Pump and valves Jan/Feb 2017

ENDORSED BY SAPMA , SAPSDA SAVAMA, AND VAMCOSA

Jan / Feb 2017

Flotation Level Measurement Techniques Complete Mobile On-site Air, Power, Light and Now Also Pump Solutions from a Single Source

Pumps and Valves Africa - Jan/Feb 2017

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Pumps and Valves Africa - Jan/Feb 2017

Pumps and Valves Africa - Jan/Feb 2017

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AGRICO Centre Pivots & Linear Irrigators

With outstanding standard specifications and many options:

NEW: Internet Control

Irrigators are galvanised in-house; Cablesaver reduces theft; the cable to minimum 100 microns (1.8 times is placed inside the pipe, where it Windsaver machines are stable and the ISO 146 standaard). This gives cannot be tampered with easily. guaranteed for 4 years.

80% longer life expectancy.

Autoflush flushes the machine every time the pump starts.

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The AGRICO 3-legged center is exceptionally strong.

Pumps and Valves Africa - Jan/Feb 2017

AGRICO one stop service: Survey, design, manfacture, delivery, installation and after sales service.

Contents ASSOCIATION NEWS SAPSDA News 6

ENDORSED BY SAPMA , SAPSDA SAVAMA, AND VAMCOSA

Jan / Feb 2017

VAMCOSA News 7 Personality Profile - Willem Benjamin van der Westhuizen

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PUMPS SA Pump Manufacturer Celebrates 37 Years of Internationally Proven Award Winning Pump Design 10 From the Desk of Pamela du Plessis, Managing Director of Invincible Valves

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6 Common Threats to Pumps in Mining Applications

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Local Pump Technology Wows International Market

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Crowning a Successful Year

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Ferrous Metals Thefts Call for a Relook at Brass Components

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Grootvlei Power Station

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Questions Commonly Asked About AOD Pumps

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New Vortex Flowmeter From Emerson Improves Reliability For Utility Applications

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BMG’s Pumprite Range

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Packo Produces Centrifugal Pump Equivalent to More Than 8 Million Bottles of Beer Per Hour!

24 Complete Mobile On-site Air, Power, Light and Now Also Pump Solutions From a Single Source

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Ecochem Pumps - Precision Metered Dosing Pumps

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U.S. Nuclear Energy Facility Undertakes RCP Refurbishment

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Sweet Coating Solutions for the Sugar Industry from Thermaspray

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PUMPS & VALVES SKF Customized Interfacing Integrates Condition Monitoring Data Into Business Management Systems

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PIPES Exciting Areas of Growth in Plastic Pipe Industry

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VALVES Afrivalve Appointed As Official Distributor Of Gemu Valves For Mining Sector In Africa 38 Flotation Level Measurement Techniques

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BUYERS GUIDE PUMPS

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BUYERS GUIDE VALVES

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Flotation Level Measurement Techniques Complete Mobile On-site Air, Power, Light and Now Also Pump Solutions from a Single Source

On the cover Agrico

Tel: +27 (0) 21 950-4111 Fax: +27 (0) 21 950-4208 Email: alfred.andrag@agrico.co.za Web: www.agrico.co.za

Pumps & Valves Africa

Sales Manager: Surita Marx Tel: +27 (0) 11 047-2400 Cell: +27 (0) 83 281-5761 Email: info@pumpsandvalves.co.za Web: www.pumpsandvalves.co.za Sales: Lusana Mrkusic Email: sales@pumpsandvalves.co.za Sales: Naomi Erasmus Email: info@pumpsandvalves.co.za Production: Jeanette Jordaan Sub-Editor: Debbie Janse van Rensburg

Index to Advertisers

Agrico OFC, 4, 39 Air & Vacuum Technologies OBC Atlas Copco IFC/DPS BMG 23 Bonfiglioli 15 CRI Pumps 27 Dosetech 28 Industrial & Design Valves Holdings 35 Invincible Valves 11 JC Impellers 13 Klinger 9 KSB Pumps IBC Mather & Platt 33 Pamodzi Unique 21 Pipes, Pumps and Valves Conference 25 Preeflow 18 Rapid Allweiller 19 SAM Engineering 6 SAPSDA 29 Tri-Pumps 41 VAMCOSA 42

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.

Pumps and Valves Africa - Jan/Feb 2017

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S

APSDA News

Over 25 years of experience in designing and manufacturing a complete range of centrifugal pumps for a broad spectrum CSO/CP of industrial, process and general applications.

CP 7

CP S

MP PU

Providing customised pump solutions to various industries

Pump design techniques that ensure our pumps are manufactured to last

High performance - high quality products, excellent service

Alloys to suit all applications Proud Manufacturers of SAMCO® Pumps

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Pumps and Valves Africa - Jan/Feb 2017

Gareth Langton (Chairperson)

Types of Membership are: •

Manufacturing Members with a membership fee of R4 000,00 per annum

•

Associated Members with a membership fee R4 000,00 per annum

•

Affiliated Members with a membership fee of R2 000,00 per annum

•

Individual Members with a membership fee of R325,00 per annum

•

Student Members – bona fide students enrolled at recognised institution enjoy free membership.

CS X

MP PU

MP PU

www.sam eng.co.za

• Horizontal Split Water Pumps • CPX/HMX Type • SP Type • Vertical Turbine • CPW Type • CSR Type

MP PU

HM

SP I

E DL N

• CP/CPO Series • CP7 Type • Vertical Spindle/ Cantilever Pump • HM Process Pumps • CSW Type • CSY Type • Process Pumps

P -C

Our range of pump products include:

PO

VERTICAL

C

SAPSDA remains committed to provide quality services to their members and other role players in the pump industry and membership to SAPSDA is open to all pump manufacturers in Southern Africa as well as to other companies and individuals whose activity in the pump industry forms a significant part of the industry and/or whom have a vested interest in the industry.

In order to promote the pump industry training courses are presented approximately every two months around South Africa and training had been presented as far afield as in Namibia, Zambia and Botswana by highly qualified experts in the industry.

Should it be required a specialised training course on any specific aspect of pumps or pumping systems will be devised tailored to a company or a sector in the pumping industry’s specific needs.

The next Introduction to Pumps training course in Gauteng will be held on 10 and 11 May 2017 at a cost of R5 000,00 per attendee for the two day course. Courses are also planned to be held in KwaZulu-Natal and Cape Town in the foreseeable future.

Members can also enjoy interaction with each other during the regular networking meetings being held. A networking meeting consists of a visit to a manufacturing facility and/or a lecture by a guest speaker on a subject relevant to the business of the pumping industry.

For further information on any of the above please visit our website www.sapsda.co.za or per email: info@sapsda.co.za

Contact us: Gareth Langton (Chairperson) Tel: +27 (0) 82 467-7551 gareth.langton@klinger.co.za

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AMCOSA News

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he Valve and Actuator Manufacturers Cluster of South Africa (VAMCOSA) kicked off the year with their first meeting in mid-January. By all accounts, the sentiment is that 2017 should be a vast improvement on the pure catastrophe that was 2016 - during which we lost a number of manufacturers and key suppliers within our value chain. The biggest losses continue to be seen in the foundry sector, which is where - in most instances manufacturing begins across multiple industries.

Unfortunately, despite the many mechanisms that have been put in place to promote local manufacturing, we continue to see increases in imports - be it through corruption or simply the complete lack of political will to enforce the policies and legislation that have been put in place.

Discover Your Career In Valves Our transformation and skills development working groups continue to make progress with the “Discover Your Career In Valves” initiative, managed by Discover Develop Deploy Services (Pty) Ltd. The programme is currently running at the Fumana Secondary School, with the aim of providing opportunities for learners to enter into the artisan trade, to ensure that the valve industry has access to a much-needed skills base in the future. The initiative will be entering into its third year in 2017, and based on the dramatic improvements in performance seen from the Grade 12 learners who have participated in the programme, who recorded a 40% matric pass rate in 2015, which increased to 70% in 2016, we look forward to a very promising 2017. The programme enjoys the support of every one of our members, who are all responsible for the success of the initiative.

VAMCOSA Events Calendar VAMCOSA will be participating in an impressive number of events this year, starting with the Africa Energy Indaba, which will be held at the Sandton Convention Centre, Johannesburg, on 21 and 22 February. We will be taking the role of industry supporter at the 2nd edition of the Metal Casting Conference (MCC), which will be hosted concurrently with the World Foundry Organisation (WFO) Technical Forum, from 14 to 17 March. We will also be attending the 10th edition of the Pumps, Valves and Pipes

Mark Wilson

Africa Conference and Exhibition, presented by INDUTEC at Gallagher Convention Centre, Johannesburg, between 17 and 19 May. In addition, you will see VAMCOSA at the Manufacturing Indaba, to he hosted at Emperor’s Palace in Ekurhuleni, Gauteng, on 27 and 28 June 2017.

Member News New Member Announcement: VAMCOSA is pleased to announce that Floval Control Valves (Pty) ltd has joined the cluster. FLOVAL as the company is referred to was founded in 1990 and is a subsidiary company of PACE (Process and Allied Contracting Equipment).

Member Changes AVK Holding Southern Africa on the 27th December 2016, acquired the assets, IP and brand name of Gunric Valves.

Operations will continue from the existing facility in Robertville, Florida, Johannesburg.

The addition of a number of products including the Triple Offset Metal Seated Butterfly and tilting disc check valves strengthens AVKs core water business and provides an extension to the company’s Industrial valve offer in the local and international markets.

VAMCOSA www.vamcosa.co.za

Pumps and Valves Africa - Jan/Feb 2017

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PERSONALITY PROFILE

PERSONALITY PROFILE Willem Benjamin van der Westhuizen 55 years old

Academic Qualifications Masters Diploma in Technology – M Tech (Mechanical Engineering) July 1987 – Vaal Triangle Technikon Graduate Diploma in Engineering – GDE (Mechanical Engineering) July 1995 – University of the Witwatersrand Master of Science in Engineering – MSc (Mechanical Engineering) December 1997 - University of the Witwatersrand Eskom Technology Leadership Programme – December 1995 Eskom Senior Management Programme - 2013

First Employer Willem joined Eskom in July 1982 as a Pupil Technician. He then studied full time from 1982 to 1987 and obtained all three diplomas [National, National Higher and Masters Diploma in Technology (Mechanical Engineering)] Cum Laude.

His four years of Practical training included: •

Eskom College - various mechanical courses

•

Grootvlei Power Station - Operating; Maintenance and Performance monitoring

•

Sulzer pump factory, Elandsfontein - Engineering design, pump selection, pump assembly, pump reconditioning, pump testing, industrial engineering and visits to various pump installations.

•

Lethabo Power commissioning

Station

-

Construction

and

Willem joined the Turbine Plant Engineering Department in Megawatt Park as a Technologist in training, after completing his Masters Diploma in Technology in July 1987.

Overseas Training and Experience Willem had the opportunity to gain advanced technical training at Sulzer Pumps, Winterthur, Switzerland from August 1987 to December 1987. At that stage Sulzer Pumps were contracted by EPRI (Electric Power Research Institute American) to conduct research and development in various aspects of Boiler Feed Water Pump design, which included: hydraulics, cavitation, material selection, rotor dynamics and pump sealing arrangements. Willem was involved in all the research activities and programmes conducted during this training period. He also had the opportunity to participate in the various testing programmes including the full size Boiler Feed Water Pump Test – Task 12.

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Pumps and Valves Africa - Jan/Feb 2017

He also had the opportunity to work with two world famous Sulzer legends, Dr. Dušan Florjančič and Dr. Johann Friedrich Gülich.

Work Experience Willem has 29 years’ experience in Power Station critical pumps which includes selection, evaluation, manufacturing, testing, installation, commissioning and trouble shooting.

He has also conducted numerous pump independent investigations and troubleshooting in the Power Industry, Petrochemical, Pulp and Paper, Water Boards and Municipalities. Willem also presents a two-day Advanced Pump Course that is registered and accredited with ECSA. He is the author of Sixteen International and Fifteen National papers on various aspects of pumps. Willem is currently appointed as the Eskom Corporate Specialist (Pump Technology) and is responsible for all the critical Pumps installed in Eskom Power Stations.

First salary (within certain parameters is fine) My first salary was R600 and was I paid on a third year scale due to the two years Army Service which I served after completing my matric.

Achievements He has been awarded with academic colours and recognition throughout his academic and training career.

In his 4th year of study his machine design project was rated as highly merited and was asked to give a presentation: ‘The conversion of a normal room to a refrigerated facility’, Branch meeting of the South African Institution of Mechanical Engineers, Eastern Cape branch,14 October, 1986.

Willem has been recognised through various Eskom Managers’ Awards for Improvement and Innovation, Exemplary Leadership, Business Efficiency and Customer Satisfaction.

All South-African pump manufactures have similar challenges but is it sad that there is not a common goal or effort between the pump manufacturers to resolve or eliminate the challenges by addressing for example foundry issues etc.

Advice to Offer I believe that one creates an opportunity and that an opportunity also comes your way.

To the Young Engineers; - don’t be scared to get dirty, work late, ask questions. Be inquisitive. Ask the experienced people if you don’t know.

Challenges faced in the Pumps and Valves Industry In my 29 years of experience I believe the three biggest challenges are:

Quality of the castings - local and some imports. In 2006 I

conducted a survey at one of the major pump manufacturers in South Africa, which revealed that only 18% of all castings could be used as-is when delivered from the foundries, the rest either had to be reworked or were scrapped!

Delivery date - always a challenge – never on time.

Price – becomes a challenge due to points 1 and 2 above.

Skills – with the advent of the manufacturing base of the South African pumping industry diminishing and the loss of skilled pump engineers, designers and experienced artisans,

I also believe that you should know the fundamentals; once you know the fundamentals it is then easy to understand any aspect of pump performance, easy to do trouble shooting, In my 29 years of working in the power and pump industry I have learnt that by building up a Customer – Supplier relationship between you and the pump manufacturer achieves much better results rather than seeing the pump manufacturer merely as a Contractor.

PERSONALITY PROFILE

successful skills and knowledge transfer to young engineers, technician and artisans is at risk.

Something fun nobody knows about you I enjoy and support my kids in all their activities at school, Academic, Athletics, Rugby and Cricket.

I like Rock and roll Music of the 70’s, 80’s and 90’s.

My favourite two Rock Bands are Pink Floyd and U2.

PROVIDING SEALING SOLUTIONS FOR POWER GENERATION

    

Pumps and Valves Africa - Jan/Feb 2017

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PUMPS

SA Pump Manufacturer Celebrates 37 Years of Internationally Proven Award Winning Pump Designs Hazleton Pumps, a family owned and managed business located in Centurion, has since the company’s inception 37 years ago, been continually awarded with numerous awards and is regarded as a world leader in the pumping of high head, high volume acidic liquids containing solids utilising their branded HIPPO submersible slurry pump range.

T

he first award Hazleton Pumps received was in 2000 and to date the company has received 34 awards for manufacturing innovation, management of technology and product development.

Hazleton Pumps was honoured with the “Minister’s Awards” on three occasions over the years.

The Hazleton Pumps team of Niël, Thehan and Thys Wehmeyer receiving the Minister’s Award from the SA Minister of Science and Technology, Minister Naledi Pandor, with Dr. Ben Ngubane in attendance.

In 2006 the “Minister’s Awards” for SMME Company of the Year was bestowed on the company for the design, development and manufacture of the largest Nickel Alloy Vertical Spindle Slurry Pump manufactured in South Africa.

In 2009 the “Minister’s Awards” for Sustainability Performance was received for the company’s ability to build long-term committed sustainable customer relationships.

In 2013 Hazleton Pumps was awarded for a third time with the “Minister’s Awards” for the application of Science and Technology during the innovation process.

During the period 2015/2016 Hazleton Pumps was awarded nine times as the winner of following awards:

• • • • • •

South African Premier Business Awards (SAPBA) Steel and Engineering Industries Federation of South Africa (SEIFSA) Awards: South African Flameproof Association (SAFA) Award The Southern African Development Community (SADC) Awards The Southern African Stainless Steel Development Association (SASSDA) awards: The All African Business Leaders Awards (AABLA)

Advertise in Pipes, Pumps And Valves Africa Magazine Contact Surita Marx on Tel: +27 (0) 11 475-0010 sales@pumpsandvalves.co.za www.pumpsandvalves.co.za 10

Pumps and Valves Africa - Jan/Feb 2017

From the Desk of Pamela du Plessis, Managing Director of Invincible Valves Water and Sanitation Water is Life & Sanitation is Dignity

W

ater is a polar inorganic compound that is a tasteless and an odourless liquid. No one person or living thing can live without it ‌.

Most precious resource known to man!

Sanitation is the conditions relating to public health, especially the provision of clean drinking water and adequate sewerage and waste disposal.

Water supply and sanitation has been a logistical challenge since the dawn of civilization. Where water resources or infrastructure or sanitation systems are insufficient for the population, people fall prey to disease, dehydration and in extreme cases death.

The water and sanitation situation should be top of the South African agenda right now. Instead we still witnessing water wastage and sanitation failure due to infra-structure issues, industrial action and the general bad attitude of South Africans. This is no single persons problem, instead it requires every solitary soul residing in this beautiful country of ours to take responsibility and do the right thing.

We cannot afford to ignore the problem and hope that some day someone will fix it. There is no quick fix instead we need to hold one another accountable and take the necessary action by being water and sanitation wise and enforcing the change, along with holding our local municipality's accountable for their lack of service.

Waste not, Want not

Invincible Valves Pamela du Plessis Tel: +27 (0) 11 822-1777 Fax: +27 (0) 11 822-3666 enquiries@invalve.co.za www.invalve.co.za Pumps and Valves Africa - Jan/Feb 2017

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PUMPS

6 Common Threats to Pumps in Mining Applications Many pumps fall prey to a myriad of problems that include corrosion and being crushed by heavier machinery.

No industry puts its pumps through the ringer quite like mining. When the price of commodities such as gold spike in the short term, there is no time to lose—companies have to act fast to extract whatever they can as quickly as possible. While this flurry of activity is great for stockholders, it is not ideal for equipment. Many pumps end up falling prey to a myriad of problems that range from corrosion to being crushed by heavier machinery.

To protect mine dewatering pumps to the fullest extent, consider these six common threats that pumps may encounter during mining operations.

1. Suspended Solids The most prevalent cause of mine dewatering pump failure is clogging from gritty, suspended solids and slurry.

Water that makes direct contact with the operation is often dirty, containing foreign materials such as drill cuttings or solids generated by underground ramp traffic. When combined with the clean water that is removed from an aquifer, the result is a slimy texture that can clog pumps.

The key to overcoming this challenge is proper sump design. Clean water should be collected at the source, while abrasive solids-laden water should be separated into an isolated area within the sump.

2. Corrosion The fluids in mining applications are among the most volatile a pump can move. From superheated water laden with pyrite, iron or sand, to emulsified brine phase drilling fluid, there is no shortage of liquids that will punish a pump over time.

If a pump is constructed using solid metallurgy, the corrosion process can be slowed to a degree. Stainless steel pumps are preferred in these applications, including one new series 12

A submersible dewatering pump operates in an open mining area at the bottom of a ditch collection sump. (Images courtesy of Tsurumi America).

Water that makes direct contact with the operation is often dirty, containing foreign materials such as drill cuttings or solids generated by underground ramp traffic

and replaced before they corrode completely.

of submersible dewatering pumps that are manufactured using SCS14, a cast equivalent of 316 stainless steel.

Location is key, and keeping a pump away from the mine’s primary activities can mean the difference between getting the job done and halting everything for a costly pump replacement.

Even the hardiest equipment can succumb to corrosion, so it is important to make use of sacrificial anodes to increase the life of cathodic protection. An anode made of metal with a lower electrode potential—such as magnesium, zinc or aluminum—will take the brunt of corrosion during the pump’s application, protecting the metal that composes the pump. These protection plates must be monitored

Pumps and Valves Africa - Jan/Feb 2017

3. Impact This is as simple as it sounds: If a pump is not kept sufficiently away from mine traffic, there is a greater risk of crushing the pump with larger, heavier equipment.

4. Overheating Overheating can occur in any pump application—and mining is no different. If water levels are too low in the sump during prolonged operation and the unit’s control panel lacks any sort of underload protection, the pump will run dry and overheat.

Suspended solids also can cause overheating by accumulating in the cooling chamber and, if concentrated enough, around the motor frame. Suspended solids are another reason to carefully monitor water levels and make sure dirty water is kept separate from clean water.

PUMPS

5. Cord Damage When a pump’s power cord is cut or otherwise damaged, water can pass into the copper conductors through the point of cable entry and wick back to the motor. This will lead to motor failure or a short circuit in the cable.

Pulling on the cord during improper lifting or moving of the pump is often the culprit. This kind of cord damage is a symptom of hasty mining operations and results in costly repairs. Careful handling of pumps is necessary to keep cable entry intact.

6. Unexpected Culprits While this may come as a surprise to some, about 20 percent of all mining pump failures stem from clogs caused by everyday materials.

Chief among these culprits are earplugs, which all workers need and often discard; assorted types of fibers, such as the steel fibers used to reinforce shotcrete; and blasting wire, which can wrap around the pump’s impeller.

A submersible dewatering pump moves water to the surface during an underground mineshaft rehabilitation project.

All of these materials are ubiquitous in mines, which makes them all the more likely to cause clogging issues.

impellers. But these six hazards listed can befall even the most reliable equipment.

Any one of these items, if improperly discarded, can jam a pump’s impellers. It is not uncommon for a mining operation to send a pump to a distributor for repair, only to discover that improperly discarded debris has caused the unit to fail.

By taking the time to safeguard an operation from these six common, simple mistakes—preferably with assistance from engineers throughout the job’s life cycle—mining operations can extend the lifespan of mine dewatering pumps well past what is expected in such a demanding application.

Mitigate Abuse in Mining Applications Many advancements in pump technology can mitigate the abuse pumps face in a mine, such as antiwicking cable entries, silicon carbide mechanical seals or high chrome

Tsurumi Pumps Africa Tel: +27 (0) 11 876-5000 sales@tsurumipumps.co.za

Pumps and Valves Africa - Jan/Feb 2017

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PUMPS

Local Pump Technology Wows International Market Pump and Abrasion Technologies® (PAT) unveiled its latest product range CURVE™ to the African market and to global markets at the recent MINExpo in Las Vegas, USA. According to Sales Director James Pienaar the reaction to the CURVE™ from potential international clients has been highly positive.

P

ienaar says that the CURVE measured up well against competitor products on show at MINExpo. “MINExpo is widely regarded as the world’s leading international mining industry tradeshow event. The best and most advanced and respected companies from around the world come to this event to showcase their products and new developments. The fact that we were there representing South Africa and the Pump and Abrasion Technologies brand, I feel, puts us and the CURVE range in the same league as these companies,” Pienaar commented.

“The CURVE brand really stood out at the event as we felt that it competed well with other products on show due to the technology and benefits that the CURVE range offers. As a product with the potential to change the industry, we believe that the CURVE was head and shoulders above the rest and was definitely perceived as a product that has made significant improvements in its field.”

The CURVE range has been designed and developed by PAT over the past three years. Its design and features are based on in-depth research into what clients need backed up by extensive client feedback. The result is an innovative pump solution that is truly customized to the requirements of its end user, answering all of their operational needs. Based on the information that was gathered, the internal hydraulic layout of the CURVE pumps was redesigned to achieve a combined optimum for capital and operational cost when plotting the specific geometric size of the pump against the total lifecycle cost. In addition to this, PAT’s designers ensured that low energy consumption was prioritised in the CURVE’s design and that the CURVE could be retrofitted to legacy pumping systems with minimal changes to existing piping. This results in 40 - 60% reduction in total ownership costs.

Overall, the products in the new CURVE range offer decreased energy consumption throughout the product life cycle, TOC reduction, longer wear life, increased efficiency and improved safety for personnel during both installation and maintenance.

According to Pienaar, the overall reaction to the CURVE from international visitors to MINExpo was one of enthusiasm and 14

Pumps and Valves Africa - Jan/Feb 2017

relief. “I think if I had to describe their reactions, the right words to use would be eureka or maybe at last!” Pienaar explains. “Many visitors to our booth said that they were incredibly excited to see a slurry pump that caters for the needs of the client not just with regards to the engineer but from the ground up. They were relieved to finally see something new and different in an industry that really has been stagnant for a number of years in terms of product design and new technology.”

“Usually when there is an upgrade in old technology there are only one or two new added benefits.

With the CURVE range of pumps the added benefits are limitless stretching from running costs and safety to ease of maintenance and efficiency. There are more than 20 added features that differentiate the CURVE range from older slurry pump technology.”

Pienaar continues that the product features that visitors were most excited by included the safety improvements that make it safer to work with the pump and the lowered maintenance requirements due to the CURVE range’s longer life cycles. Engineers were captured by the CURVE’s overall reliability and uptime. Most foremen were drawn to the fact that the CURVE’s disassembly and reassembly time is half that of other pumps on the market. Overall, says Pienaar, the feature that made the largest impact was the CURVE’s offering of reduction in total cost of ownership for the supply chain, engineer and the owner. “The CURVE truly takes a holistic approach to its clients’ needs and ensures that every single division benefits.”

This overall enthusiasm has translated into numerous new business and sales opportunities for PAT. “Following the launch of the range, there have been many enquiries from local, regional and international clients. We are currently in negotiations with several companies to facilitate an effective global rollout for the CURVE range,” Pienaar concludes.

Pump and Abrasion Technologies Tel: +27 (0) 12 666-0904/5, info@pumpab.co.za, www.pumpandabrasion.co.za

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PUMPS

Crowning a Successful Year Local pump supplier KSB Pumps and Valves has continued its strong gains in the mining sector with several large-scale slurry pump contracts being awarded to the company in the latter half of 2016.

KSB Pumps and Valves MDX750c.

T

hese include projects in the ferrochrome, gold and copper industries as well as pumps to be used for stainless-steel processing. In all instances the customers selected KSB pumps due to their performance and reliability, as well as the aftersales service offered by the company which is designed to ensure uninterrupted production in these high-value plants.

According to KSB Pumps and Valves slurry specialists, Mohamed Trabelsi and Rob Bond, the ability of the company to supply a full range of high quality pumps with full backup and support, as well as readily available spare parts, has placed the company in a unique position where mines can meet all their pumping requirements through a single supplier.

Impressive projects “This has put us in a position to supply pumps for several projects being undertaken by Minprotech, a company which processes downstream products from Samancor ferrochrome mines in Steelepoort, Rustenburg, Mooinooi and Milsaai.

“These projects are currently underway in phases and require the supply of a variety of slurry process pumps and water pumps. In this instance our slurry pumps were found to be best suited for the project and our already wellproven water pumps perfectly complement the company’s requirements.

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Pumps and Valves Africa - Jan/Feb 2017

“Significantly, this international client also found that KSB Pumps and Valves globally had the best aftersales support for such complex and demanding high production work,” says Rob.

Continuous production “Another largescale project that we have been awarded is the tailings expansion project being undertaken by QKR Mining Company, at its Navachab Gold Mine in Namibia.

This calls for the supply of two trains of six LSA high pressure (severe duty) slurry pumps in the discharge segment of the plants grinding circuit.

“The two trains are designed for redundancy to ensure that pumping capacity is always available even in the event of a pump failure. Also, considering the severe nature of pumped materials and high pressures involved the second train allows regular maintenance without affecting production.

“In this project the supervision and expertise of the company’s Namibian branch manager, Klaus Streit ensures that despite the elative remoteness of the plant the mine has full-time access to KSB expertise,” Rob adds.

Technical expertise Mohamed also explains that mines value the expertise of a globally connected company such as KSB Pumps and Valves, where engineered solutions can be found to ensure the right materials, types and sizes of pumps are used to reduce

PUMPS “In this case we carefully analysed the requirements versus the materials being pumped, as well as the volumes required, and specially designed a pump solution based on our standard large size 250 mm LCV heavy duty vertical pump. The application to remove steel scaling called for a pump with high wear resistance and the ability to operate in harsh conditions in high temperatures.

Latest technology

Rob Bond (left) and Mohamed Trabelsi of KSB Pumps and Valves.

downtime and wear parts for the pumps. “That means that if the mine makes the right selection it will get the best production and longevity from their equipment.

“This is proving to be the case at Columbus Stainless in Middleburg where previous solution supplied by another company was proving problematic - with excessively high numbers of breakdowns and abnormally high wear on exposed parts. Also, aftermarket service was lacking and no solution was ever found by the previous supplier to remedy the situation.

“We were able to meet and exceed these requirements and needless to say this particular pumping circuit on our customer’s plant is no longer problematic. Our growing reputation for expertise and quality has also given us the opportunity to Australian firm, First Quantum with a trial MDX 550 mill circuit pump for its Kansanshi Copper Mine.

“This pump will primarily supply the cyclone feed for the secondary mill, where it will be the most critical production pump on the plant requiring a constant supply of course ore material to be delivered directly to the mill. This is one of the newer pumps that is receiving a lot of attention locally and abroad so we are confident that its performance will meet the company’s strict requirements,” Mohamed says.

KSB Pumps and Valves, Annett Kriel, Tel: +27 (0) 11 876-5600, annett.kriel@ksb.com, www.ksbpumps.co.za

Pumps and Valves Africa - Jan/Feb 2017

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automotive

WANTED: DEALER LED/LCD

electronic

Ferrous Metals Thefts Call for a Relook at Brass Components It is advisable for mining companies to consider converting brass components to polymer alternatives, says Vesconite Bearings’ Marius van Zyl.

N

We are looking for a business sales partner for our micro dispensing equipment.

on-ferrous-metal thefts are associated with direct costs and the indirect costs of production losses, with one study finding that, while copper-related incidents comprised 51% of mine incidents on South African mines, they made up 73% of primary and production losses.

medical tech.

Polymer bearings.

PV

bio chemistry many more

You can find more information on our website!

While copper cabling is the most worrying type of non-ferrous metal theft — since it is associated with possible endangerment or loss of life, with ventilation and transportation failure likely in the event of a power interruption, in addition to the substantial drops in revenue and profit associated with work stoppages — other brass components’ thefts are also a concern for mines.

This is because brass components are concealable, removable, disposable and available and so are also an attractive target for thieves. In addition, many components that are stolen are also not recovered and are only detected after a piece of equipment is found to be inoperable.

Van Zyl, who acts as the representative of Vesconite Bearings to the mining sector, believes that mining companies may reduce substantial losses if they convert brass components to ones made of the company’s polymers, including Vesconite, Vesconite Hilube and HiTemp 150.

He notes that, particularly in underground mines, items such as pumps are stripped for their brass parts long before they wear out.

“Our products last longer than bronze ones in many of the applications and are not sought after in the metals scrap market,” advocates Van Zyl.

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“Using our polymers will reduce losses due to theft,” he comments.

Vesconite, Charlie Simpson, Tel: +27 (0) 11 616-1111 18

Pumps and Valves Africa - Jan/Feb 2017

GROOTVLEI POWER STATION THE POWER STATION THAT IS LOCATED IN THE AREA OF GROOTVLEI, CLOSE TO HEIDELBURG ON THE N3.

Grootvlei had been mothballed in 1989, to be recommissioned by our honourable president Jacob Zuma in September 2013.

The power station has been running on old equipment that had been used since it had been mothballed. It was time to replace!

Turbine team had been having problems with their seal oil IMO pumps for a long time. The system requirements had changed, and they were told that IMO was not available in South Africa. IMO being part of Colfax made our job easier to convince the engineering team and maintenance crew that we have the right pump for their current issue.

We changed the ACE038 IMO known for its U-type flange set-up and having an internal pressure relieve valve. The client required an external relieve valve being a primary component for the new pumps so that they may be able to regulate the pressure.

We offered the IMO ACG7052k pump. The pumps could handle their new parameters and it has an external PRV.

WE HAVE ALL THE TICKS WE MANUFACTURE WE REPAIR WE FIND SOLUTIONS

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Resulting in a happy client and very good working system with Rapid pumps installed.

OWN GREY IRON & STAINLESS STEEL FOUNDRY

Rapid Allweiler Pumps – we have the right pump for the right solution.

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08600 RAPID 10 Girder Street

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Isando

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HEAVY-DUTY PROCESS PUMPS

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Est. 1932

Pumps and Valves Africa - Jan/Feb 2017

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PUMPS

Questions commonly asked about AOD pumps (Air Operated Diaphragm) & Answers.

What is a diaphragm pump?

A diaphragm pump is a positive displacement pump that uses a combination of reciprocating action and either a flapper valve or a ball valve to transfer liquids. This pump is sometimes referred to as a membrane pump.

Diaphragm pumps are self priming and are ideal for viscous liquids.

How long have diaphragm pumps been specified for waste transfer?

Diaphragm pumps have been in existence since the 1920's. Many consulting engineering firms have been specifying diaphragm pumps for wastewater and slurry handling since the 1930's.

What sizes of diaphragm pumps are available?

Our PRICE AOD pumps are available with connection sizes from ¼” up to 4". One can get couplings to fit almost any piping arrangement.

What kinds of fluids does a diaphragm pump transfer?

Once the correct materials of construction are selected, diaphragm pumps can transfer almost any kind of slurry, debris laden waste, food processing residual, liquid, stones, sticks, sugar, oil sludge, refinery waste, mud, clay pharmaceutical, industrial fluids and much more.

What kinds of facilities use a diaphragm pump?

Facilities of all sizes use diaphragm Pumps. We provide food and beverage companies, pharmaceutical, construction, oil and mining groups with diaphragm pumps. We also provide homeowners, local businesses, restaurants, hotels, Fuel stations, bio-fuel producers, marinas and campgrounds with our range of PRICE AOD pumps for their pumping applications.

What types of diaphragm pump configurations are available?

There is a wide selections of options such as stationary, wheel kit, skid mounted or trailer mounted models. Let us have your design ideas & we will most likely be able to accommodate your needs.

Is it easy to use a diaphragm pump?

PRICE pumps are designed and engineered, placing the operator and application first. This means that when you choose the right pump for your application, you get long 20

Pumps and Valves Africa - Jan/Feb 2017

life cycle, easy to maintain design all at an affordable price. In most cases, you connect the PRICE AOD pump to the process & air supply and turn it on.

Air and Vacuum Technologies Tel: +27 (0) 861 822-832 info@vactech.co.za www.vactech.co.za

Rosemount 8 600 Vortex flowmeter reduces installation and maintenance costs with no moving parts.

E

merson Automation Solutions expands its vortex flowmeter portfolio with the addition of the Rosemount 8 600 Utility Vortex Flowmeter, designed specifically for utility applications.

Its application-specific design reduces installation costs, provides accurate and reliable flow measurement, and extends vortex technology into a wider range of applications.

The Rosemount 8 600 Utility Vortex delivers the benefits of vortex technology by minimizing potential leak points and eliminating impulse lines – improving reliability and reducing installed cost. With no moving parts to repair or maintain, the Rosemount 8 600 reduces maintenance and downtime.

For saturated steam applications, a multivariable measurement option provides temperature compensated mass flow output directly from the meter. Unlike traditional multivariable vortex designs, the Rosemount 8 600 Utility Vortex with the multivariable option uses an isolated temperature sensor. This allows the temperature sensor to be

verified or replaced without breaking the process seal. Operator safety is enhanced by limiting personnel exposure to process conditions and throughput is maximized by eliminating the need to shut down the process to maintain the temperature sensor.

PUMPS

New Vortex Flowmeter From Emerson Improves Reliability For Utility Applications

The Rosemount 8 600 is part of the broadest portfolio of vortex flowmeters designed for a variety of process and utility applications. From the most aggressive flows, to clean fluid applications, Emerson offers a range of tailored vortex solutions to meet any requirement.

Emerson Automation Solutions, Michael Eksteen, Tel: +27 (0) 11 451-3700 michael.eksteen@emerson.com www.emersonprocess.com/MEA

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ive o explos NEW Ec e h T . s nd spareump unit. p pumps a e double e cavit ylsion dispensing iv s s re g s lube fre emu Eco pro a zardou h n o n , friendly and spares. en D50 Eco s rgest op 25 and Diaphragm pump D D lo ilf e of the la d m o s in NEW W s pit truckica. operate fr tographscast mines in A n a P d a ro f f O S E B

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Eco Pumps

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Wilflo Double

Diaphragm Pumps

Tel: +27 (11) 826 6111 Fa x: +27 (11) 826 6162 Email: sales@uniqueeng.co.za Website: w w w.uniqueeng.co.za

Pumps and Valves Africa - Jan/Feb 2017

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PUMPS

BMG’s Pumprite Range

“

BMG’s Pumprite range, which forms part of the company’s fluid technology portfolio, encompasses lubrication, grease, oil and abrasive fluid handling equipment, designed and manufactured locally to cope efficiently in Africa’s arduous operating conditions.

BMG’s strategy to enhance its fluid technology services to meet growing market demand in diverse industries, incorporates the introduction of new products, with the latest developments in design technologies, materials and coatings,” says Weylin Kapp, national product manager, lubrication, BMG. “The company’s expansion programme in the fluid technology sector also involves increasing product stockholdings through more than 160 BMG branches and a wide distribution network in South Africa and across borders into Swaziland, Zambia, Botswana, Mozambique, Namibia and Tanzania.

“The Pumprite portfolio - which includes a wide range of pneumatic and manual pumping and transfer solutions for grease, oil, grout and abrasive fluids - is supported by a one year manufacturing warranty.

“BMG’s dependable technical support service ensures optimum safety, efficiency and extended service life of every system, even in corrosive environments. With broad technical capabilities, the team is able to solve problems, in applications where conventional components have failed after short periods of service. BMG’s fluid technology services also cover project engineering and consulting, cylinder design and manufacture, training, repair and testing, as well as onsite container services.”

Pumprite equipment – a key brand in BMG’s portfolio – has been designed for use in diverse applications, including the transfer of product, lubrication of machinery, greasing, pack setting, rock grouting, washing, fixed systems, mobile systems and drag lines.

Pumprite pneumatic and manual pumps handle a wide range of products that include grease, oil, chemicals, grout 22

Pumps and Valves Africa - Jan/Feb 2017

and cement, air, water, petroleum, antifreeze, hydraulic oils, diesel fuel and detergents.

BMG’s Pumprite grease range encompasses pneumatic grease transfer pumps, heavy-duty retractable hose reels, spring feed lubricators, foot-operated grease pumps, bearing packers and hand lever grease guns.

Products recommended for handling viscosity oils include pneumatic oil pumps and retractable hose reels for oil and fuel.

The manual oil and fuel range also includes pumps for gear oil, hand rotary pumps and wing pumps.

The pneumatic abrasive pump range handles cementitious products and wash/solvent pumps efficiently handle all water based fluids, as well as chemicals, acids, solvents and anti-freeze.

Robust Pumprite pumps, with a refined design that can be stalled without damage, also ensure failsafe operation in arduous conditions. The reciprocating air piston has been designed for an even and non-pulsating delivery of product. The This complete pneumatic grease dispensing roller cart is used to easily transport, dispense and safeguard the grease drum. It is complete with a z-swivel and grease control nozzle.

PUMPS This pump is ideal for heavy duty cleaning and maintenance in industrial applications and where hygiene is critical.

Pumprite pneumatic grease pump, used to pump grease from all available sized grease drums.

Parker filter/lubricator system removes dirt and excess moisture from the air before entering the air motor of the pump and ensures air input is regulated at a safe pressure.

BMG’s extensive range of components for fluid technology systems and general industrial applications, includes valves, hydraulic hoses and fittings, accumulators, cylinders, heat exchangers, hydraulic motors and hydraulic plumbing, as well as pumps and reservoir accessories.

Components are manufactured from high grade material, such as LM25 aluminium and EN8 mild steel. Crucial parts are heat treated with a ground finish for protection against wear, even in demanding environments. Air motors are anodised for extended service life and robust LLDPE accessories, including drum covers, are corrosion resistant.

Weylin Kapp BMG Tel: +27 (0) 11 620-1500 weylink@bmgworld.net

FLUID TECHNOLOGY PRODUCTS THAT DELIVER

Our Range of Quality Fluid Technology Products include: • Lubrication Systems • Industrial Valves • Instrumentation

• Bulk Filtration Systems • Pneumatics • Hose & Fittings

• Industrial Filtration • Hydraulics • Pumps

For more information, contact our BMG Fluid Technology team: Tel: 011 620 1500 or 011 614 2004, fluidtech@bmgworld.net or your nearest BMG branch.

Pumps and Valves Africa - Jan/Feb 2017

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PUMPS

Packo Produces Centrifugal Pump Equivalent to More Than 8 Million Bottles of Beer Per Hour!

T

Packo Pumps has just successfully produced and tested his biggest pump ever.

his colossus, which is an extension of the current MCP3 and MFP3 range, weighs 1,6 ton, has a flow of 1 200 m³/h and is driven by a motor of 200 kW. The production was made possible thanks to the expansion of the test bank, which is part of a complete renewal of the test lab. For the reason that every pump is tested before they are shipped to the customer, an upgrade of the test bank was favorable to increase its range.

Packo is now able to produce pumps with flow rates up to 1 600 m³/h at a maximum power of 250 kW. When the renovation is fully completed, by the end of this year, it will even be possible to manufacture pumps with a flow rate up to 2 000(!) m³/h.

The tested pump will be installed in the largest dairy farm of Europe.

For them it will be the biggest pump ever taken into production Increasing demand for bigger pumps Increasing production capacities, more efficient processes and larger food factories in general are the drivers for producing bigger food grade pumps at high efficiency.

Finally it leads to an ideal solution for handling shear sensitive products (f.i. mash) while saving money on the electricity bill!

The tested pump will be installed in the largest dairy farm of Europe. For them it will be the biggest pump ever taken into production.

Setting a new standard Also in breweries, beverage and juices industry and industries with filtration applications in general, the call for stainless steel pumps with a flow rate over 1000 m³/h gets louder.

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Pumps and Valves Africa - Jan/Feb 2017

Thanks to, among other things, the European Regulation 1935/2004 EC Packo Pumps succeeds in supplying these markets successfully.

Packo is now the only player on the market that can offer a pump with such a large flow in a hygienic execution.

Because food regulations keep on tightening, Packo responds with these pumps. Moreover, they hope to set the standard in multiple areas.

For instance, look at breweries that mostly still use pumps in cast iron for higher flow rates. Hygienic pumps, like this one, could perfectly become the standard on the long term.

8 million beer bottles One more fact about the pump to finish off. The average beer bottle contains 25 cl beer. If we extend this fact to the pump of 2 000 m³/h, we can state that the pump is capable of pumping 8 million beer bottles per hour! Feeling thirsty?

Verder Pumps S.A. Tel: +27 (0) 11 704-7500 www.verderliquids.com/za/en/

17–19 MAY 2017

THE LARGEST AND MOST COMPREHENSIVE AFRICAN TRADE-SHOW DEDICATED TO THE INDUSTRIES INVOLVED IN THE CONVEYANCE OF LIQUIDS, GASES & SLURRIES.

Pumps, Valves & Pipes Africa 2017 will take place from 17–19 May 2017 at Gallagher Convention Centre, Johannesburg, South Africa. If you are looking to build your business into Africa, generate new leads, find out about new projects and meet new partners, then PVP Africa is the trade show for your business.

CONTACT US FOR STAND BOOKINGS TEL +27(0)11 783 7250 EMAIL exhibiting@indutecafrica.com

www.indutecafrica.com

Organised by

Pumps and Valves Africa - Jan/Feb 2017

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PUMPS

Complete mobile on-site air, power, light, and now also pump solutions from a single source Atlas Copco Portable Energy leads the market as a single source supplier of turnkey on-site mobile solutions with the development and extension of its pump portfolio to complement the division’s already well-established range of compressors, generators and light towers.

“

The shared synergies between Portable Energy’s three pillars compressors, generators and light towers – made the development of our dewatering pump ranges to form a fourth pillar within the division a natural progression,” explains Portable Energy Business Line Manager, David Stanford. He notes that pumps are not new comers to the Atlas Copco portfolio with small hydraulic as well as pneumatic and electrical submersible pumps having been part of the offering for quite a few years. “We have now made a solid strategic commitment which will ensure that our pumps enjoy the same focus and investment as our compressors, generators and light towers and I am really most pleased that our hard work is finally coming to fruition.” Roll out of the expanded pump portfolio whch relates to both pressure and flow-rate capacities, will take place over the coming months.

The efficient and safe removal and disposal of water from a job site is fundamental to maintaining safety and productivity. “Performance under pressure within the most challenging environments is where our pump ranges perform to their maximum,” affirms Stanford. Suitable for transporting or lifting water with abrasive solids in suspension, the pumps are ideal for applications such as construction and mine-site dewatering and diversion of flood water or streams.

The comprehensive range of electrical submersible and self-priming diesel pumps available from Atlas Copco Portable Energy provide solutions 26

for virtually any mobile dewatering application within the flow range of 210 – 16 500 l/min.

The portable dewatering pump range saw further extension in January 2016 with Atlas Copco’s acquisition of Varisco.

“Varisco’s Padua location has become the dedicated global competence centre for pump development within Atlas Copco Portable Energy complementing our other two global competency centres in Antwerp (air) and Zaragoza (power and light),” adds Stanford.

The new motor design of the Weda 50 and 60 electrical submersible pumps has resulted in improved power to weight ratios. The Weda hydraulic parts deliver enhanced performance with flow management from 225 to

Pumps and Valves Africa - Jan/Feb 2017

16 500 litres per minute with a maximum head of 85 meter . Stanford also reveals that as a result of customer demand, a diesel driven open canopy range will also be introduced in Q4 2016.

“The same unique value proposition and forward-thinking approach that underpin our compressor, generator and light tower ranges are assigned to our pumps,” notes Stanford. “It is about continuously improving product performance, reliability and efficiency to take on even the most stringent conditions and here engineering and manufacturing excellence, environmental consciousness and expert service all come into play.”

“Portable Energy’s value proposition differentiates us as a preferred supplier of portable energy products that

Atlas Copco Portable Energy is committed to creating customer value through anticipating and exceeding future needs while never compromising on environmental principles. In order to produce products that are fit for customer purpose, all Atlas Copco products are engineered and not assembled. “We take cognisance not only of our own manufacturing processes but also of the customer’s working environment through the provision of energy efficient products.

In closing, Stanford points out that Atlas Copco Portable Energy customers invest in so much more than just a product, they invest in a massive support network that includes factory

PUMPS

are inherently energy efficient, lightweight, compact, easy to move and transport, meeting customers’ exact needs and contributing to enhanced customer productivity at the lowest cost of ownership over the products’ lifetime.” The division’s six-point value proposition begins with a focus on customer needs.

trained technicians that deliver fast, reliable, expert service to help maintain uptime and production levels. “As their long-term portable energy partner, our customers are ultimately the winners as they are now able to choose their all-inclusive on-site mobile compressor, generator, light tower and

pump solutions from a single source,” concludes Stanford.

David Stanford Atlas Copco Tel: +27 (0) 11 821-9136 david.stanford@za.atlascopco.com

Pumps and Valves Africa - Jan/Feb 2017

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PUMPS

Ecochem Pumps - Precision Metered Dosing Pumps This graph is a dosing flow trend recording from the EPL Plant SCADA historical data base.

The recording depicts the dosing flow of rate four (4) separate dosing points (i.e. Blue, Green, Purple and Red) – as can be seen each flow rate trend shows instability with abrupt and erratic changes being present throughout.

I

n particular the red dosing flow rate trend clearly shows loss of control with "constant oscillation" taking place – this type of instability is typical of Ring Main Systems implying that the technical staff are constantly receiving call outs to resolve problems with many of the components utilised in the system.

The graph represents reagent dosing flow rate trend recording using the concentrator plants New "Ecochem Modular Reagent Dosing System" with Milton Roy precision metered hydraulically actuated industrial grade dosing pumps.

Once again all four (4) separate dosing point flow rate trends (i.e. Blue, Green, Purple and Red) are depicted – However in this case two identical dosing flow rate set-points have been put in place for the dosing points on both the A and B process streams.

Fig 1 – EPL Concentrator: Old Ring Main Reagent Dosing System

The dosing performance of the pumps is so accurate that the resolution of the trend recording makes it appear as if the dosing flow rates of only two dosing pumps instead of four dosing pumps has been recorded. This is because there is there is an overlay effect with the recorded pump flow rates on the graph.

The new dosing system clearly demonstrates the guaranteed 1 – 2% dosing flow rate accuracy delivered by the Milton Roy precision metered dosing pumps which is unsurpassed and never previously seen before within the Lonmin group and as per the plants own testimonials already showing improvements in the plants recovery performance as well as reagent chemical consumption.

Ecochem Pumps Dosing Systems is Proven its quality, Durability and most of all accuracy!

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Pumps and Valves Africa - Jan/Feb 2017

Fig 2 – EPL Concentrator: New Ecochem Modular Reagent Dosing System with Milton Roy Precision Metered Dosing Pumps.

Ecochem Pumps Johan Jacobs Tel: +27 (0) 11 455-5710 info@ecochempumps.co.za www.ecochempumps.co.za

Pumps and Valves Africa - Jan/Feb 2017

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PUMPS

U.S. Nuclear Energy Facility Undertakes RCP Refurbishment

by Gerry Ottman & Will Murray For decades, the U.S. fleet of nuclear power facilities has efficiently and reliably generated low-carbon electricity. Inside each facility, reactor coolant pumps (RCPs) and other components play a critical role in creating this electricity. This equipment, however, operates for extended periods of time under harsh conditions. Eventually, these components need to be refurbished or replaced.

T

he nuclear industry is constantly exploring innovative and efficient ways to complete these replacements and to ensure operational excellence.

In 2015, Dominion Virginia Power completed one of the largest RCP refurbishment projects in the U.S. at the Surry Power Station in southeastern Virginia.

The project scope included five pump replacements.

The facility partnered with an international nuclear energy services company to renovate and qualify four 12-foot, 24-ton pumps, including two from Dominion’s closed Kewaunee Power Station in Wisconsin. One additional pump previously refurbished by the nuclear energy services company was used to complete the project scope.

performed in Unit 1 during the spring 2015 outage and Unit 2 during the fall 2015 outage.

Overcoming Obstacles to RCP Refurbishment With an aggressive outage schedule, spare pumps had to be obtained in 10 months—a monumental task when, historically, lead times to secure RCPs were two to three years.

Faced with such a challenge, the nuclear energy services company looked into reclaiming two RCPs from Dominion’s retired Kewaunee plant in Wisconsin and refurbishing them to like-new conditions. This innovative idea presented significant challenges that needed to be addressed before the company could proceed with purchasing the pumps from Kewaunee:

Deciding to Replace RCPs In 2014, inter-granular stress corrosion cracking (IGSCC) was found on turning vane bolts in a U.S. power plant. These bolts secure the turning vane diffuser assembly inside the RCP, located above the pump impeller.

The original equipment manufacturer identified a problem with pumps manufactured with 1-inchdiameter turning vane bolts.

After evaluating this issue, Dominion decided to upgrade and replace all its facilities’ RCPs that contained 1-inchdiameter turning vane bolts. At Surry, five RCPs were affected: two in Unit 1 and three in Unit 2. Dominion contracted the nuclear energy services company to refurbish the RCPs, including replacing the turning vane bolts. This work was 30

With the old RCP removed, a field engineer places a foreign material exclusion (FME) shield over the pump housing. (Images courtesy of AREVA).

Pumps and Valves Africa - Jan/Feb 2017

PUMPS

The RCP shaft is placed in the lathe to measure total indicated run-outs (TIR). The TIR indicates the trueness of the shaft. This process ensures that both ends of the shaft rotate on the same axis.

Over time, normal wear occurs in the operation of the impeller. Here, the refurbished impeller is in its final balance operation.

The refurbished main flange is installed in the up-ender and ready for pump reassembly.

•

The FME cover is placed over the pump impeller after the balance is complete.

•

Ownership: The ownership of the pumps had to be resolved. Kewaunee is part of the unregulated business at Dominion, but Surry is a regulated business facility.

Moving assets from unregulated to regulated facilities required meeting certain regulations.

•

Condition: The team had to determine whether the pumps were in a condition to support more than 20 years of service at Surry after operating for more than 30 years at Kewaunee. To be refurbished for another facility, the pumps could not be degraded.

•

Codes and licensing: American Society of Mechanical Engineers (ASME) requirements vary from plant to plant based on state and date of construction. As a result, the team had to evaluate each state’s codes and standards to determine if the Kewaunee pumps were built to code requirements that satisfy those governing Surry.

Physical interchangeability: A number of physical requirements had to be evaluated, including the size of the Kewaunee pump and the Surry pump casing, the Kewaunee pump flow rate and pressure compared with the Surry pump, the location of the interface for the motor (coupling, motor stand bolts), and the location of the piping connections (seal water, cooling water).

The nuclear energy services company performed a detailed engineering study that confirmed that the Kewaunee pumps were a safe and reliable solution for installation at the Surry station. The team then decided to proceed with the purchase.

Undertaking the Refurbishment Project The RCP refurbishment project included replacement of the shafts, impellers, couplings, bearings and all bolting on the pumps. The accelerated delivery schedule required the nuclear energy services company to manufacture these replacement parts in less than six months—a task that normally takes one to two years.

Alongside the engineering and manufacturing efforts, the company’s field implementation teams planned the complex logistics of replacing multiple RCPs during a normal maintenance outage. The company’s pump and motor field service team and Surry’s maintenance technicians completed extensive mock-up training exercises, which were integral to the planning and preparation. This also led to the development of new and improved tooling and equipment.

With these investments in planning and preparation, the replacement was a success. A key factor was close Pumps and Valves Africa - Jan/Feb 2017

31

PUMPS Engineers hook rigging to the pump for transport.

The refurbished pump is placed in the cask.

Using full-scale mock-ups for the RCP and machining activities, both management and crew members trained and performed all tasks based on field-like conditions.

Ensuring team members experience radiation doses well within regulated limits is a key aspect of every project plan.

The refurbished pump is moved to a shipping cask.

coordination among the teams from the Surry station, Dominion engineering in Innsbrook, Virginia, the nuclear energy services company’s pump and motor service center in Lynchburg, Virginia, and the company’s manufacturing facility in Jeumont, France.

Identifying & Integrating Lessons Learned Project personnel learned several lessons throughout the process of refurbishing and qualifying the RCPs, including opportunities to integrate safety improvements, enhance outage excellence and innovate technologies in preparation for the next scope of work.

Maintaining a Clear Focus on Safety Five RCPs were refurbished and installed without any safety issues, personal contamination events or human performance errors. This performance is attributed to the team’s rigorous focus on safety, which was the No. 1 priority during the entire project.

32

Pumps and Valves Africa - Jan/Feb 2017

Practicing critical tasks where expected radiation exposure is higher, such as removing and installing the RCP and the shield plug access cover on the mock-ups, allowed the team to explore best practices to reduce process time and to integrate new techniques that resulted in lowering expected REM dose exposure, also called achieving dose savings. REM is a standard unit of measurement for radiation dosage; it combines the amount of energy produced by the radioactive material with the medical effects of the given type of radiation.

This focus on safety resulted in measurable reductions in the radiation levels the team experienced during each refurbishment. The dose savings from the first pump to the last were 1,521 REM, equivalent to a dose savings of approximately 76 milli-REM per individual per RCP outage.

Enhancing Outage Excellence Because timeframes for outages are decreasing at plants across the country, largely for economic reasons, the project team identified numerous ways to improve processes, incorporate best practices and develop solutions for equipment efficiency. By continually improving, the team maintained the outage schedule and stayed within budget.

Improved communication between the field and project teams was critical to the success of the project. A key lesson

services company to fabricate new shafts and impellers for the pumps to achieve flow requirements.

Having a unified base location eliminated communication delays and improved handoffs between teams.

Because of the RCP’s complex geometry, state-of-the-art digital measurement technology was used to measure the different dimensions of the pump components.

Three-dimensional overlays of the new and old pumps identified possible deviations with more accuracy and speed than was previously possible through manual measurements.

In addition, remote video monitoring and communication equipment supported inspections and eliminated the need for multiple oversight personnel.

As a result, the team could provide status updates and troubleshoot issues in real time in the field with outside support.

Integrating Innovative Processes & Technologies Improved processes and innovative technologies allowed the team to be proactive, which increased productivity and reduced critical path time and impacts to the schedule and other work groups.

Innovative solutions for transporting and installing components also improved overall project performance. For instance, the nuclear energy services company designed a shielded transport RCP cask with one hook to up-end the large component.

The cask’s smaller footprint and easy lift design simplified the process of repositioning the component, reducing polar crane and critical path time by eight hours per pump.

Engineering innovations helped configure the unique style of Kewaunee’s pumps for Surry. Flow curves, piping configurations and thermal monitoring systems all required attention. Dominion worked with the nuclear energy

Using these new processes and equipment allowed for a reduced critical path schedule. Standard RCP replacements can extend an outage by as much as seven days. By implementing lessons learned from this RCP project, others in the industry can now replace multiple pumps within a normal maintenance outage schedule.

PUMPS

learned and adopted early in the process was to organize the entire project team in the same working area.

Supporting the Safe & Reliable Operation of the U.S. Fleet The turning vane bolt issue proved to be one of the most important reasons for utilities to replace and refurbish RCPs. The IGSCC of turning vane bolting is one example of service-related degradation, but experience and advancements in equipment and processes can greatly improve the reliability of RCPs. There is now a proven, systematic approach to replace and repair these parts, allowing the existing fleet to continue to operate safely and reliably for years to come.

Suppliers of pumps and valves to the mining and industrial sectors for over 60 years.

Stockists of Tianjin small submersible, vertical multi-stage and close coupled water pumps.

Suppliers of the following: M+P Split Casing Pump

Multi-stage Pump

E.I.M.

Viking Gear Pump

Tel: 011 824 4810

Fax: 011 824 2770

Web: www.matherandplatt.com

26 Nagington Road, Wadeville, 1422, Gauteng mather&platt A5.indd 1

2015/07/17 11:08 AM

Pumps and Valves Africa - Jan/Feb 2017

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PUMPS

Sweet Coating Solutions for the Sugar Industry from Thermaspray Thermaspray, South Africa’s surface engineering and thermal spray coating technology specialist, offers a range of high quality coating techniques that assist the sugar industry in reducing maintenance costs by protecting both new and worn equipment parts and components against abrasive, adhesive, erosive and corrosive degradation.

M

aintenance costs for the multiple-process sugar industry which includes the crushing, refining and packing of cane and beet sugar can make up as much as ten percent of the value of goods produced.

Equipment maintenance as a direct result of abrasion, adhesion, erosion and corrosion leading to rapid wear and corrosion and subsequently expensive downtime can account for up to one third of plant maintenance costs, including replacement and/or repairs.

Thermaspray Managing Director, Dr. Jan Lourens, notes the importance of using a specialist coating company like Thermaspray. “As a DQS ISO 9001 Quality Management and Eskom level 1 certified company with close to 20 years’ experience in wear- and corrosion-resistant thermal spray coatings, we possess the necessary capabilities and knowledge of the correct coating techniques and applications using best practices as well as quality control of coating processes that are fundamental to ensuring successful results. The excellent protection offered by our superior quality, highly dependable coating solutions against surface wear and corrosion delivers numerous cost saving benefits including the enhancement of equipment lifespan, a reduction in downtime, replacement and maintenance costs, and improved equipment and plant uptime, productivity and production.”

34

Methods applied by Thermaspray to overcome abrasion, adhesion, erosion and corrosion specifically in the sugar industry include: •

Thermal Spraying, a generic term used to define a group of processes that deposit fine metallic or nonmetallic materials onto a prepared substrate to form a coating.

The coating material may be in powder, rod or wire form. The different processes include: - High Velocity Oxy-Fuel (HVOF): Operates on a continuous steady-state basis with continuous powder feed. Thermaspray offers two processes - gas and liquid fuelled.

Pumps and Valves Africa - Jan/Feb 2017

- Wire Arc Spraying (Also known as twin-wire arc spray process). Direct current (DC) electric arc is used to melt the feedstock with compressed air behind the arc atomising the molten material. Higher thermal efficiency is achieved as wires are melted directly.

Coatings are coarse with higher porosity.

- Powder Plasma Spraying: Plasma (4th state of matter) consists of neutral and positive atoms and free electrons. Plasma gasses are heated as they ionise in the arc and high degree of melting and relatively

high particle velocities are achieved. Finely structured coatings with high adhesion strength.

•

Plasma Transferred Arc (PTA) welding and hardfacing process a versatile method of depositing high quality metallurgically fused deposits on relatively low cost substrates.

Polymer Applications -

- Diamant Metallplastic (Polymeric Solutions): Thermaspray is the exclusive Southern African representative of German-based DIAMANT Metallplastic GmbH. DIAMANT Metallplastic offers the metalworking industry high-quality polymeric solutions to restore functionality to castings, thereby significantly reduce scrap.

The DIAMANT polymeric solution includes products for impregnating and sealing leakages, repair of blow holes and surface treatments as well as wear protection and services.

Plasma Coatings (Non-Stick and Traction Coatings): Thermaspray has undertaken a strategic partnership with Plasma Coatings in the USA to offer the South African market a new range of surface technologies and coatings to tackle the sugar, food, printing and packaging, tyre and rubber, paper and pulp, fempro/ diaper and many more industries. These coatings are designed to solve many of the above industries’ problems resulting in reduced maintenance, higher outputs and an increase in

Typical applications in sugar industry include knife and trash plate replacement components in sugar mill, shredder hammers, crushers rolls, scrapers, pump casings, conveyor screws, valves covers, flanges and bearings and bearing journals.

Thermaspray, in a joint venture with Cape Town-based Surcotec, offers an extensive portfolio of engineering and thermal spray coating solutions that extend component life cycles to assist OEM and end-user clients across southern Africa in reducing costs and increasing production.

PUMPS

•

cost savings. These coatings combine the advantages of thermal spray (metal base) coatings with polymer top coatings to offer benefits of wear resistance, slip and traction. These coatings can be applied to aluminium, steel, stainless steel, tool steel, copper, ceramics as well as synthetic materials.

The companies’ world-class quality wearand corrosion-resistant thermal spray coatings, Plasma Transferred Arc (PTA) cladding and Polymer coatings (in partnership with Plasma Coatings USA and DIAMANT Metallplastic Germany) are augmented by a host of specialised allied services

Dr. Jan Lourens Thermaspray Tel: +27 (0) 11 316-6520/8/9 jlourens@thermaspray.co.za

Industrial and Designer Valves Holdings (Pty) Ltd.

Valves for the Petroleum, Gas and Chemical Industry

IDV is the sole distributor in South Africa for GOYEN and MECAIR

Goyen and Mecair offer efficient reverse pulse filter cleaning solutions for air pollution control.

Fire-safe ball valves, gate valves and check valves (double-door wafer and swing type) are internationally approved and CERTIFIED (API 6D), PED and SIL. COMPLETE PRODUCT AND SOLUTION PROVIDERS Tel: +27 11 475 1024 • Fax: + 11 679 5461 E-Mail: info@idv.co.za • Web: www.idv.co.za

Their technology is acknowledged as market leading, offering tailored solutions for the world’s dust collector manufacturers and system users.

Tel: +27 11 475 1024 • Fax: + 11 679 5461 E-Mail: info@idv.co.za • Web: www.idv.co.za

Pumps and Valves Africa - Jan/Feb 2017

35

PUMPS AND VALVES

SKF Customized Interfacing

Integrates Condition Monitoring Data Into Business Management Systems SKF Customized Interfacing connects SKF @ptitude suite with business management systems to make critical condition monitoring data available for review in one location and enables better decision making.

In particular, the improved integration of data, often in real time, creates the potential for greater business automaton, new performance improvements and reduced operating costs.

B

y integrating the SKF @ptitude condition monitoring suite with customers’ existing ERP and CMMS solutions, allows businesses to review all condition monitoring data in their existing business management system, helping to ensure better decision making for improved performance, efficiency and reliability of systems.

To date, process and condition monitoring data has been widely available, but has traditionally been stored in different and separate data silos. This has made strategic decision making a difficult and complex task. Now, the SKF Customized Interfacing allows data from multiple condition monitoring and asset management systems to be integrated with information from enterprise-wide resource planning and programming platforms.

This approach from SKF allows companies to take a far more holistic view of their plant-wide operating technologies.

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Pumps and Valves Africa - Jan/Feb 2017

SKF is in a unique position to help customers in this area, as it is the only specialised global supplier that offers a full set of solutions.

These include: condition monitoring and asset optimisation hardware and software, management tools and in-house consultancy plus, with the new ESB interface, the knowledge and technology to integrate operational data with strategic business planning.

Bjoern Robel, Development Manager with Industrial Mobile Solutions at SKF explains,“This is an important step forward, and the first time that such a system has been available to harness the power of SKF’s @ptitude suite of condition monitoring technologies with the strategic management potential of ERP platforms. We see this as a critical tool to help customers enhance their business processes still further, while gaining a vital edge in increasingly competitive global markets

SKF Samantha Joubert Tel: +27 (0) 11 821-3602 samantha.joubert@skf.com www.skf.com

Despite numerous appeals made to government by industry, not enough has happened this past year to improve South Africa's water infrastructure. Numerous promises were made regarding the replacement of aging infrastructure which have long since reached the end of their lifespan, but not much has come from these talks

PIPES

Exciting Areas of Growth in Plastic Pipe Industry

W

ater distribution, waste disposal, irrigation and telecommunications all rely on pipelines to function.

Pipelines, therefore, lie at the heart of South Africa’s infrastructure and should be replaced before they fail.

For several years now, Southern African Plastic Pipe Manufacturers Association (SAPPMA) has been issuing stern warnings about an unavoidable water crisis due to the fact that the replacement of old water pipes around the country is long overdue. As early as 2012, we starting communicating to role players and decision makers that the existing steel and asbestos cement pipe infrastructure in South Africa has corroded since they were installed more than 50 years ago.

We have been warning government for a long time now about the possibility of water shortages in the country, especially in areas of high population. Their reluctance to listen to us and slow action is now starting to take its toll in the light of severe water restrictions. When looking at the current water crisis and possibility of water shedding, however, it is clear that we were not crying wolf. Unfortunately, it has taken too long for the message to sink in nor are they doing enough to address related problems such as the pollution of the country’s water sources.

Growth areas for the plastic pipe industry Despite the fact that we are operating in very difficult economic and market conditions, there are exciting areas of growth in the plastic pipe industry. Water distribution and sewage disposal in particular are two areas where the demand for HDPE and PVC pipes are growing in demand.

The potential for strong recovery in the plastics pipe industry is great, provided a few sensible decisions are made at government level. Apart from this, there is still good potential to grow market share at the cost of other materials, due to the inherent benefits of PVC and HDPE piping systems.

This includes the ability of some materials enabling larger diameters and higher pressures.

We are also optimistic about the positive impact potential that new services in areas not yet linked to the infrastructure will have on the plastic pipe industry, as well as the upgrading of pipe networks that have reached the end of their useful life or lines that are currently inadequate. They are also anticipating that natural gas distribution will eventually contribute to the demand of plastic pipe.

Facing the challenges Some of the most pressing issues facing the local plastic pipe industry continue to be the typical problems of the country, such as labour issues, skills shortages and work ethic.

Fortunately, it seems as if the electricity supply problem experienced a year ago now appears to be a thing of the past, although the high cost of electricity still has a crippling effect on industry role players. There is increasing worry that electricity supply could very well again become an issue if the industrial and mining demand in the country increases.

Another challenge is the need for modernising production equipment in order for local pipe manufacturers to become more efficient. However, in light of the current low demand, it is hard to motivate such a much-needed investment.

Conclusion From our perspective, not enough is materialising to improve the country’s water infrastructure. One can only hope that the current water crisis that is staring our nation in the face will galvanise action at government level and that the political infighting does not totally distract from setting priorities and working towards it.

There are many exciting, new markets and opportunities emerging for the plastic pipe industry.We have an everincreasing role to play, and are making a difference where it matters. As an industry, we are committed to doing everything in our power to ensure the future of the industry through maintaining excellent quality and adhering to industry standards. We want to make sure that we are part of the solution – not part of the problem.

SAPPMA, Jan Venter, Tel: +27 (0) 11 314-4021, admin@sappma.co.za www.sappma.co.za Pumps and Valves Africa - Jan/Feb 2017

37

VALVES

Afrivalve Appointed As Official Distributor Of Gemu Valves For Mining Sector In Africa

Afrivalve, part of the eDART Group of Companies, have further expanded their range to now offer the Gemü Valve and Control Systems range in the mining and metal refining sector in Africa. This further compliments the eDART Slurry Control Valves, C-Tech knife gate valves, Red Roc Pinch valves and AVI range of industrial valves.

G

regor Hopton of Afrivalve has over 20 years of experience selling the Gemü range in South Africa and knows the quality and reliability that the brand offers. This gives Afrivalve the ability to offer a complete valve solution typically from Mill discharge all the way through the process to the final refined metal. This was a necessary addition due to Afrivalve’s success with larger projects in the mining sector and the customer’s preference for a single source solution.

This was a necessary addition due to Afrivalve’s success with larger projects in the mining sector and the customer’s preference for a single source solution The Gemü range includes metal body valves, metal body lined in thermoplastic (or Fluoropolymer lined) and full thermoplastic valves. Full bore and Weir Type Diaphragm, Butterfly, Angle Seat, Globe and Solenoid valves are commonly used in the mining sector. Both abrasive and corrosive applications are catered for in the wide range of materials of construction.

Control solutions including position indicators, positioners and Variable Area Flowmeters.

In-house expertise within the eDART Group includes mechanical, instrumentation, process and design engineers. Control valve sizing and specialised valve training courses are also offered within the group 38

Gregor Hopton of Afrivalve

and more information is available on request.

Gemü valves are stocked locally and are available from their new facility in Kya Sand - Randburg, Gauteng.

Pumps and Valves Africa - Jan/Feb 2017

Gregor Hopton, Tel: +27 (0) 11 791-1411 gregh@afrivalve.co.za www.afrivalve.co.za

Pumps and Valves Africa - Jan/Feb 2017

39

VALVES

Flotation Level Measurement Techniques The requirement for good level control of flotation machines is well established and documented. In this article we will focus on the more common level measurement options available in the market in the flotation plant today, including the pros and cons associated with each one.

A

ll level control loops consist of essentially three main components: the level measurement sensor, the level controller and the level control valve. In order to achieve good level control each of the components need to work well. eDART Slurry Valves (PTY) LTD have been manufacturing and supplying a range of level control dart valves specifically for global flotation market for over 10 years. Our customers include the largest OEMs, and engineering firms and mining houses that operate in this niche market space.

A well known expression amongst Control and Instrumentation engineers is “the most reliable measurement will always be non-contact and have no moving parts.�

The reason for this is linked to the robustness and reliability of the instrument. Any instrument that is in contact with the measured medium and has moving parts is going to be far more prone to failure, more so, if that medium happens to be slurry.

Unfortunately this is not always achievable and in this case we generally settle for as close to the ideal as is practically possible.

Level measurement of a flotation cell is not as straightforward as it first sounds. By level we are actually meaning froth depth.

Of interest in a flotation cell is how deep is the froth above the slurry, as this determines the grade of the resulting concentrate.

The typical range for a froth depth of a flotation cell is 600 mm from the top of the cell, the launder, down to the slurry interface. Here we are actually trying to measure the depth of a froth, or foam layer. As the level we are interested in is covered in froth, measuring it is a lot more challenging.

Measurement Techniques All the measurement techniques share a few common requirements. The ability to transmit the measured level back to the control room reliability, often through a hostile environment, resist EMI and RFI, and update within an acceptable time frame.

The loop powered current signal which works on a range of 4 – 20 mA is still by far the most common way of transmitting a level signal to the control room. It has proven itself as being reliable, stable and has the useful ability to indicate a wire break or fault. As the current signal would then fall away to zero.

40

Pumps and Valves Africa - Jan/Feb 2017

Modern digital bus technology is gaining popularity due to the minimising of signal cables required, even more recently wireless transmitters are being introduced ,which eliminate signal cables altogether. Even though changes in level in the average flotation cell are relatively slow you still need to update the signal frequently. For control, you always want your sample rate to be at least ten times faster than your loop update rate, and you need to refresh the level signal at worst once per second.

One of the oldest level measuring techniques is via a rotary potentiometer connected to a float arrangement. The float at the slurry/froth interface is connected to the rotary potentiometer by a set of mechanical linkages not unlike a pantograph. This is a simple instrument, but it has been so unreliable that it is seldom used in modern plants. The mechanical linkages become stiff and jammed with froth and eventually the instrument does not respond to the changes in level. These devices are maintenance intensive. In addition the conversion from the linear movement of the float to a rotary potentiometer introduces a non-linear error as well. With all float systems, if a cross current exists in the flotation machine it will be necessary to install a stilling well around the float.

An ultrasonic level measurement alone cannot be used as the froth absorbs the ultrasonic signals, likewise with infrared and radar.

The ultrasonic transmitters are now a mature technology having been in the market for over 15 years and supplied by a number of world class instrumentation suppliers.

Generally they work well and are cost effective.

However, the problem with this technique is once again with the mechanical components that are in contact with the froth and slurry. They suffer from coming into contact with the froth, causing them to stick or jam, and the slurry build-up changes the buoyancy of the float. All resulting in increased maintenance and wear rates and decreased reliability.

Guided wave radar is a step closer to the ideal instrument in that it does not have any moving parts. These instruments use a metal tube as the antennae, or wave guide, for the radar. The wave guide is extended into the slurry interface, the radar signal traveling along the wave guide is reflected back off the slurry interface to be detected by the instrument. The time the signal takes to return to the instrument is directly proportional to the level. A slurry build up on the wave guide used to be a problem for this technique instrument, however the introduction of modern instruments that feature multiple frequency radar waves have virtually eliminated this problem. Even so these units are not popular for the simple reason that they are costly, when compared to the alternatives.

Understanding that flotation concentrators often have in excess of fifty flotation machines requiring level measurement, explains the customer’s sensitivity to cost per level point.

Another approach, which is fairly common is based on the magnetoresistive principal. Here a magnetic sensor within a sealed pipe moves in relation the slurry level in the flotation cell, up and down, a wire sensor. The signal transmitted down the wire is reflected by the induced magnetic field in the wire

Conductance type level sensors can also be found in this market. Here the sensors make use of the electrical conductivity to indicate the slurry level. As the slurry level changes so does the conductance of the sensor. Sometimes also referred to as resistivity type instruments as conductance is the reciprocal of resistance, or resistivity. As the ore is never consistent, these sensors suffer from the fact that ore changes, changes in the conductivity of the water, or reagent changes in type and strength will result in a change of conductance measured, resulting in frequent re-calibration requirements. More modern instruments include more than one measurement technique which has resulted in more reliable measurements.

VALVES

Probably the most common, although not ideal, method of measuring level in a flotation cell is via a combination of an ultrasonic level transmitter and a target plate assembly. This technique involves connecting a “target plate” to a float and then measuring the changes in height of the target plate using an ultrasonic instrument.

sensor and therefore indicates the level in the flotation machine.

This type of sensor is accurate and repeatable and it also has extremely fine resolution, in the order of 0,5 mm. However as the magnetic sensor is coupled to a float on the slurry interface, it is susceptible to slurry build up as in all float systems. Despite this, it is now one of the more successful techniques seen in use in the market.

There is a lot of exciting development work being done using this measurement principal. These instruments have been developed to the extent where they can give an output signal of “froth density” over the length of the measured range and the froth/slurry interface as well as the froth height, other than the simple slurry interface point Again, it is the sophisticated instruments that work fairly well, which come at a cost.

Theoretically, it is possible to use X-Ray to determine the slurry level interface however the costs and safety considerations make this an impractical option. Personally, I have never seen such an instrument in use in flotation.

As you can see there is no shortage of choice for flotation level measuring instruments out there but as yet none of them meets the full requirements for the ideal instrument, “Noncontact and moving parts“, so the search continues….

eDART Slurry Valves, Richard Rule, Tel: +27 (0) 11 823-6620, richardr@edart.co.za www.edart.co.za

Pumps and Valves Africa - Jan/Feb 2017

41

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VAMCOSA

VALVE AND ACTUATOR MANUFACTURERS CLUSTER OF SOUTH AFRICA

Tel: +27 (0) 11 748-0200 Fax: +27 (0) 11 421-2749 Email: dfc@dfc.co.za www.dfc.co.za

Tel: +27 (0) 79 492-3043 +27 (0) 82 677-5374 Fax: +27 (0) 57 357-4217 Email: info@ariafrica.co.za Web: www.ariafrica.co.za

Tel: +27 (0) 11 951-5000 Fax: +27 (0)11 955-4389 Web: www.cobra.co.za

Tel: + 27 (0) 11 397-3665 Fax: + 27 (0) 11 397-3803 Email: info@az-armaturen.co.za Web: www.southafrica.az-armaturen.de

Tel : +27 (0) 11 422-4326/7 Fax: +27 (0) 11 421-7842 Email: sales@dualvalves.com web: www.dualvalves.com

Tel: +27 (0) 11 864-2582 Fax: +27 (0) 11 864-2381 Email: sales@ithubavalves.co.za Web: www.ithubavalves.co.za

Tel: +27 (0) 11 474-6180/4 Fax: +27 (0) 11 474-6136/7 Email: sales@gunric.com Web: www.gunric.com

Tel: +27 (0) 11 433-3968 Fax: +27 (0)11 433-9107 Email: sales@uvc.co.za Website: www.ainsworth-valves.co.za

Tel: +27 (0) 11 823-6620 Email: info@edart.co.za Web: www.edart.co.za

Tel +27 (0) 11 955-1119 Email: sales@klepvalves.co.za Web: www.klepvalves.co.za

Tel: +27 (0) 39 315-7093 Fax: +27(0) 39 315-7896 Email: info@lwtanks.co.za joanne@lwtanks.co.za james@lwtanks.co.za

Tel: +27 (0) 12 653-1156 Email: sales@paltech.co.za Web: www.paltech.co.za Tel: +27 (0) 11 927-4850 Fax: +27 (0) 11 927-4878 Email: enquiries@mitech.co.za Web: www.mitech.co.za

Tel : +27 (0) 11 882-8030 Fax : +27 (0) 11 882-8038 Email: nivenp@rgrtech.co.za Web: www.rgrtech.co.za

Tel: +27 (0) 21 556-1805 Email: info@valcogroup.co.za Web: www.valcogroup.co.za

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Pumps and Valves Africa - Jan/Feb 2017

Tel: +27 (0) 11 452-6826 Fax: +27 (0) 11 609-4223 Email: enq@floval.co.za Web: www.floval.co.za

PUMPS ANSI PROCESS PUMPS

SAM Engineering Tel: +27 (0) 11 823-4250 Fax: +27 (0) 11 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za

CENTRIFUGAL PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

FIRE PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

BOOSTER PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za BOREHOLE PUMPS

KSB (Pty) Ltd Tel: +27 (0) 11 876-5600 Fax: +27 (0) 11 822-2013 Email: info-za@ksb.com Web: www.ksb.com

SAM Engineering Tel: +27 (0) 11 823-4250 Fax: +27 (0) 11 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za DIAPHRAGM PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

Unique Engineering Tel: +27 (0) 11 826-6111 Fax: +27 (0) 11 826-6162 Email: sales@uniqueeng.co.za Web: www.uniqueeng.co.za

Stewarts & Lloyds (Pty) Ltd Tel: +27 (0) 11 917-0778 Fax: +27 (0) 11 917-0769 Email: peterk@sltrading.co.za Web: www.stewartsandlloyds.co.za

Unique Engineering Tel: +27 (0) 11 826 6111 Fax: +27 (0) 11 826 6162 Email: sales@uniqueeng.co.za Web: www.uniqueeng.co.za

SPP Pumps SA (Pty) Ltd Tel: +27 (0) 11 393-7179 Fax: +27 (0) 86 425-7595 Email: sales@spppumps.co.za Web: www.spppumps.com

SAM Engineering Tel: +27 (0) 11 823-4250 Fax: +27 (0) 11 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za HOT OIL PUMPS

Air & Vacuum Technologies (Pty) Ltd Tel: +27 (0) 861 822-832) +27 (0) 11 318 3241/2/3/4/5 Fax: +27 (0) 86 522-9188 Email: burnm@vactech.co.za Web: www.vactech.co.za JET PUMPS

HIGH PRESSURE PUMPS

Hawk High Pressure Pumps

Tel: +27 (0) 031 274-8555 +27 (0) 10 010-0144 Fax: +27 (0) 31 205-4332 +27 (0) 11 822-2868 Email: sales@hawkpumps.co.za Web: www.hawkpumps.co.za HORIZONTAL SPLIT CASE PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805 8631 Fax: +27 (0) 11 805 8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za METERING PUMPS

Seko (Pty) Ltd Tel: +27 (0) 11 704-6589 Fax: +27 (0) 11 704-6588 Email: m.varkevisser@seko.com Web: www.seko.com MOBILE PUMPS

END SUCTION PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

SAM Engineering Tel: +27 (0) 11 823-4250 Fax: +27 (0) 11 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za

Air & Vacuum Technologies (Pty) Ltd Tel: +27 (0) 861 822-832) +27 (0) 11 318 3241/2/3/4/5 Fax: +27 (0) 86 522-9188 Email: burnm@vactech.co.za Web: www.vactech.co.za

Rocktuff Pumps and Mining Supplies Tel: +27 (0) 13 690-2597 Fax: +27 (0) 13 690-2269 Email: rocktuffpump@lantic.net Web: www.rocktuff.co.za MULTISTAGE PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

Agrico Tel: +27 (0) 21 950 4111 Fax: +27 (0) 21 950 4208 Email: alfred.andrag@agrico.co.za Web: www.agrico.co.za

Pumps and Valves Africa - Jan/Feb 2017

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PUMPS SELF-PRIMING PUMPS

SPP Pumps SA (Pty) Ltd Tel: +27 (0) 11 393-7179 Fax: +27 (0) 86 425-7595 Email: sales@spppumps.co.za Web: www.spppumps.com PISTON PUMPS

Hawk High Pressure Pumps

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C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za SLURRY PUMPS

TRASH PUMPS

Bovu Pumps Tel: +27 (0) 16 362-2571 Fax: +27 (0) 16 362-0635 Email: bovugroup@telkomsa.net Web: www.bovu-pumps.co.za

POSITIVE DISPLACEMENT PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za VACUUM PUMPS

PLUNGER PUMPS

Hawk High Pressure Pumps Tel: +27 (0) 031 274-8555 +27 (0) 10 010-0144 Fax: +27 (0) 31 205-4332 +27 (0) 11 822-2868 Email: sales@hawkpumps.co.za Web: www.hawkpumps.co.za

Stewarts & Lloyds (Pty) Ltd Tel: +27 (0) 11 917-0778 Fax: +27 (0) 11 917-0769 Email: peterk@sltrading.co.za Web: www.stewartsandlloyds.co.za

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

Hizonex Tel: +27 (0) 87 550-1984 Fax: +27 (0) 86 723-5429 Email: maritzrenee@gmail.com Web: www.hizonex.co.za

Walter Meano Engineering Tel: +27 (0) 11 873-8620 Fax: +27 (0) 11 825-1401 Email: wme@mweb.co.za Web: www.versaflo.co.za VERTICAL TURBINE PUMPS

APE Pumps Tel: +27 (0) 11 824-4810 Fax: +27 (0) 11 824-2770 Email: apepumps@mweb.co.za Web: www.apepumps.co.za

SPP Pumps SA (Pty) Ltd Tel: +27 (0) 11 393-7179 SAM Engineering Fax: +27 (0) 86 425-7595 Email: sales@spppumps.co.za Tel: +27 (0) 11 823-4250 Fax: +27 (0) 11 823-4943 Web: www.spppumps.com Email: sales@sameng.co.za Web: www.sameng.co.za VANE PUMPS

vacuum pumps and valves

Unique Engineering Tel: +27 (0) 11 826-6111 Fax: +27 (0) 11 826-6162 Email: sales@uniqueeng.co.za Web: www.uniqueeng.co.za

SAM Engineering Tel: +27 (0) 11 823-4250 Fax: +27 (0) 11 823-4943 Email: sales@sameng.co.za Web: www.sameng.co.za

SA Biotech Tel: +27 (0) 11 938-3581 Fax: +27 (0) 86 586-8501 Email: info@sabiotech.co.za Web: www.sabiotech.co.za

SAMCO PUMPS (Pty) Ltd Tel: +27 35 751-1202 Fax: +27 35 751-1204 Email: joffre@samcopumps.com Web: www.samcopumps.com

SUBMERSIBLE PUMPS

VERTICAL SUMP PUMPS

WELL PUMPS

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

RNE Pumps (Pty) Ltd Tel: +27 (0) 11 452-3528 Fax: +27 (0) 82 612-0358 Email: mark@rnepumps.com Web: www.rnepumps.com

Pump and Abrasion Technologies Tel: +27 (0) 12 666-0904/5 Email: sales@pumpab.co.za Web: www.pumpandabrasion.co.za

PUMP CASTINGS

Ukuthela Foundry Projects Tel: +27 (0) 12 719-8860 Fax: +27 (0) 86 239-2597 Email: ukuthela@live.co.za 44

Pumps and Valves Africa - Jan/Feb 2017

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

VALVES AIR VALVES

BUTTERFLY VALVES

CHECK VALVES

Agrico Tel: +27 (0) 21 950 4111 Fax: +27 (0) 21 950 4208 Email: alfred.andrag@agrico.co.za Web: www.agrico.co.za

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

Rotork Africa Tel: +27 (0) 11 453-9741 (Jhb) Tel: +27 (0) 21 556-4677 (CT) Email: juan.oglesby@rotork.com Web: www.rotork.com

KayTar Valves Tel: +27 (0) 21 987-8292 Email: clinton@kaytarvalves.co.za Web: www.kaytarvalves.co.za

Invincible Valves (Pty) Ltd Tel: +27 (0) 11 822-1777 Fax: +27 (0) 11 822-3666 Email: enquiries@invalve.co.za Web: www.invalve.co.za

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 Email: malan.bosman@tectra.co.za Web: www.hytecgroup.co.za

KSB (Pty) Ltd Tel: +27 (0) 11 876-5600 Fax: +27 (0) 11 822-2013 Email: info-za@ksb.com Web: www.ksb.com

BALL VALVES

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

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

Stewarts & Lloyds (Pty) Ltd Tel: +27 (0) 11 917-0778 Fax: +27 (0) 11 917-0769 Email: peterk@sltrading.co.za Web: www.stewartsandlloyds.co.za

Stewarts & Lloyds (Pty) Ltd Tel: +27 (0) 11 917-0778 Fax: +27 (0) 11 917-0769 Email: peterk@sltrading.co.za Web: www.stewartsandlloyds.co.za

Invincible Valves (Pty) Ltd Tel: +27 (0) 11 822-1777 Fax: +27 (0) 11 822-3666 Email: enquiries@invalve.co.za Web: www.invalve.co.za GATE VALVES

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 Email: malan.bosman@tectra.co.za Bearing Man Group (BMG) Tel: +27 (0) 11 620-1500 Web: www.hytecgroup.co.za Email: fluidtech@bmgworld.net CONTROL VALVES Web: www.bmgworld.net

KSB (Pty) Ltd Tel: +27 (0) 11 876-5600 Fax: +27 (0) 11 822-2013 Email: info-za@ksb.com Web: www.ksb.com

VAG-Valves South Africa Klamflex Pipe Couplings Tectra Automation Tel: +27 (0) 11 762-5326 Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 762-5674 Fax: +27 (0) 11 971-9440 Email: malan.bosman@tectra.co.za Email: Web: www.hytecgroup.co.za r.loggerenberg@vag-group.com Web: www.vag-group.com

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

Invincible Valves (Pty) Ltd Tel: +27 (0) 11 822-1777 Fax: +27 (0) 11 822-3666 Email: enquiries@invalve.co.za Web: www.invalve.co.za

DIAPHRAGM VALVES

VAG-Valves South Africa Klamflex Pipe Couplings Tectra Automation Tel: +27 (0) 11 762-5326 Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 762-5674 Fax: +27 (0) 11 971-9440 Email: Email: malan.bosman@tectra.co.za r.loggerenberg@vag-group.com Web: www.hytecgroup.co.za Web: www.vag-group.com

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

VAG-Valves South Africa Klamflex Pipe Couplings Tel: +27 (0) 11 762-5326 Fax: +27 (0) 11 762-5674 Email: r.loggerenberg@vag-group.com Web: www.vag-group.com

Pumps and Valves Africa - Jan/Feb 2017

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VALVES KNIFE GATE VALVES

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

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

Invincible Valves (Pty) Ltd Tel: +27 (0) 11 822-1777 Fax: +27 (0) 11 822-3666 Email: enquiries@invalve.co.za Web: www.invalve.co.za

VALVES CASTINGS

Ukuthela Foundry Projects Tel: +27 (0) 12 719-8860 Fax: +27 (0) 86 239-2597 Email: ukuthela@live.co.za

ACCESSORIES

KLINGER South Africa Tel: +27 (0) 11 842-8300 Fax: +27 (0) 11 827-8663 Email: gareth.langton@klinger.co.za Web: www.klinger.co.za

ACTUATORS

MANUAL

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 Email: malan.bosman@tectra.co.za Web: www.hytecgroup.co.za MECHANICAL PACKING

KLINGER South Africa Tel: +27 (0) 11 842-8300 Fax: +27 (0) 11 827-8663 Email: gareth.langton@klinger.co.za Web: www.klinger.co.za PIPES PNEMATIC - DOUBLE ACTING

PLUG VALVES

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 Email: malan.bosman@tectra.co.za Web: www.hytecgroup.co.za

Invincible Valves (Pty) Ltd Tel: +27 (0) 11 822-1777 Fax: +27 (0) 11 822-3666 Email: enquiries@invalve.co.za Web: www.invalve.co.za SLEEVE VALVES

VAG-Valves South Africa Klamflex Pipe Couplings Tel: +27 (0) 11 762-5326 Fax: +27 (0) 11 762-5674 Email: r.loggerenberg@vag-group.com Web: www.vag-group.com 46

Rotork Africa Tel: +27 (0) 11 453-9741 (Jhb) Tel: +27 (0) 21 556-4677 (CT) Email: juan.oglesby@rotork.com Web: www.rotork.com

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 Email: malan.bosman@tectra.co.za Web: www.hytecgroup.co.za

Agrico Tel: +27 (0) 21 950 4111 Fax: +27 (0) 21 950 4208 Email: alfred.andrag@agrico.co.za Web: www.agrico.co.za

C.R.I Pumps S.A. (Pty) Ltd Tel: +27 (0) 11 805-8631 Fax: +27 (0) 11 805-8630 Email: cri@cripumps.co.za Web: www.cripumps.co.za

Pumps and Valves Africa - Jan/Feb 2017

PNUEMATIC - SPRING RETURN

PNUEMATIC - DOUBLE ACTING

ENGINEERED PLASTICS

KLINGER South Africa Tel: +27 (0) 11 842-8300 Fax: +27 (0) 11 827-8663 Email: gareth.langton@klinger.co.za Web: www.klinger.co.za

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 Email: malan.bosman@tectra.co.za Web: www.hytecgroup.co.za

Invincible Valves (Pty) Ltd Tel: +27 (0) 11 822-1777 Fax: +27 (0) 11 822-3666 Email: enquiries@invalve.co.za Web: www.invalve.co.za

Tectra Automation Tel: +27 (0) 11 971-9400 Fax: +27 (0) 11 971-9440 Email: malan.bosman@tectra.co.za Web: www.hytecgroup.co.za

KSB Etanorm 210x275.indd 1

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Vacuum & AOD pumps for mining applications along with a range of laboratory equipment, since 1985 AV&T offers a range of quality products at market related prices, with sound technical advice, efficiency and friendliness forming the base of our sales and service support to all sectors of the mining industry.

We pride ourselves on our efforts to take more care, offer better service, advice, support and guarantees. We offer sales, service & repairs of almost all types of vacuum pumps & AOD pumps and lab equipment.

A&VT = ADDING VALUE TOGETHER

SALES, SPARES AND REPAIRS info@vactech.co.za 0861 VACTEC (822 832) www.vactech.co.za 48

Pumps and Valves Africa - Jan/Feb 2017