standard blades for screening applications and axe blades when a crushing or shredding effect is required. The TS assembly is available in seven different models for 17.6- to 49.6-ton (16- to a 45-metric ton) excavators and 7.7- to 33-ton (7- to a 30-metric ton) wheel loaders. ALLU Group, +27 (0) 81 556 4519, tebogo@egelquip.com, www.egelquip.com 6

Pipes, Pumps and Valves Africa - May/Jun 2021


Slurrysucker succeeds where old methods fail

PUMPS

Integrated Pump Rental’s innovative SlurrySucker desilting barge is successfully cleaning a large process dam for a coal mine in Mpumalanga, after past attempts by numerous contractors had failed. The dam – at a mine in the Delmas area – measures a substantial 300 metres by 100 metres in size, with a six-metre depth. It was unable to function effectively as it had become 90% filled with coal slurry from the processing plant. Ruaan Venter, rental development manager at Integrated Pump Rental, says the pond is also lined with a geomembrane to prevent the coal slurry from contaminating the groundwater. “Manual excavation methods had been tried by previous contractors, but these could not efficiently move the required volume of sediment,” says Venter. “In fact, some attempts made matters worse by damaging the environmentally important membrane under the pond. In addition, extensive reed growth in the dam also hampered the desilting efforts.” By contrast, the application of the SlurrySucker was able to meet the safety priorities of the mine while cost-effectively removing the slurry. Operating the barge remotely from a defined distance away from the dam’s edge is much safer than having personnel or equipment on the dam itself, he says. Operators also use a buddy system with a harness

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Pipes, Pumps and Valves Africa - May/Jun 2021

for added safety. Extensive training of operators was also required by the mine before work began. “We were able to float the SlurrySucker on those parts of the dam with sufficient water, while also employing hydromining on the drier areas,” he says. “This allowed our highsolids pumps to dredge quickly and cost effectively over the whole area of the dam.” Two monitoring guns, each fed by a 7-bar high-pressure discharge hose, are blasting the drier slurry towards the discharge point. Specialised pumps with chopper-impellers are employed, which can deal with the dislodged reeds without becoming clogged. After setting up on-site in December 2020, Integrated Pump Rental is expected to complete the slurry removal process by the second quarter of 2021, says Venter. Integrated Pump Rental, +27 (0) 11 894 2906, admin@pumprental.co.za, www.pumprental.co.za


SKF pumps up the volume in lubrication management Robust pump from SKF delivers grease to large automatic lubrication systems, for demanding applications such as excavators, loaders and other heavy machinery. SKF has developed a hydraulic barrel pump for large automatic lubrication systems, which helps reduce the risk of machinery failure.

PUMPS

The BPH30 pump is available with or without sensors and can be configured to individual needs. It is aimed at large automatic lubrication systems such as single-line, progressive or dual-line – as well as filling processes. Target applications include excavators, loaders, haul trucks and other heavy machinery used in the construction and mining industries. “This pump is designed to work reliably under demanding conditions,” says Daniel Seitz, Product Manager at SKF. “The pump head is fully encased, which reduces the risk of damage during tough operations.” The BPH30 is constructed from heavy-duty materials, making it very robust. It also has a compact design, allowing it to be mounted in tight spaces. It has an operating temperature range from -40°C to +80°C and accepts greases up to NLGI 2. The pump has a single outlet, which can be positioned on the left, right or front of the device. A special three-seal design helps to prevent leakage of both hydraulic oil and lubrication grease. This maintains safe and reliable operations while minimizing the risk of contamination. A leakage indicator provides clear visual confirmation that the sealing system is working. Built-in sensors monitor oil pressure, temperature and piston movement, which helps to avoid sudden machine failure. At the same time, flow rate and reverse pressure can be adjusted according to the needs of the application. The BPH30 is available to OEMs, end-users and dealerships. It will initially be launched in EMEA, with other regions to follow.

Authorized Distributor of

SKF Group, +27 (0) 11 821 3500, samantha.joubert@skf.com, www.skf.com

Sole ARO® distributor for Mpumalanga and Limpopo provinces. ARO® is an Ingersoll Rand brand, specialising in air operated diaphragm pumps, air driven centrifugal pumps & air operated piston pumps for pumping, moving or transferring liquids, powders and greases. Commonly used in mining dewatering applications, chemical, food and beverage industries.

SALES, SPARES AND REPAIRS

instrupump2@vactech.co.za 082 575 6339 www.vactech.co.za

Pipes, Pumps and Valves Africa - May/Jun 2021

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Abrasive solids handling made simple with the new Warman submersible pump

PUMPS

The new, high chrome Warman® SSB-A submersible pump from Weir Minerals presents a versatile pump and robust solution for slurry and sludge removal. “Conceptualised and commercialised by Weir Minerals Africa, the Warman® SSB-A pump is well suited for duty in Africa,” says Marnus Koorts, Product Manager - Pumps at Weir Minerals Africa. Engineered for abrasive applications and for handling solid particles, the pump’s applications include mine dewatering, removing mill scale and cleaning up sumps as well as moving slurry, coal-pile run-off or dirty water with a solids content of up to 60% by volume. Koorts highlights that the pump can be moved easily between applications, so is ideal for dealing with temporary problems such as pipe bursts or leakage. The hard-wearing design includes casting the casing, impeller and wear plates from Weir Minerals’ Ultrachrome® A05 high-chrome alloy, while the motor is designed for continuous and efficient operation though using the pumped media to assist in dissipating heat buildup in the motor windings. “This durability enhances the range of applications in which the pump can be deployed, including even hardened slurry,” he says. “Customers will move the unit around extensively to wherever it is needed, so we designed the outer housing to avoid snagging by ensuring there are no

points that could potentially hook or break as the pump is transported and operated.” The impeller radial load is balanced out by the opposing forces created by the twin-volute discharge. This stabilises the pump during operation, allowing it to be placed in any position without the risk of oscillating, he says. The design also optimises the life of the cantilevered shaft and its components. “Users of the Warman SSB pump can also choose to run it in manual or the optional extra, in automatic mode,” Koorts says. “The automatic mode provides the convenience of self-monitoring water levels, switching on and off as required.” Electrical control philosophies can be adapted to suit site applications, such as over-current protection, an earth leakage circuit breaker, while the safety delay feature can reduce the number of starts per hour. “The robust, fit-for-purpose design makes this pump a reliable and cost effective solution in a wide range of duties,” says Koorts. “It represents the ideal combination of wear resistant materials and specialist hydraulic engineering.” Weir Minerals Africa, +27 (0) 11 929 2600, Africa.minerals@mail.weir, www.minerals.weir

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The new SCUBA compact close-coupled submersible pump from Xylem brings a new level of reliability and flexibility to primary water supply options for wells, tanks or reservoirs, sprinkler irrigation systems, and pressure boosting. SCUBA quiet, compact multistage pumps are high performance and corrosion resistant, and designed to help people solve mainly domestic, light commercial and agricultural water challenges


Bravo pump pushes out contenders in dense slurry work

Competitors are feeling the heat from the hard-working Grindex Bravo 600 submersible slurry pump, which has replaced under-performing products at two mine sites in Limpopo and North West provinces recently.

PUMPS

The attraction, according to Jordan Marsh, sales manager at Integrated Pump Technology, has been the Grindex Bravo 600’s reliability and efficiency. This is due largely to its innovative cooling jacket between the outer casing and the motor. “Mines have a frequent requirement for a hard-working pump to transfer slurry from process tanks, where levels change quickly and the material often becomes quite viscous,” says Marsh. “In these dry-bed applications, many pumps struggle with the density or even burn out when no longer submerged.” The Grindex Bravo 600, though, has proven ideal for these applications, being supplied in South Africa as standard with a glycol-filled cooling jacket to keep its temperature down. This allows it to function reliably even when exposed above the slurry level. “Plant operators are not always able to be present to check the levels in these tanks, or to add water to dilute slurry, so the specific gravity of the material can rise considerably,” he says. “This is where the Grindex Bravo 600’s agitator comes into its own, agitating the solids into suspension for easier removal. It even handles particle sizes up to 40 mm.”

To demonstrate the pump’s performance under these arduous conditions, Integrated Pump Rental offers mines a trial unit to run over an extended period. These tests are now resulting in purchases, says Marsh, after the customer is satisfied that the pump delivers. Both the impeller and casing are manufactured from hard iron, making for a robust product with long working life. “This 22 kW pump also punches above its weight in terms of output, achieving the same performance as our competitors’ 30 kW pumps,” he says. “This makes the solution energy efficient, saving mines on electricity costs.” Integrated Pump Technology has been distributing Grindex pumps in sub-Saharan Africa since 2014. So confident is the company about these advanced workhorse pumps, that the company offers a 30-month warranty on the units. Its well-equipped engineering facility in Jet Park undertakes maintenance and repairs to OEM standards. Integrated Pump Technology , +27 (0) 11 894 2906, info@pumptechnology.co.za, www.pump-technology.com 12

Pipes, Pumps and Valves Africa - May/Jun 2021


RADAR IS THE BETTER

ULTRASONIC 80 GHz level sensor with fixed cable connection (IP68)

R8 760.00 VEGAPULS C 11

All advantages of the radar technology:

www.vega.com/vegapuls


Pumping for prosperity

PUMPS

The demand for food is expected to grow substantially by 2050. A major factor for this increase is world population growth. With agriculture under pressure to increase output, pumps are increasingly being recognized as the mainstay of the sector. Few people would visualize a pump when asked to think about agriculture. Yet, pump systems play an integral role in farming operations – especially on large commercial smallholdings. To increase productivity and remain competitive in the market, farmers are moving away from the humble water pump and increasingly wanting complex, bespoke systems that meet their direct needs. According to agricultural economist Wandile Sihlobo, the agricultural sector offers a major opportunity for African countries to slingshot their economies out of the doldrums. But, he warns, agriculture is changing rapidly and relying on the ways of the past will no longer suffice. He says African governments need a fresh look at agriculture that involves embracing technology. Grundfos product manager Stephen Venter says highefficiency pumping solutions are part of this new approach. “Modern farming requires technology that can free the farmer from physically checking the equipment in the field which is time-consuming and inefficient in terms of additional costs, fuel wasted on driving to and around the fields not to mention labour and other costs.” Easy-to-use and fully integrated pumping systems are allowing farmers to make groundbreaking changes that not only saves time and money but also ensures energy

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optimization and better use of water resources. Globally about 1% of mega farmers produce between 20 to 40% of the output. These operations are run by professional management teams that are completely focused on productivity gains. High investments are typically made in technology and efficiency measures. In South Africa, about 250 farms of this nature are under irrigation, but at least 2000 farms are part of the 9% of farmers that generate some 50% of the overall value. This category also pursues efficiency. Another 18 000 farmers, however, are in the small farming category. “Many of these farmers just rely on a local ‘pump guy’ who in turn buys from traditional distributors. The approach is usually quite conservative.” In the emerging farmer sector, there are millions of farmers that have no resources and are struggling to make ends meet. What this highlights, says Venter, is the major opportunity to transform farming operations with well-designed, highly efficient and cost-effective pump solutions. Selecting a pump At Grundfos, much emphasis is placed on making the right pump decision from the get-go. The OEM has a long history in the agricultural sector considering that the very first


Today, it boasts a range of products including submersible pumps, vertical turbine pumps, end suction pumps, horizontal split-case pumps, smart and digital dosing pumps, multi-stage in-line pumps, variable frequency drives (VFD), chemical feed as well as pressure boosting pumps. According to Venter, the company provides pumps for groundwater and surface water systems. “Groundwater serves primarily as a backup for surface water for cost reasons. It is much more expensive to use groundwater as it has to be pumped from deep aquifers. Increased pumping demand can cause aquifers to drop and ultimately run dry.” Despite this, the increasing trend is towards groundwater usage and wells are getting deeper and deeper. Venter says when selecting a pump the pump must match the irrigation system, that flow pressure is kept low and that proper controls are used. In its Irrigation Pump Handbook, Grundfos experts explain that different types of irrigation techniques place varied demands on how water is pumped from a source and distributed across a farm. Ultimately the goal is to supply an entire field uniformly using as little energy as possible. “Flow and pressure are important for any sprinkler system to get high uniformity,” says Venter. “To distribute an equal amount of water over the entire surface is vital for efficient use of water. A uniformity of 100% means that all the crops get the same amount of water. Water pressure, water flow and sprinkler spacing are required for proper irrigation uniformity. Two out of three of these parameters are pump

Bilfinger Intervalve Africa (Pty) Ltd. is one of the enterprises in Bilfinger Power Africa (Pty) Ltd., the South African subsidiary of German based Bilfinger SE. For years, we have been adding value to the power, mining, paper pulping and broader industry through comprehensive valve supply, valve maintenance and heat treatment solutions. www.intervalve.bilfinger.com

related.” He says VFDs on pumps save energy everywhere there is a need for variable flow and or pressure. “With more than one zone, where these zones have to be on and off at different time slots, the pumping need is varied. One pump with a VFD, for example, would be able to supply all three zones and still maintain a high pumping efficiency.” Other consideration Typically in the agricultural sector pumps for irrigation have been oversized. According to Venter, having the correct sized pump is crucial to the success of any irrigation system. The water source should also be considered not just from a depth point of view, but also the distance to fields are considerations. Furthermore, the performance of pumps must be regulated to ensure they are functioning at optimal pump design points. With a wide variety of products, available farmers are advised to call in a pumping expert to ensure that all the elements of the irrigation pumping system are aligned and integrated. Adding monitoring and control to the system only delivers further efficiency.

PUMPS

lve

pump it ever created was a water pump.

According to Grundfos operating costs are generally lowered if the pump matches the irrigation system, if pressure is not higher than necessary and controls are used. It also ensures better irrigation that in turn delivers improved crop results which bode well for the success of any farmer. Grundfos South Africa (PTY) Ltd, +27 (0) 10 248 6000, info_za@grundfos.com, www.grundfos.com

WE MAKE VALVE SUPPLY WORK

7823 Bilfinger Intervalve - Pipes, Pumps & Valves Africa advert 130(h) x 180mm(w) Valves - Pr1.indd 1

2021/02/17 4:10 PM

Pipes, Pumps and Valves Africa - May/Jun 2021

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What is backflow and how must we protect against it?

VALVES

The movement of any substance in any direction is called flow. So why the term backflow when water moves from an installation towards the municipal potable supply? Firstly, it is assumed that the water in any installation originates from the municipal supply and so the water that flows back towards there is viewed as flowing back and thus called “Backflow”. In most instances this would be the case, so why would we need to guard against it? What has happened to the water that makes it unsafe to return it from where it comes from? Firstly, we need to take cognisance of the fact that once the water passes past the water meter it now becomes the responsibility of the homeowner and the municipality no longer has control over what happens to it. Once they have lost control over what happens to the water, they do not want to let it back into the municipal system. We could let the water back into the municipal system if we had it tested and certified as SANS 241 quality compliant, but we know that that is not practical. What do we do to the water that could be viewed as contaminating it? • We often have water softeners on the supply to the home and this is done by adding chemicals to the water. • The water is often heated in an aged Hot Water Cylinder that will add limescale to the potable water in a backflow situation. • When summer comes and we are filling the pool and fishponds with a hose this could also be a cause of contamination.

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So, if we look at it from their view the probability of getting contaminants from domestic installations is very high and we have not even ventured into the water from alternative sources such as boreholes and rainwater harvesting. Thus, it is no wonder that SANS10252/1 of 2018 says in D.1.1 Design, installation and maintenance. All water supply systems shall be designed, installed, and maintained to prevent contaminants from being introduced into the potable water supply system. The big question now is not the quality of our water but how to prevent backflow from happening. The regulations are very clear on what is expected from us and how to achieve zero backflows from entering the potable system. In terms of the National Regulations, SANS10252 -1 (water supply installations for buildings) refer to 7.4 of SANS 10252-1 ‘Preservation of Water and Water Quality. Reduced Pressure Zone Back Flow Preventers must be installed in any installation where there is a risk of contaminated water or harmful substances being back syphoned or flowing back into a potable water supply line. The regulations state that Back-flow Preventers shall be installed in certain types of installations and buildings, for example:


VALVES

Medical treatment of people and animals, pharmaceutical or chemical research and manufacturing, dairies, nurseries, stadiums, abattoirs, combined fire systems etc. Most of the municipal bylaws underpin this by stating that it is the responsibility of the Homeowner (Not the tenant) to have this maintained once a year. A record must be kept of when this maintenance was done and by whom. The unit must be overhauled or replaced every five years and a record of this must also be kept. A national regulation requires that any Backflow Preventer discharges where it is visible so that any malfunction of the system can be readily detected and attended to. This means that we cannot hide this valve somewhere in a duct or a manhole, it must be above ground level where the discharge is visible. If theft is a factor the valve may be closed with a surround, but the discharge must still be where it is visible. Below is a drawing of a typical installation. How does the valve work? There is a mechanical check valve at the inlet and outlet of the valve. In the middle, there is an area (Zone) that is open to the atmosphere.

As soon as water pressure enters the valve a diaphragm is pushed down, and the relief port is closed. Once this area is now filled with water the second check valve is opened and the downstream plumbing system can be filled with water. If for any reason the upstream pressure drops below the downstream pressure, the check valves will close, and the Reduced Pressure Zone will open to discharge any water in that area. If any of the check valves are faulty and are causing water to enter the Operating Chamber, a discharge of water will be visible from the Discharge Port to alert any passers-by of the system failure. It would be prudent to have a contact number near the valve so that anybody could contact the responsible person for this. A full range of spares is available from the manufacturer. Contact your local valve supplier for availability. CALAFRICA, +27 (0) 11 795 1519, technical@calafrica.co.za, www.calafrica.co.za Pipes, Pumps and Valves Africa - May/Jun 2021

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VALVES

Festo at the heart of absolute automation thanks to its intuitive industry solutions Festo is renowned as one of the leading pneumatic automation suppliers. Over the years, they have also set the pace in both Process and Electric Automation. This is backed by their proven record of reliability and product performance in these industries. Their ability to provide complete solutions has placed Festo at the heart of absolute automation as very few companies can provide solutions for all three technologies without requiring third-party components. ‘The Heart of absolute automation’ is also the theme for their new 2021 campaign! Tying into this theme, their Process Automation solutions are regarded as the veins that help keep the heart beating. In anatomy, the veins are the channels that provide blood to the heart. This is the same in Festo real-life applications. With their process valves and configurator tools, they give their customer’s production a seamless and unstoppable media flow. Continuing with this analogy, the global company‘s Electric Automation solutions are the conduction system that provides seamless connectivity from the brain to the heart. In industry, their seamless connectivity solutions aim to reduce the complexity of automation tasks from the workpiece to the cloud, making different interfaces simple and easy to handle. Russell Schwulst, the Head of Process Automation and Marcus Gericke, Head of Electric Automation, delve more into the unique Festo offerings in these industries.

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Pipes, Pumps and Valves Africa - May/Jun 2021

Process Automation technology for basic and sophisticated tasks Festo offers a complete range of Process Automation products extending from a mechanical process valve to pneumatic, electric, and hybrid solutions. Their diverse product range and services include Linear Actuator DFPI, Quarter-turn Actuator DFPD, Angle Seat Valve VZXA, KVZA butterfly assembly just to name a few! “With our diverse product range and our modular automation concept, Festo provides solutions for basic and sophisticated tasks. We can integrate our products as a complete solution and seamlessly tie them into your existing process, “ said the Head of Process Automation at Festo South Africa, Russell Schwulst. He also added that their Customised Solutions department can assemble, test and commission butterfly valve assemblies locally to save their customers time. They can also manufacture state-of-the-art panels that comprise PLCs, HMIs, drives and all peripherals in-house. Their team of local Process Automation experts combined with their engineering tools, years of expertise and international support allows them to provide their customers with the highest level of efficiency. They help designers specify the best solution for applications. Their


VALVES

passion for automation, industry and service excellence inspires them to provide customers with world-leading service. They take great pride in solving Process Automation challenges and providing customers with tailor-made solutions. Connectivity with Electric Automation technology “When we developed our automation platform, priority was placed on seamless connectivity from the outset. The mechanical system, drive system with motor and controllers, as well as software modules were designed as one unit“, said Head of Electric Automation at Festo South Africa, Marcus Gericke, as he elaborates on their Electric Automation offering. This applied to the mechanical, electrical and intelligent interfaces. Furthermore, compatibility with the many thirdparty controller manufacturers was also key, he added.

For example, the latest generation of Servo Drives CMMT and Servo Motors EMMT from Festo, together with the intuitive commissioning software Festo Automation Suite, makes integration easier and speeds it up significantly. These components can be integrated seamlessly into all commonly available ethernet-based external controllers, and users will not notice that the hardware manufacturers are different. A seamless communication chain is established from the simple sensor or IO link device, PLC, to the cloud. With the new Remote IO system from Festo, the CPXAP-I connectivity extends directly to the valve terminals, bringing all the diagnostic advantages. This opens end-users and OEMs to advantages such as preventative maintenance and faster fault finding to name a few. Festo seamless connectivity from the workpiece to the cloud offers solutions to many of the challenges faced by today’s machine builders. Reducing the complexity of the automation task enables faster, more reliable build times, reduced work-in-progress, and lower costs. Reliable partner for technical training Festo understands that to become competitive; system users and commissioners need to be adequately trained. As leaders in technical training, Festo also offers CPD accredited webinars such as Electro-pneumatic and Introduction to PLC. They further provide face-to-face training courses such as Process valves and actuation technology to equip the machine users with skills to excel in the industry. Interested customers can visit www.festo.co.za/didactic. The company is a one-stop automation partner for an array of products, training and engineering tools. Festo, +27 (0) 86 003 3786, sales.za@festo.com, www.festo.co.za Pipes, Pumps and Valves Africa - May/Jun 2021

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Benefits of rubber check valves for processing harsh fluids

VALVES

Learn how this material choice can help municipalities prepare for extreme weather and other challenging conditions. According to the Center for Climate and Energy Solutions (C2ES), tropical storms have become more common in North America since around 2000. Frequency and intensity vary from basin to basin. In the North Atlantic Basin, the long-term (1966-2009) average number of tropical storms was about 11 annually, with about six becoming hurricanes. More recently (2000-2014), the average is over 15 tropical storms per year, including about seven hurricanes. This increase in frequency is correlated with the rise in North Atlantic sea surface temperatures, which could be partially related to global warming. Hurricanes and Climate Change Natural disasters remind us of the unpredictability we all face daily—but on a grander scale. Weather events especially can cause large amounts of damage with little warning and in extremely short periods. But their reach isn't over when the storm passes. Lots of property damage and even health and safety threats continue in the hours, days and weeks after natural disasters. This is true whether it's a hurricane, a tornado, a flood, or another dangerous storm system. The best way to minimize this damage is to prepare ahead of time. For most individuals and municipalities, it's not a question of if—but when—systems will be tested by a storm. It's everyone's responsibility to prepare for these storms. For municipalities and other local governments, this means making sure infrastructure is up to date and designed to handle extreme conditions. A failure of stormwater or wastewater systems during a hurricane can take a problem from bad to worse. In a natural disaster, stormwater drainage system components can struggle to keep up with demand. Ideally, the system would continue to drain the influx of water. But even if the system can’t work fast enough, preventing backflow is essential. The Dangers of BackflowBackflow is a condition in which the fluid in a system moves backwards—flowing

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Pipes, Pumps and Valves Africa - May/Jun 2021

back toward the source. Of course, backflow means the system isn't operating as designed. It's never a word that operators want to hear. But backflow is most dangerous in applications that involve harsh chemicals, sewage or other hazardous fluids. Having these fluids move in a way that the system wasn’t designed to accommodate can lead to all kinds of issues. For example, stormwater that’s mixed with other system fluids could end up coming back out of storm drains and into the street. Backflow in these situations can contribute to flooding, standing water and contaminated water exposure for citizens in residential areas. Stormwater management isn’t the only application in which backflow is a dangerous condition. For example, some systems are at risk of causing land erosion if a system failure leads to backflow. Or when dealing with other infrastructure systems, saltwater could end up in a freshwater pond. All of these risks demonstrate why preventing backflow should be a priority during system design. The Importance of Check Valves The check valve is a crucial system component for preventing backflow. Check valves help a system maintain one-way flow. They open based on the pressure of the fluid flowing through the system, then close to prevent the fluid from flowing back toward the system inlet. Check valves are often overlooked because some system designers believe these nonmechanical, fully passive devices are simple, and when the best check valve is installed in a particular application or system, their dependable operation can make them seem simple. These very low- to no-maintenance, long-lasting devices


quietly do their job. Once they’re installed, they can fade into the background and do their part to keep a system running for years. But an improperly selected check valve can be a major headache. A design that’s mismatched for the application can lead to the valve being stuck in an open position. A material that doesn’t work well with the system fluid can lead to rust or corrosion, requiring frequent maintenance or replacement. And some selection errors can even lead to loud and dangerous water hammer, putting other system components at risk.

Using rubber check valves helps avoid a variety of common issues with check valves of the past. Metal check valves seem like they would be durable and long-lasting, and they often are. But depending on the fluid, metal materials can have a lot of vulnerabilities as well. For example, a saltwater that finds its way into a local stormwater or wastewater system can be highly corrosive to metal components. More common fluids like raw sewage can be too corrosive for many metals. Using rubber check valves helps avoid a variety of common issues with check valves of the past. Metal check valves seem like they would be durable and long-lasting, and they often are. But depending on the fluid, metal materials can have a lot of vulnerabilities as well. For example, a saltwater that finds its way into a local stormwater or wastewater system can be highly corrosive to metal components. More common fluids like raw sewage can be too corrosive for many metals. In both of these situations, rubber check valves offer a great solution. The advanced elastomers that makeup Proco’s rubber check valves are specifically designed to work in these applications. They allow users to design a system to prevent backflow without the maintenance headaches of other check valves. Rubber check valves can withstand harsh, erosive fluids without rusting or deteriorating. For example, the elastomers used in the Series 700 ProFlex™ Rubber Check Valves from Proco Products, Inc., are designed for these applications. Advantages Rubber check valves can withstand harsh, erosive fluids without rusting or deteriorating. For example, the elastomers used in the Series 700 ProFlex™ Rubber Check Valves from Proco Products, Inc., are designed for these applications. Special Circumstances for Rubber Check Valves Operators can consult with an expert at Proco Products, Inc., on how to choose the correct check valve for their system. These valves are designed to be long-lasting and require no maintenance, automation or manual assistance to operate. They’re often installed in hard to access locations—underwater where only divers can access them, for instance. In those situations, it’s important to get the

right valve in place from the start. If the valve will be installed in a submerged condition, it's critical to choose a check valve that's designed for that situation. Rubber is often a great choice for these conditions since it's resistant to many types of wear. The valve can stay installed and continuously operate without requiring expensive, inconvenient maintenance or assistance.

VALVES

Rubber Check Valve Advantages Choosing construction material is one important part of the check valve selection process. Opting for a rubber or elastomer material can offer some major advantages for modern applications.

Rubber check valves are also a great choice when dealing with a very high flow application. The elastomer often absorbs energy from the fluid much better than a metal check valve would. This can lead to quieter operation, which is critical if it’s being installed in a residential area. In any system, maintenance is a major consideration for every single component. When a user chooses an elastomer check valve, maintenance can be left off the checklist. There’s nothing to lubricate and no need to perform any regular or preventative maintenance. The valves operate continuously without intervention. Another condition that might indicate a rubber check valve would be a system handling fluids at a very high or low temperature. The specialized elastomers used in Proco’s check valves can handle fluids ranging from -65 F to 400 F. This low maintenance component offers great peace of mind when users are designing or operating a system for a tough thermal application. Conclusion When reliability is the goal, check valves are excellent tools for system designers and operators. Keeping fluid moving in the correct direction, even when a water management system is outside of ideal conditions, can prevent some of the most dangerous effects of major storms. Rubber check valves, when selected and installed properly, make important contributions toward system reliability— even when extreme weather puts systems to the test. https://www.procoproducts.com/benefits-of-rubber-checkvalves-for-processing-harsh-fluids/ Proco, sales@procoproducts.com, www.procoproducts.com Pipes, Pumps and Valves Africa - May/Jun 2021

21


Fugitive emissions addressing the challenge

VALVES

An estimated R27,5 billion ($2 billion) of natural gas is lost to leaks each year. From an environmental perspective, this is worrying considering that raw methane is 28 times more potent as a greenhouse gas than CO2 . Around the world, experts agree that if natural gas is to rival coal as a means of reducing greenhouse gas emissions, then raw methane emissions must be held to less than one percent of total production. Pipes, Pumps and Valves Africa finds out more. James Simpson of Trelleborg Sealing Solutions in Italy says fugitive emissions are a growing concern for the valve industry. "The global control valve market is expected to be worth around R143 billion ($10,4 billion) by 2025 with the volume of control valves set to reach around 13 734 thousand units by that time. The market is driven by energy production activities,” he explains. “Demand is centred around exhaustive applications throughout upstream, midstream and downstream gas production activities. Within downstream sectors such as refineries and chemical process plants, control of leakage

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Pipes, Pumps and Valves Africa - May/Jun 2021

has to be tightly controlled.” In the USA alone an estimated 300 000 tons of emissions are released from chemical plants each year. Valves, says Simpson, account for 60% of fugitive emissions. “Environmental legislation and sustainability policies are driving requirement to reduce emissions. While downstream valves are key drivers, the upstream sector has demand for secure gas systems at pressures above 69Mpa. What are fugitive emissions? Defined as the emission of gases or vapours from pressurized equipment due to leaks and other unintended or irregular releases of gases, mostly from industrial activities, valves, flanges gaskets and other fittings are increasingly being tested for fugitive emissions by trained test engineers.


recognized international standards. They can also be redesigned to any given customer’s specifications to ensure application suitability. “At least 80% of all valve leakage is from the stem. Test standards are therefore focusing in this area in particular.” According to Simpson, due to the large number of potential leak sources detecting valve leaks and repairing them are not always easy. From a cost perspective alone the impact of these leaks is severe while the environmental damage is extensive. Fugitive emissions also pose a real risk to workers and local communities proximity of industrial facilities.

Simpson says the industry is working hard to come up with solutions. Typical solutions include engineered packing sets typically using PTFE or elastomer sealing rings.

VALVES

It is therefore essential that valve manufacturers and suppliers realise the dangers around fugitive emission and take extra measures to ensure their valves have secured stem seals to prevent them from leaking hazardous gas or vapour into the environment.

“Anti-extrusion elements from high modulus thermoplastic or metal is another option. Rings squeezed into a gland or ‘preset” using spring energized seals is also used.” Simpson says some manufacturers are opting to use multiple barriers to achieve low interface leakage – a move that was proving to be very successful.

These components, says Simpsons, can be tested at different temperatures with helium or methane test gas using the sniffing or vacuum method according to

“It has been found that greater leak-tightness can lead to increased wear and lower endurance levels so that needs to be kept in mind. All in all, there does, however, need to be further information to clarify what industry needs are.” He said improved collaboration between the industry and valve manufacturers was critical going forward to ensure that exact needs around fugitive emission were met.

HIGH PERFORMANCE

FLOW CONTROL SOLUTIONS Bray offers a complete portfolio of flow control solutions to handle your most challenging applications. Learn more at BRAY.COM

Bray Controls Africa (Pty) Ltd Unit 11, ABC Business Park Mastiff Rd, Linbro Business Park Sandton 2090, South Africa Telephone: +27 10 007 3222 Territory Sales Manager Jan Hattingh +27 76 276 2062 jan.hattingh@bray.com

Pipes, Pumps and Valves Africa - May/Jun 2021

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e g n a R e l f a o s r d En s fo m e t I Gate Valves: 15 mm Bonney Forge A105 800# RS BB OS&Y c/w weldon ASME B16.5 150# R/F Flanges - 6 in stock

40 mm Bonney Forge A105 800# NRS BB OS&Y c/w weldneck ASME B16.5 150# R/F Flanges - 1 in stock

50 mm SV SS316 RS BB OS&Y ASME B16.5 150# R/F Flanges 1 in stock

15 mm PQ CF8MSS RS BB OS&Y ASME B16.5 300# R/F Flanges 4 in stock

R400.00

R700.00

R800.00

R900.00

200 mm WCB RS BB OS&Y ASME B16.5 300 Flanged and Drilled to suit SANS 1123/2500 Flanges 1 in stock - R10 000.00

150 mm CF8MSS RS BB OS&Y ASME B16.5 600# R/F Flanges 1 in stock

20 mm Gate Valve Crane A105 800# RS BB OS&Y c/w weldon ASME B16.5 150# R/F Flanges 44 in stock

50 mm CF8MSS RS BB OS&Y ASME B16.5 300# R/F Flanges 7 in stock R2 000.00

R4 850.00

OTHER

R300.00

Miscelaneous Valves OTHER

40 mm Gate Valves Smith F11 + CR13 Trim 800# BB OS&Y Socket Weld Ends - 1 in stock

40 mm Tank Bottom Ball Valve CF8M Floating Ball Flanged - 1 in stock

40 mm Bottom Ball Valves CF8M Floating Ball Flanged - 1 in stock

100 mm AZ Plug Valve CF8M Flanged Class 600 - 2 in stock

R600.00

R500.00

R500.00

R7 500.00

Globe Valves 40 mm “LM BRAND” WCB RS BB OS&Y ASME B16.5 150# R/F Flanges 6 in stock

100 mm PQ WCB RS BB OS&Y PN16 Flanges - 1 in stock

R700.00

R3 673.00

40 mm PQ CK20 RS BB OS&Y ASME B16.5 150# R/F Flanges 1 in stock

OTHER

25 mm PQ CF8MSS RS BB OS&Y ASME B16.5 300# R/F Flanges 3 in stock

80 mm PQ CF8MSS RS BB OS&Y ASME B16.5 300# R/F Flanges 2 in stock R8 000.00

OTHER

R5 000.00

40 mm Bonney Forge A105 800# RS BB OS&Y c/w weldon ASME B16.5 150# R/F Flanges - 1 in stock

R1 000.00

R700.00

20 mm Hisaka CF8M 2-Piece Floating Ball ASME B16.5 150# R/F Flanges 4 in stock

80 mm PQ 904L 2-Piece Floating Ball ASME B16.5 150# R/F Flanges - 2 in stock

PQ Cast Iron 2-Piece Floating Ball PN10 Flanges

R900.00

R6 500.00

R9 800.00

25 mm PQ CF8MSS RS BB OS&Y ASME B16.5 600# R/F Flanges

Ball Valves

25 mm - CF8M 3-Way L-Port BSPT Screwed R200.00 40 mm - CF8M 3-Way L-Port BSPT Screwed R250.00

R1 800.00

25 mm PQ CF8M Wafer Sampling Ball ASME B16.5 150# R/F Flanges - 1 in stock

80 mm PQ CF8M Wafer Ball ASME B16.5 150# R/F Flanges 1 in stock

R1 000.00

R1 000.00

T: +27 (0) 11 736 4994

50 mm PQ WCB 2-Piece Floating Ball ASME B16.5 600# R/F Flanges - 1 in stock R4 000.00

C: +27 (0) 83 461 0801


Check Valves 25 mm PQ CF8M SS ASME B16.5 600# R/F Flanges 3 in stock

50 mm Crane Cast Iron PN16 R/F Flanges 2 in stock

25 mm Saunders Diaphragm Check Valve Cast Iron Flanged 150# - 2 in stock

R1 500.00

R1 000.00

R250.00

Various Sizes PQ Cast Iron / Aluminium Bronze / EPDM

50 mm “VALPRO” A105 800psi Forged Steel S/W 1 in stock

80 mm Heaton WCB + 13Cr ASME B16.5 150# R/F Flanges 2 in stock

40 mm PQ CF8M SS ASME B16.5 300# R/F Flanges 1 in stock

R500.00 - R2 100.00

R1 400.00

R2 800.00

R1 500.00

50 mm CF8M SS Screwed End Swing Check 1 in stock R200.00

25 mm PQ CF8M SS ASME B16.5 600# R/F Flanges 4 in stock R1 500.00

Chemline Valves Ball Valves WCB+PTFE+PFA ASME B16.5 150# R/F Flanges - 25mm, 40mm & 100mm

Plug Valves WCB+PTFE+PFA ASME B16.5 150# R/F Flanges Various sizes

Ball Check Valves WCB+PTFE+PFA ASME B16.5 150# R/F Flanges Various sizes

R1 900.00 & R6 500.00

R950.00 R2 200.00

R800.00 R4 750.00

Butterfly Valves WCB+PTFE+PFA to suit ASME B16.5 150# R/F Flanges Various sizes

Butterfly Valves 150 mm WCB+PTFE+PFA to suit ASME B16.5 150# R/F Flanges 1 in stock

Butterfly Valves 300 mm WCB+PTFE+PFA to suit ASME B16.5 150# R/F Flanges 5 in stock

R7 100.00

R12 800.00

R1 700.00 R7 100.00

Wafer Check Valve 25mm - WCB+PTFE+PFA to suit ASME B16.5 150# R/F Flanges 4 in stock R300.00

Polypropylene & PVDF Valves 40 mm Asahi PVDF Ball valve 1 in stock

15 mm SafeBlock Polypropylene Ball valve R250.00

R250.00

Type 21 PVC Ball Valve R250

80 mm Polypropylene Ball Check valve Screwed 5 in stock

25 mm Polypropylene Diaphragm valve 2 in stock

25 mm - Socketweld Polypropylene Diaphragm valve 17 in stock

R500.00

R500.00

R500.00

50 mm Polypropylene Diaphragm valve 4 in stock

15 mm PVDF Diaphragm valve - 1 in stock

80 mm Asahi PVC Ball valve & Safeblock PP Ball Valves R500.00

R500.00

OTHER

20 mm +GF+ Type 346 Ball Valve R300.00

OTHER

80 mm SafeBlock Polypropylene Ball valve R500.00

R500.00

Please check stock with us before ordering. Prices quoted Excl. VAT, Ex works - Brakpan Subject to prior sale

E: tiaans@pleixquip.co.za

www.pleixquip.co.za


Additive manufacturing importance to valve manufacturers VALVES

Additive manufacturing brings some very real advantages to the process of valve making, says Holger Ekhholz of Samson in Germany. He advises manufacturers to keep a close on developments making sure they are on top of this fast-evolving industry. Pipes, Pumps and Valves Africa finds out more. Dealing with additive manufacturing (AM) means having a very clear understanding of what it means and that it does not describe a specific manufacturing process, says Eckholz. “Rather, the expression describes processes that produce components from a 3-D model data by joining material, as opposed to subtractive and forming manufacturing methods, usually layer by layer. There are many different additive manufacturing processes.” And each user, he says, must weigh up which processes he/ she considers most suitable for their products and future applications. Dealing with the topic of additive manufacturing According to Eckholz, many questions need to be clarified before embarking on a process of additive manufacturing.

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Pipes, Pumps and Valves Africa - May/Jun 2021

This includes: • Which AM processes are available? • What are the advantages and disadvantages of the different AM processes? • Which of these processes are considered to be the most innovative and promising for one’s company? • Which processes are already able to shorten development cycles? • Which processes are best able to reproduce current products? • Which processes are best able to generate new, innovative products? • Which procedures are best suited for the qualification of parts in compliance with local standards and regulation? He says the method of production, the usability of materials, the purity of the produced material, the


VALVES

mechanical technological properties, the product accuracy, production speed and required post-processing are all aspects that should be taken into consideration as well. “To be able to produce quality additively manufactured components with high standards and following local standards and regulation, the focus at Samson was on the production of purely metal materials without any binders and with high density.” He said this would be different for each company and required one to look carefully at one’s production processes and its particular requirements. At Samson, the current focus was on the laser-based powder bed fusion of metals (PBF-LB/M) process. “The reason for this is that although high build-up rates are desirable in terms of productivity, Samson considers other aspects to be even more important such as the near-netshape production of parts, the interchangeability or fast replacement of existing cost or forged parts and the highly flexible part design.” He said at heart faster and more flexible manufacturing processes were being sorted resulting in the innovation process being accelerated. “There is also a move towards more parts integration with fewer components. The process described According to Eckholz, at Samson the LB-PBF-M process sees powder pushed upwards from one or two supply cylinders via pistons and draw on the building platform with a coater. The powder is then fused on the building platform under an inert gas atmosphere using laser along paths and taking into account the desired geometry. The piston moves down into the building cylinder according to the intended thickness of the individual layer and the whole process is repeated until the entire component has been built up and is surrounded by powder in the building cylinder. Overhangs must be compensated for by support material at a certain angle, he said.

Advantages are seen at Samson The interchangeability or fast replacement of existing cast or forged parts has been a big benefit, said Eckholz. “Also the production of minimum quantities and custom manufacturing. Usually, even different components can be produced simultaneously with AM.” Furthermore, it allows the company to realise complex geometries and the near-net-shape production of prototypes along with a highly flexible part design. “The introduction of AM has made our manufacturing process faster and far more flexible than it ever was,” he says. “It has allowed the company to react very flexibly and promptly in three particular areas namely rapid prototyping, tooling and manufacturing.” He said the AM process took place without tools and a mould. “The form is generated directly from the 3-D CAD data and as said, usually different components can be produced at the same time. This enables us to produce, adapt and optimize prototypes in very short development cycles.” Faster production with a very high degree of design freedom and complex geometries that cannot be manufactured using conventional methods brought further boons. “Moreover, from the point of the bionic design, it makes it possible to implement novel valve designs in terms of topology, flow and function,” he says. “Especially very complex components, which often are only required in small quantities, can be produced this way without a great deal of time and without disrupting our series production through complex retooling processes of the machinery park. The individual production of components is also possible for already discontinued services.” Samson Aktiengesellschaft, samson@samsongroup.com, www.samsongroup.com Pipes, Pumps and Valves Africa - May/Jun 2021

27


Standing the test of time The Quadax four-offset butterfly valve is a patented design butterfly valve with all the qualities of the proven triple offset butterfly valves with unique features that offer significant advantages. Pipes, Pumps and Valves Africa finds out more. According to Patrick Hofacker of Mueller Quadax in Germany, innovation lies at the heart of the business today.

VALVES

Whilst the concept of the fourth offset may be difficult to understand, these uniquely designed and patented butterfly valves are offering straightforward benefits. “Less wear, lower torque, higher Cv and unique seal options is what these valves bring to the table,” explains Hofacker. Previous valve designs Looking at past valve designs says Hofacker, first, there was the centric design with the turning point in the centre of the seat and the centre of the pipe. With the single offset (ball valve) the turning point of the disc is offset along the direction of the pipe, while the double offset saw the turning point of the disc also offset from the centre of the pipe towards the outer edge. With the triple offset, explains Hofacker, the seat has a conical shape. “The tip of the cone is offset from the centre of the pipe towards the outer edge. A circular cone results in an elliptical narrow seat in the valve body.” Due to the limitations with these designs, Quadax opted to find a solution that they say they have in the four offset butterfly valve. “In the case of this butterfly valve, the output cone uses is elliptical. By cutting at a specific

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Pipes, Pumps and Valves Africa - May/Jun 2021

angle, it results in a round and thus larger sealing area.” Thanks to the metal to metal sealing it can handle higher demands, higher pressure ranges and higher temperatures and is proving to be extremely in demand in the cryogenic industry. Benefits According to Hofacker, the design is also very compact. “it can be produced in bigger sizes without being more costintensive, one of the reasons why butterfly valves have become more popular.” He attributes the design to the company’s problem-solving approach. “We had customers who were struggling with sealing especially in cryogenic applications. The triple offset valves were leaking in these applications and were problematic.” The fact that the material thickness was not the same all around was problematic. “In other words in very extreme temperatures, there was shrinking and expanding happening but not in the same dimensions and direction at the same time meaning the valve would leak.” He said it was clear that they needed to design a butterfly valved that kept its structure on one side straight while reducing the friction to almost zero. The only way to achieve this would be to have around sealed with the same wall thickness all around.


VALVES

“This was achieved by cutting an elliptical cone,” says Hofacker. “When you slice the cone the result is a circle giving you the four completely round offset shape. Now you have a higher Cv which means a smaller nominal diameter. It is friction-free which translates to increased service life and life cycles while it also has lower driving forces, in other words, low torques and smaller actuators.”

sealing geometry. According to Hofacker, the introduction of these valves at various operational sites has led to increased operational safety. “The valves are friction-free on the seat and it reduces the risk of failure. There is no wear on the sealing area and has a longer service life.”

Ultimately, he said, it delivered an extremely cost-effective valve of which the design success has been proven in practice “It has been applied at the biggest LNG terminal in Europe where serious issues were being experienced with the leaking of triple offset valves. The introduction of this new design has completely stopped all the leaking issues.”

The extreme temperature ranges from -270 degrees Celsius to +800 degrees Celcius means the valves can easily handle a large temperature difference. “Our clients have also reported reduced operating costs and reduced maintenance costs,” he says. “Another benefit we have seen is the superior tightness. These valves are bubble-tight even in cryogenic applications.”

The valves were manufactured to operate in extreme conditions and have resulted in the highest performance and maximum economy based on the perfectly rounded

Müller Quadax Gmbh, info@quadax.de, www.quadax.de

BEING IN THE BUSINESS FOR MORE THAN 120 YEARS, WE KNOW HOW TO ASSIST YOU Presently, KEW FOUNDRIES is the ONLY SOUTH AFRICAN FOUNDRY with the EUROPEAN PRESSURE EQUIPMENT DIRECTIVE (P.E.D.) 2014/68/EU accreditation. WE are well positioned to produce VALVES of all designs for the SOUTH AFRICAN and EXPORT MARKET. KEW FOUNDRIES has built up the expertise to produce SMALL to LARGE VALVE ASSEMBLIES produced in various grades of GREY IRON and SG IRON castings weighing between 1 KG to 11500KG. KEW FOUNDRIES has built the expertise that allows the Company to service the requirements of various industries, including the VALVE, PUMP, WATER RETICULATION, MATERIALS HANDLING, ROLLING ELEMENTS AND RAILWAYS industries. Servicing OVER 100 CLIENTS within these industries, KEW FOUNDRIES is centrally located to attend to all our CLIENT’S needs. CONTACT US TODAY: KEW Foundries Tel: +27 (0) 53 841 0474 • Fax: +27 (0) 53 841 0473 e-mail: info@kewfoundries.co.za • jaime@kewfoundries.co.za Web: www.kewfoundries.co.za

Pipes, Pumps and Valves Africa - May/Jun 2021

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Wastewater treatment plant cuts energy use by 20% with a new biological treatment system WATER

Xylem's innovative solution helps improve the water quality of the local river. The Alto Seveso urban wastewater treatment plant, located in northern Italy, treats wastewater from local textile manufacturers. The plant wanted to reduce the risk of pollutants in its discharge while reducing energy consumption. With an innovative biological treatment system from Xylem, the plant has cut energy use by 20 percent and improved the water quality of the nearby Seveso River. The Alto Seveso plant is located in the municipality of Fino Mornasco, in the heart of Italy's Como fabric district. Completed in 1978, the plant has expanded and adapted its wastewater treatment line over the years to increase efficiency and meet new discharge standards. Since the plant is only a few kilometres away from the source of the Seveso River, the plant’s discharge can have a significant impact on the quality of the river. In dry weather, 90 percent of the flow of the river is made up of the plant’s discharge. On average, the plant’s discharge rate is 1,000 m3/hour, while the Seveso River has a flow rate of about 100 m3/ hour in dry weather.

The owner and operator of the plant, Lariana Depur SpA, needed to reduce the risk of pollutant peaks in its discharge, caused by variations in the input load, while at the same time optimizing resources and energy consumption. A few years ago, Xylem had helped upgrade a racetrackstyle tank at the plant, so it called on Xylem to solve this challenge. Xylem was contracted to revamp the biological treatment process of one train of the treatment plant, a bioreactor where each section can work alternatively as an anoxic or aerobic process, depending on treatment needs. This allows flexibility in reaching the target results depending on variable industrial loads, particularly for nitrogen. More flexibility and control over treatment processes Xylem designed the new, industry-leading biological treatment system to enable a huge range of flexibility and control. One way this was achieved was by adding instrumentation and sensors to control six different areas of the bioreactor. The aeration system was also upgraded and optimized. In a typical wastewater treatment plant, the blowers in an aeration system are the single highest energy consumer. Previously the plant had mechanical surface aerators, which could only operate in on or off mode, so the ability to regulate oxygen was limited. The plant could only turn the aerator off for a few minutes, otherwise settling would occur in the tank. Mechanical aeration is also generally less efficient than fine-bubble aeration. With the new solution, the plant now has a highly efficient, fine-bubble Sanitaire aeration system, combined with five highly efficient Flygt 4320 adaptive submersible mixers. This solution enables the plant to operate at a reduced airflow for hours or days within sections of the tanks, resulting in significant energy savings. The Alto Seveso plant now also uses Sanitaire TurboMAX turbo blowers to feed different quantities of air to six Sanitaire fine-bubble systems. Sanitaire turbo blowers are direct-drive, high-speed, turbo blowers using the latest airfoil bearing technology to deliver unmatched results with low energy consumption. They use up to 40 percent less energy than traditional blowers.

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Dynamically adjusting operations according to the pollutant load The upgrades at the plant enabled huge energy savings of 20 percent, or 640,000 kWh a year, compared to the previous system. Much of the energy reduction was achieved by the new ability to dynamically adjust operations according to the pollutant load to be removed. This flexibility is critical since discharge from local textile businesses can lead to highly variable nitrogen peaks loads. The improvement of the wastewater treatment plant helped Lariana Depur to enhance the water quality of

the Seveso River, and consequently, meet the stringent discharge directives regulating the Lake Como area. The upgrade helps the plant to drastically reduce the risk of exceeding the limit of nitrogen concentrations in its discharge (15 mg/l). At the same time, the integrated solution lowers the plant’s energy footprint to make the community more sustainable.

WATER

The plant's new PLC-based control system was developed by Lariana Depur with help from Xylem. The system receives process data from Xylem WTW sensors, for dissolved oxygen and nitrogen, and enables the plant to know when to add more air or less air, or no air at all, in which case the adaptive mixers are started to avoid sedimentation in the tank.

"This upgrade sets a new standard for wastewater treatment in industrial zones, particularly those where there is textile manufacturing," says Marco Leoncavallo, Customer Excellence Manager, Xylem Water Solutions Italia. “We are proud to partner with Lariana Depur in helping to preserve local water resources.” Xylem, makingwaves@xyleminc.com, www.xylem.com

Most advanced foundry group in South Africa Steloy Foundries specializes in the supply of machined & As Cast components for pump and valve castings manufactured in stainless steels, nickel-based corrosion resistant alloys, carbon steels and low alloy steels for applications where severe corrosion, high pressure and high or cryogenic temperatures are prevalent. Castings are produced at Steloy Foundries, all of which have access to simulation analyses and modelling programs such as Magma Soft & Solidworks. Including CNC patternmaking capabilities. All components are produced in accordance with the relevant ASTM, DIN EN and SEW specifications and conform to applicable NACE specifications. +27 (0) 13 110 2681 support@steloyfoundries.com www.steloyfoundries.com Pipes, Pumps and Valves Africa - May/Jun 2021

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WATER

Cut planned infrastructure budget by addressing billions of litres of wasted water Water waste, leaks, and the use of drinking water for manufacturing is resulting in billions of litres of potable water going to waste, which – if addressed – could reduce the water infrastructure spend that is necessary, this is according to local water sector stakeholders. Stakeholders say that currently, massive volumes of potable water are going to waste and huge infrastructure spend is being planned to meet growing water needs, at a time when the country can least afford it, largely because of a lack of coordination and communication between the public and private sector. Suzette Scheepers, CEO of Messe Muenchen South Africa, presenters of IFAT Africa says: “The latest budget has underlined the concerning state of our economy, and the need for everyone to collaborate to overcome our infrastructure issues and drive economic growth as cost effectively and efficiently as possible. In the water and waste sectors – both facing crisis situations – the private sector is anxious to bring its expertise and technologies to the table, to support state efforts to achieve this.” Dean Mulqueeny, Managing Director - AECI Water, explains: “Water is cleaned to different levels, depending on what it is to be used for. So it’s not necessary for example to use drinking water from Rand Water for many manufacturing processes. At AECI, we’re cleaning and reusing effluent water for many of our own manufacturing sites, and at our AECI Mining Explosives Modderfontein factory alone, we have a project underway that will remove demand for 400 million litres of potable water from the grid each year.” “We have a target to remove a billion litres of potable water off the grid this year; and most major enterprises are making similar efforts to be more sustainable. Their efforts to reduce their use of potable water will increase the government’s ability to take drinking water to more under-served communities as well as reducing pressure on current water infrastructure restrictions.” “However, because there are no current regular forums where the government and the private sector can discuss and share their medium and long-term plans, government stakeholders may not be aware of the impact these collective private sector efforts will have,” Mulqueeny says. Water as an economic enabler The experts point out that reducing water waste and ensuring access for all should be a top priority for the government as it seeks to revitalise the economy. Benoît Le Roy, Environmental, Technology & Project Alchemist, notes: “Water is a fundamental economic enabler, so to attract investment, you need to address the country’s water challenges. Investors are very aware of our energy and water issues, and they don’t want to touch us. The government just has too much to handle and can’t do it all alone – it needs to work with the private sector to address the

situation.” Mulqueeny says: “Good, clean sanitised water is a fundamental right – we can’t live without it. Water is foundational to agriculture and industrial development, investment, and job creation.” Government must overcome water issues that are barriers to investment, which would then stimulate job creation and economic growth. South African industry has the capacity to optimise ageing water and waste infrastructure at lower cost than replacing it, and to add billions of litres of potable water to the grid to alleviate water scarcity in under-served communities, they say. Pointing to massive volumes of unaccounted-for water, which is stolen, leaked or lost, Le Roy says this 30 – 41% of ‘lost water’ is a result of inefficiency in the system. “South Africa does not have the resources to replace its ageing infrastructure right now, but intelligent 4IR water demand management and pressure management technologies can address the lost water issue and ensure that everyone gets water at the right time without wasting it.” Hennie Pretorius, Industry Manager Water and Waste Water at Endress+Hauser South Africa, says current procurement processes for maintenance are slow and cumbersome, delaying essential maintenance on existing infrastructure. On top of that, water use monitoring and revenue collection needs to be improved: “South Africa needs to be more efficient in its revenue collection; we must reduce the non-revenue water and use that money to run proper maintenance,” he says. According to the National Water and Sanitation Master Plan, municipalities are losing at least 1660 million m³ of water per year through non-revenue water, amounting to nearly R10 billion a year. “We are moving close to crisis in a lot of areas, where communities are under-served and the quality of water is not where it should be, but complicated procurement processes are slowing down progress in addressing this.” The stakeholders note that the National Water and Sanitation Master Plan seeks to address these issues, but that little progress has been made in implementing the plan. Financing for water infrastructure development is available, but the environment needs to be made more conducive, say stakeholders. Wayne Taljaard, Managing Director at WEC Projects, says: “In our experience, people are queuing to invest in the right projects with the right guarantees. So the money is there, but we need to get to the point where the government and its institutions start to implement the National Water and Sanitation Master Plan.” www.ifat-africa.com


NON-RETURN VALVE SPECIALISTS SINCE 1969

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• Slurries, mine drainage, clean water, acids, Alkalines, etc • Pressure ranges: 1mm H2O up to 120 bar • River water, leaves, stones, twiggs, mine bilge water etc ok • No high density fibre: sewage, paper pulp

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PRODUCTS & SERVICES

Polymers for more reliable seals in cryogenic conditions Effective sealing is critical in any modern industrial process whether it involves gases, solids or liquids. Delivering improved product performance is increasingly being demanded from seal manufacturers, according to Christian Salvatori of Victrex. Increased reliability, reduced costs and improved operational efficiency is what operators are looking for. Considering the substantial growth in demand that has resulted in significantly increased amounts of particularly natural gas being produced to be liquefied and transported around the world, seal manufacturers are under even more pressure to deliver solutions that meet these requirements, while simultaneously dealing with the challenges posed by extreme low-temperature operations. According to Salvatori, the choice of material for a sealing application is dependent on the nature of the media to be sealed, the operating temperature range, the operating pressure, the materials of construction of the equipment to be sealed and the velocity between the seal and counterface. Speaking during a recent online event he said design challenges existed with current non-metallic materials such as the high coefficient of thermal expansion, the brittleness at low temperatures, the lack of standardised testing and the differential properties with steel components that in turn lead to fitting and sealing issues. “There is no denying that extremely low temperatures affect the performance of the seal,” he said. Polyaryletherketone (PAEK) polymers are normally associated with high-temperature performance, high chemical resistance and a unique range of mechanical

properties. The two best-known polymers for cryogenic sealing are modified polytetrafluoroethylene (MPTFE) and polychlorotrifluorethene (PCTFE). “In the last few years the growing trend of LNG and the transition to clean energy with a particular eye on hydrogen production and carbon dioxide storage have led to the need for new materials that extend the range of temperature, offer a more reliable sealing, lower the torque and allow for cost savings,” said Salvatori. High-level performance Polyether ether ketone (PEEK) polymers have prompted advances across industries, said Salvatori. They remain a source of active innovation. As a metal replacement solution, these high-performance polymers help meet key engineering requirements in critical components. Offering round excellent mechanical, chemical, high temperature and electrical performance, applications are for higher strength and stiffness as well as high ductility. “They are also chemically resistant to aggressive environments, and suitable for sterilization.” According to Salvatori, a test has shown that the company’s PEEK polymer has a continuous use temperature of 260 degrees Celcius. This can make it suitable for use in a wide range of thermally aggressive environments. It is also chemically unreactive making it ideal for use in an operational environment such as down holes in wells in the oil and gas industry. “It is also mechanically strong demonstrating excellent strength and stiffness over a wide temperature range. It has both high creep and fatigue resistance thanks to its semi-crystalline structure and is more durable than many other polymers and some metals over a long and useful lifetime.” Furthermore, the PEEK molecule is exceptionally stable and so the polymer can easily be re-melted and reprocessed again and again with minimal change to its properties making it completely recyclable. “ultimately these polymers give a more robust sealing performance in conditions that require higher ductility and toughness,” he says. Victrex, +(27) 11 974 9040, helmut@plastichem.co.za, www.victrex.com

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Ukuthela Foundry Projects specialise in castings for pumps and valves. 80% of the castings that exit the foundry are made up of components for the pump and valve industries.

+27 (0) 12 719 8860 +27 (0) 83 631 9986 ukuthela@live.co.za


INDUSTRY NEWS

Additive manufacturing make way for the future Additive manufacturing is taking centre stage as the ongoing Covid-19 pandemic plays havoc with global supply chains. Louisa Elena Mondora, general manager at Valland and Valeria Tierelli, CEO Aidro Hydraulics, are excited about the prospects it offers manufacturers. Pipes, Pumps and Valves Africa finds out more. It was already back in 2019 at an industry conference in Europe that Mondora was first introduced to the concept of additive manufacturing. She admits to being immediately “star-struck” by it and after extensive discussions with Tierelli, who had already adopted 3D printing in the manufacturing process at Aidro Hydraulics, that she returned to Valland intent on seeing it introduced into their operations as well. “I immediately started looking at a possible use case and we extensively brainstormed it with our engineering department. The first project that we undertook was aimed at learning more about the process and how it could be incorporated into our manufacturing processes large scale.” The team were much encouraged by the developments they had seen at Airdro Hydraulics where the use of 3D printing in research and development to re-design hydraulic components had benefited the company. Several industries including the automotive and aerospace sectors have seemingly embraced additive manufacturing.

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Tierelli has been an advocate for the increased use of additive manufacturing, particularly in the oil and gas sector. Additive manufacturing or AM as it is also sometimes referred as is the process of building 3D objects by adding layer-upon-layer of material, whether the material is plastic, metal, concrete or human tissue. It provides opportunities for both prototypes and final components. According to Mondora, a variety of materials can be used in additive manufacturing. Polymers and metals are the most common and are particularly efficient for low-volume manufacturing minimizing waste. Valve case study Mondora and Tierelli worked together on a valve component conferring revolutionary properties to conventional materials. In the study, the team willingly did not follow the design standards and purposefully set out to stress the material properties. Says Mondora, “The goal was to test the limit of additive manufacturing and not necessarily the safety factor on the component itself.”


mere 1,6kg for the 3D printed version. This represents a weight saving of 60% which is of particular importance if one is manufacturing for the oil and gas sector.

“The original design involved two tubes coming out of a central body,” explained Mondora. “These two tubes were close together near the centre. The manufacture of this component was by no means trivial manufacturing and involved complex machining and welding.”

A weight reduction reduces the handling and transportation costs of parts.

Mondora explains that they could not change the shape of the component as this was required for the actual functioning of the part. The AM also had to be done promptly and at a competitive price. The final design also had to be reliable. “It had to deliver what is expected of every valve – to work well and last long.” Looking at the original manufacturing design Mondora said time was one of the biggest challenges as the forging process for the body could take up to 12 weeks alone, while the complex machining and welding involved around the two tubes was at least another six weeks of work. “A component such as this can easily require at least 18 working weeks and involve several production steps along with a host of testing to ensure its final reliability.” Tierrelli said the valve component was a good case study to showcase the capability of additive manufacturing. Conclusions Following the redesign and 3D printing of the valve bonnet, several immediate benefits were seen. “Possibly the biggest was the massive weight saving we saw going from the 3,9kg of the conventional part to a

According to Mondora, a huge quantity of bulk and unnecessary material was removed during the redesign of the connection. The avoidance of welding and other risky and timeconsuming processes also reduced manufacturing time. “There was also a reduction in the raw materials used. For the conventional piece, we started with a metal bar of 8,5kg compared to the 3D printing process that used 2,6kg of power to produce the redesigned valve component. Furthermore, the valve component, once no longer required or in use, can also be recycled and reused for another part.” Both Mondora and Tierrelli say the ability to reduce the cost of the part without compromising the material performance was a major win for additive manufacturing.

INDUSTRY NEWS

Using a bonnet for a sub C rotatory gate valve, pressure class 15 000 PSI designed to operate at a depth of 3000 meters this critical component was transformed.

Also, when compared to the traditional product both the yield and ultimate strengths were favourable meaning 3D printing for this particular valve component was very feasible. All credit to Pixabay for the photographs!

Aidro Hydraulics, aidro@aidro.it, www.aidro.it

Pipes, Pumps and Valves Africa - May/Jun 2021

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INDUSTRY NEWS

New Cloud-Based, Remote Performance Monitoring and Alert System for AODD Pumps Innovative AODD pump-monitoring technology from Wilden® enables tracking of pump performance as a way to address and prevent operational shortcomings that can result in costly failures. Despite their appearance, manufacturing systems are delicate ecosystems that must be kept in tune at all times if they are to operate effectively, efficiently and safely. The key to ensuring the expected level of operation is the pumps that are used to transfer liquids through the manufacturing process. Therefore, these pumps must be able to reliably meet their required demands, but at the same time, each pump is a unique beast. This makes monitoring pump performance a critical consideration for facility operators, but staying on top of that is often easier said than done, even when the most tightly considered maintenance plans are developed and put in place. Knowing that, here are some of the common performancerelated worries that can keep manufacturing-facility operators tossing and turning at night: • A pump in a far-off corner of the facility fails without the knowledge of the operator. The result is 3785 litres (1,000 gallons) of the product (which may or may not be hazardous) spilt on the floor or a ruined product batch that will cost thousands of dollars to replace. The outcome in either instance is system downtime, along with associated cleanup, repair, maintenance and – in the worst-case scenario – replacement costs. • An unmonitored pump begins operating abnormally, but this change in performance is not readily recognizable to the operator. The possible negative outcomes from a pump that is operating outside of its optimal range are many. They can range from a ruined product batch to a

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compromised production process that takes more time and cost to complete to a catastrophic failure. • A facility with a preventative maintenance schedule in place still has pumps that malfunction outside of the maintenance-plan window. Preventative maintenance plans can also be overly conservative, calling, for example, the changing out of diaphragms that still have life in them. The schedules themselves could also be inaccurate or not account for the varying life cycles of different pump styles, increasing the chance of unplanned breakdowns or failures. In truth, the list of potential pump disruptions and their outcomes is innumerable. Operators must live with the fact that all pumps, no matter their method of design or operation, can (or will) fail at some point, and they must take steps to ensure that those failures are not catastrophic. AODD is A-OK That being said, all pump technologies are different, with varying requirements regarding monitoring, maintenance, repair and replacement. This leads to the fashioning of different reputations for the various technologies, with the air-operated double-diaphragm (AODD) pump having built a reputation since its invention in 1955 as a reliable, durable and flexible option for difficult pumping applications.


In many ways, the AODD pump has become a victim of its success. AODD pumps are indeed highly flexible, reliable and resilient in even the toughest pumping environments; in fact, they are routinely trusted for use in many critical and potentially hazardous applications because of their ability to handle solids, deadhead, self-prime and run dry.

Seeing into the future The science behind the drive to improve the remote diagnostic monitoring of pumping technologies has its roots in what has become known as the Industrial Internet of Things or IIoT. The IIoT is defined as a network of physical devices, systems and platforms that use embedded communication technology to share the operational intelligence of industrial machines. It combines data technology and machine learning to bring together sensor data and machine-to-machine communication technologies. This enables the identification of operational inefficiencies sooner and more reliably, creating real-time operational transparency and significant cost savings for the operator. Specific to AODD pumps – despite their perceived simplicity of operation and maintenance – are several component and performance parameters that can be measured via remote diagnostic monitoring technology: • All AODD pumps have wear parts – diaphragms, balls, ball seats, air distribution system (ADS) components – that can break down or fail over time. • Diaphragm failures need to be sensed and reported as soon as possible to prevent catastrophic product leaks • Predicting a diaphragm failure is critical in ensuring that downtime is minimized. • Identifying the window for a potential failure is critical and can be the difference between total loss of the pump or a less costly repair/replacement operation. • Excessive dry-run conditions that will compromise the pump’s performance and its overall lifespan. • Operational impediments such as clogged pipes, air leaks and closed or faulty valves that can adversely affect the pump’s expected performance. Anticipating potential failure conditions is not the only benefit of remote diagnostic technology. Since pump performance is likely to change over time, whether by normal wear or through outside system influence, monitoring indicators such as stroke rate or stroke count can be an invaluable tool for the operator. Any variance can be noted and recorded, letting the operator know if a failure may be imminent or if a proactive maintenance check may be needed.

INDUSTRY NEWS

However, because of its simple method of operation, few moving parts, easy maintenance and relatively low purchase cost when compared to other pump technologies, the AODD pump has been an afterthought in the development and installation of advanced diagnostics and Cloud-based performance monitoring. In reality, many of the same pump-performance concerns – including the high cost of downtime, repairs, lost product and product cleanup – that mark other pump technologies can be managed through the advanced monitoring of AODD pumps.

From a big-picture perspective, measuring total pump strokes also allows the operator to better construct and implement a more targeted and robust preventative maintenance plan. Since each system and installation is different, crafting an effective maintenance plan requires that special and specific attention be paid to a unique set of operational variables. Things to consider in this area include: • The age of the AODD pump, along with a history of how long pumps have typically performed in the specific application • How long do the diaphragms typically last before failing? Whether it be three, six or nine months, the operator can use history as a gauge when constructing a maintenance plan. • What are the typical costs for spare parts? Having a welldocumented history of pump and component performance can help streamline spare-part inventory requirements, which helps lower capital costs. Gaining a digital edge Until now, the users of AODD pumps only had manual or analogue solutions for their pump-monitoring needs – if they even chose to monitor their AODD pumps at all. That, however, is about to change as Wilden® has created a simple diagnostic and monitoring technology for its lines of AODD pumps. Called Wilden SafeGuard™, it allows the AODD pump to be remotely monitored 24/7 via continuous Cloud connectivity. Wilden SafeGuard promises to be a true game-changer in optimizing AODD-pump performance, reliability, and cost of operation and maintenance. Wilden SafeGuard is an all-inclusive pump-monitoring system that tracks, records and alerts customers to key performance indicators of AODD pumps at all times of operation via cellular access.

Pipes, Pumps and Valves Africa - May/Jun 2021

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INDUSTRY NEWS The SafeGuard system consists of a battery-powered stroke sensor and transmitter (called an Edge device) that is installed on the pump. The sensor collects and analyzes pump performance data in real-time and transmits it to a central gateway for encryption and transmission to the Cloud. Once stored on the Cloud, real-time and historic operational information can be accessed by the user anywhere in the world through a secure smartphone app or an online portal. The design and operation of the SafeGuard system allow for complete monitoring and real-time alerts related to several critical performance parameters for the pump (diaphragms, balls, seats).

These readings can show the user such things as: • Leak detection to indicate diaphragm leaks and failures, preventing product loss and safety hazards • Stroke rates to monitor changes to highlight performance abnormalities • Stroke count for batching and setting maintenance schedules • Real-time alerts via SMS or email to indicate any noteworthy change in operation that may be a precursor to pump or component failure • Maintenance records that can indicate patterns and help manage preventative maintenance plans • Management of an entire fleet of AODD pumps within one dedicated software system Conclusion Pump breakdowns and compromised performance, no matter how comprehensive the maintenance schedule, is always possible, making it imperative that the operators of manufacturing facilities know how their pumps have been performing. Advances in digital-monitoring technology and the growth and acceptance of IIoT principles have opened the door for users of AODD pumps to better inform themselves of the capabilities and potential shortcomings of the technology. Recognizing this, Wilden has created SafeGuard, a digital, Cloud-based pump-monitoring tool that relies on cuttingedge diagnostics that give AODD pump users the ability to observe exactly how – at any moment in time – their pumps are operating and if any performance-related issues may occur in the foreseeable future. https://www.psgdover.com/docs/default-source/wildendocs/white-papers/wildensafeguard_aodd_iot_product_ whitepaper.pdf?sfvrsn=9865e33c_8&submissionGuid=3be3 2e30-515d-4697-acc4-18edc40c8ad3 Wilden Pumps, wilden@psgdover.com, www.psgdover.com

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C.R.I Pumps S.A. (Pty) Ltd T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

APE Pumps T: +27 (0) 11 824-4810 F: +27 (0) 11 824-2770 E: info@apepumps.co.za W: www.apepumps.co.za

Pipes, Pumps and Valves Africa - May/Jun 2021

43


PUMPS SELF PRIMING PUMPS

Sulzer Pumps (South Africa) (Pty) Ltd T: +27 (0) 11 820 6000 F: +27 (0) 11 820 6206 E: CSSEnquiries@sulzer.com W: www.sulzer.com PINCH PUMPS

VERTICAL SPINDLE PUMPS

KSB (Pty) Ltd C.R.I Pumps S.A. (Pty) Ltd T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com VACUUM PUMPS

Walter Meano Engineering VersaFlo VSE Pumps T: +27 (0) 11 873-8620 F: +27 (0) 11 825-1401 E: wme@mweb.co.za W: www.versaflo.co.za VERTICAL TURBINE PUMPS

LVSA Group (PTY) LTD T: +27 (0) 11 680 2005 E: sales@lvsa.co.za W: www.lvsagroup.co.za PISTON PUMPS

Integrated Pump Rental T: +27 (0) 11 894-2906 E: admin@pumprental.co.za W: www.pumprental.co.za SLURRY PUMPS

PRICE PUMPS, for Air Operated Double Diaphragm Pumps for harsh mining applications. A&VT are the SOLE Agents for Southern Africa.

Air & Vacuum Technologies SALES, SPARES AND REPAIRS

T: +27 (0) 861 822-832 +27 (0)11 318 3241/2/3/4 C: +27 (0)82 576 9373 E: burnm@vactech.co.za W: www.vactech.co.za info@vactech.co.za

0861 VACTEC (822 832)

www.vactech.co.za

PRICE PUMPS, for Air Operated Double Diaphragm Pumps for harsh mining applications. A&VT are the SOLE Agents for Southern Africa.

Air & Vacuum Technologies SALES, SPARES AND REPAIRS

Hawk High Pressure Pumps T: +27 (0) 031 274-8555 +27 (0) 10 010-0144 F: +27 (0) 31 205-4332 +27 (0) 11 822-2868 E: sales@hawkpumps.co.za W: www.hawkpumps.co.za PLUNGER PUMPS

T: +27 (0) 861 822-832 +27 (0)11 318 3241/2/3/4 C: +27 (0)82 576 9373 E: burnm@vactech.co.za W: www.vactech.co.za info@vactech.co.za

0861 VACTEC (822 832)

AESPUMP SA T: +27 (0) 17 631-1003 F: +27 (0) 17 631-1002 E: craigg@aespump.co.za W: www.aespump.co.za

www.vactech.co.za

HORMA PUMPS (PTY) LTD T: +27 (0) 11 452 4300 F: +27 (0) 11 452 4400 C: +27 (0) 82 779 2464 E: sales@horma.co.za w: www.horma.co.za

Integrated Pump Rental

APE Pumps T: +27 (0) 11 824-4810 F: +27 (0) 11 824-2770 E: info@apepumps.co.za W: www.apepumps.co.za

T: +27 (0) 11 894-2906 E: admin@pumprental.co.za W: www.pumprental.co.za

Hawk High Pressure Pumps T: +27 (0) 031 274-8555 +27 (0) 10 010-0144 F: +27 (0) 31 205-4332 +27 (0) 11 822-2868 E: sales@hawkpumps.co.za W: www.hawkpumps.co.za POSITIVE DISPLACEMENT PUMPS

SUBMERSIBLE PUMPS

T: +27 (0) 11 824-4810 E: info@pumptechnology.co.za W: www.pumptechnology.co.za

C.R.I Pumps S.A. (Pty) Ltd T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

AESPUMP SA T: +27 (0) 17 631-1003 F: +27 (0) 17 631-1002 E: craigg@aespump.co.za W: www.aespump.co.za

Integrated Pump Technology

Integrated Pump Rental

uality

Sulzer Pumps (South Africa) (Pty) Ltd T: +27 (0) 11 820 6000 F: +27 (0) 11 820 6206 E: CSSEnquiries@sulzer.com W: www.sulzer.com WASTEWATER PUMPS

VAC-CENT SERVICES (PTY) LTD.

VAC-CENT SERVICES (PTY) LTD T: +27 (0) 11 827 1536 F: +27 (0) 11 824 3590 E: karishma@vaccent.co.za W: www.vaccent.co.za VERTICAL SUMP PUMPS

T: +27 (0) 11 894-2906 E: admin@pumprental.co.za W: www.pumprental.co.za

KSB (Pty) Ltd T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com WELL PUMPS

KSB (Pty) Ltd Unique Engineering T: +27 (0) 11 826-6111 F: +27 (0) 11 826-6162 E: sales@uniqueeng.co.za W: www.uniqueeng.co.za 44

Integrated Pump Technology T: +27 (0) 11 824-4810 E: info@pumptechnology.co.za W: www.pumptechnology.co.za

Pipes, Pumps and Valves Africa - May/Jun 2021

T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

KSB (Pty) Ltd T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com


VALVES BALL VALVES

CONTROL VALVES

VESCONITE

MAKES VALVES

Pleix-Quip

LVSA Group (PTY) LTD

T: +27 (0) 11 736-4994 C: +27 (0) 83 461 0801 E: tiaans@pleixquip.co.za W: www.pleixquip.co.za

T: +27 (0) 11 680 2005 E: sales@lvsa.co.za W: www.lvsagroup.co.za

LAST LONGER

Bray Controls Africa T: +27 (0) 10 007-3222 E: sales@bray.com W: www.bray.com

C

M

Y

CM

Valcon Valve & Controls Pleix-Quip T: +27 (0) 11 736-4994 C: +27 (0) 83 461 0801 E: tiaans@pleixquip.co.za W: www.pleixquip.co.za

T: +27 (0) 11 453-7537 E: valconsa@iafrica.com Web: www.valcon.co.za CHECK VALVES

BUTTERFLY VALVES

MY

CY

CMY

Enserve Engineering Services (Pty) Ltd T: +27(0) 16 971 3385 F: +27(0) 16 971 3935 E: mail@enserve.co.za W: www.enserveonline.co.za

www.vesconite.com

CALAFRICA Hydronic Solutions Bray Controls Africa T: +27 (0) 10 007-3222 E: sales@bray.com W: www.bray.com

C.R.I Pumps S.A. (Pty) Ltd T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

T: +27 (0) 11 795 1519 C: +27 (0) 83 303 1437 E: technical@calafrica.co.za W: www.calafrica.co.za

C.R.I Pumps S.A. (Pty) Ltd

Call: +27 11 616 1111

Macsteel Fluid Control T: +27 (0) 82 495 2772 C: +27 (0) 11 383 4000 E: Rowan.Blomquist@macfluid.co.za W: www.macsteel.co.za DIAPHRAGM VALVES

T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

Invincible Valves (Pty) Ltd Invincible Valves (Pty) Ltd Kaytar Valves (Pty) Ltd T: +27 (0) 21 987-8292 C: +27 (0) 81 555-5288 E: clinton@kaytarvalves.co.za W: www.kaytarvalves.co.za

T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za

T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za

Kaytar Valves (Pty) Ltd Macsteel Fluid Control KSB (Pty) Ltd T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

T: +27 (0) 82 495 2772 C: +27 (0) 11 383 4000 E: Rowan.Blomquist@macfluid.co.za W: www.macsteel.co.za

Pleix-Quip KV Controls (Pty) Ltd T: +27 (0) 16 100-4592 E: fred@kvcontrols.co.za W: www.kvcontrols.co.za

T: +27 (0) 11 736-4994 C: +27 (0) 83 461 0801 E: tiaans@pleixquip.co.za W: www.pleixquip.co.za

K

T: +27 (0) 21 987-8292 C: +27 (0) 81 555-5288 E: clinton@kaytarvalves.co.za W: www.kaytarvalves.co.za

LVSA Group (PTY) LTD T: +27 (0) 11 680 2005 E: sales@lvsa.co.za W: www.lvsagroup.co.za

Mine Track & Tools (Pty) Ltd T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za FLOW CONTROL VALVES

VACSERVE (PTY) LTD T: +27 (0) 11 827 1536 F: +27 (0) 11 827 3590 E: karishma@vaccent.co.za W: www.vacserve.co.za GATE VALVES

KSB (Pty) Ltd T: +27 (0) 11 876-5600 F: +27 (0) 11 822-2013 E: info-za@ksb.com W: www.ksb.com

Invincible Valves (Pty) Ltd T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za

Pipes, Pumps and Valves Africa - May/Jun 2021

45


VALVES THERMOSTATIC CONTROL VALVES

KV Controls (Pty) Ltd T: +27 (0) 16 100-4592 E: fred@kvcontrols.co.za W: www.kvcontrols.co.za

ADVERTISE WITH US TODAY !!

VACSERVE (PTY) LTD T: +27 (0) 11 827 1536 F: +27 (0) 11 827 3590 E: karishma@vaccent.co.za W: www.vacserve.co.za

Macsteel Fluid Control T: +27 (0) 82 495 2772 C: +27 (0) 11 383 4000 E: Rowan.Blomquist@macfluid.co.za W: www.macsteel.co.za KNIFE GATE VALVES

VALVE RECONDITIONING

Enserve Engineering Services (Pty) Ltd T: +27(0) 16 971 3385 F: +27(0) 16 971 3935 E: mail@enserve.co.za W: www.enserveonline.co.za

C.R.I Pumps S.A. (Pty) Ltd T: +27 (0) 11 805-8631 F: +27 (0) 11 805-8630 E: cri-za@crifluidsystems.com W: www.cripumps.co.za

Mine Track & Tools (Pty) Ltd T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za

Mine Track & Tools (Pty) Ltd

VALVES FOUNDRY

T: +27 (0) 11 412 4536/1665 E: info@minetrack.co.za W: www.minetrack.co.za PRESSURE REDUCING VALVES

Steloy Foundries T: +27 (0) 13 110 2681 E: support@steloyfoundries.com W: www.steloyfoundries.com

CALAFRICA Hydronic Solutions T: +27 (0) 11 795 1519 C: +27 (0) 83 303 1437 E: technical@calafrica.co.za W: www.calafrica.co.za SAFETY & RELIEF VALVES

KEW Foundries T: +27 (0) 53 841 0474 F: +27 (0) 53 841 0473 E: info@kewfoundries.co.za W: www.kewfoundries.co.za

CALAFRICA Hydronic Solutions T: +27 (0) 11 795 1519 C: +27 (0) 83 303 1437 E: technical@calafrica.co.za W: www.calafrica.co.za

46

Ukuthela Foundry Projects T: +27 (0) 12 719 8860 E: ukuthela@live.co.za

Pipes, Pumps and Valves Africa - May/Jun 2021

+ 27 (0) 83 281 5761 info@pumpsandvalves.co.za www.pipespumpsandvalves.co.za


E SIV ENT U CL EV EX RID B HY

23 - 25 AUGUST 2021 | jOHANNESBURG, SOUTH AFRICA

CONNECTING THE CONSTRUCTION INDUSTRY IN SOUTHERN AFRICA ACCELERATE YOUR BUSINESS BY SUPPORTING AFRICA’S CONSTRUCTION GROWTH AND RECOVERY

Meet industry buyers and distributors

Gain access to latest project updates

Access to alternative market opportunities

Access to credible and affordable training

NEW THIS YEAR! EXTENDED CONTENT DRIVEN FEATURE:

Connect with a wider audience face- to-face and digitally.

Contact Kenneth Masvikeni T: +27 21 700 5509 E: KennethMasvikeni@dmgevents.com Host city:

Co-located with:

AFRICAN

CONSTRUCTION POWERED BY: NAFBI

www.africanconstructionexpo.com

AWARDS

soaring


VSA

GROUP (PTY) LTD

PROUDLY SOUTH AFRICAN MANUFACTURERS

Petro Chemical

Power Generation

Mining

General Industry

Water & Waste

Durban - Manufacturing Facility

LVSA Group - Johannesburg

LVSA Group - Cape Town

LVSA Limitada - Mozambique

8 Uitsig Road, Astra Park, Kingsburgh, Durban, South Africa.

46 Kindon Road, Robertsham, Johannesburg, South Africa, 2091.

97 Neil Hare Rd, Atlantis Industrial, Cape Town, 7349, South Africa

Avenida Unido Africana numero 759, armazém 7, Matola - Mozambique

Telephone : +27 (0) 31 914 1025

Telephone : +27 (0) 11 680 2005 Email : sales@lvsagroup.co.za

Telephone: +27 21 534 2451 Email : ctsales@lvsagroup.co.za

Telephone: +258 83 911 1111

Email : kznsales@Ivsagroup.co.za

www.lvsagroup.co.za

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Pipes, Pumps & Valves Africa May/Jun 2021  

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