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Worlds largest gate valve


Treat your water-energy like gold Unmet efficiency with up to 10%-20% energy cost reduction Super high flow rate Designed for superior cavitation resistance High regulation capabilities

+27 (0)11 383 4000 www.macsteel.co.za


CONTENT COVER STORY Transducer Technology

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PUMPS KSB Pumps and Valves recently tested an impressive pump set 6 Vesconite wear rings offer pump operating advantage 7 The life of any centrifugal pump is based mainly on the lubrication

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Reading a centrifugal pump curve does not have to be a daunting task 10 Krebs® pumps excel in Africa

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IIoT enabled pumps are slashing maintenance costs and downtime

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BMG distributes Garlock sealing technologies

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Slurrysucker helps farmer save water

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Responsiveness to pit dewatering needs differentiates IPR

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INDUSTRY NEWS Monitor water levels and flows from mobiles Sulzer introduces wireless condition monitoring

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VALVES AVK Valves quality endorsed by large local mining company Finding the right partner for control valve solutions in the pulp and paper industry can be challenging Local content inspires AVK’s international expansion Allmech – sole authorised agent for Runxin Valves World’s largest gate valve Digitisation of water processes saves almost 40% in costs Nuclear technology remains lucrative for valve manufacturers

Transducer Technology

Tel: +27 (0) 11 425 2094 Email: sales@transducers.co.za Web: www.transducers.co.za

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REPORT BACK Pipes, Pumps & Valves Africa at Electra Mining Botswana 2019

On the cover

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PRODUCTS & SERVICES

Pumps & Valves Africa

Managing Editor: Surita Marx Tel: +27 (0) 87 153-1217 Cell: +27 (0) 83 281-5761 Email: info@pumpsandvalves.co.za Web: www.pumpsandvalves.co.za Sales: Lusana Mrkusic Email: lusana@pumpsandvalves.co.za Sales: Kyle Rametsen-Spalding Email: kyle@pumpsandvalves.co.za Graphic Designer: Nomfundo Nene

A leading supplier of vacuum pumps and blowers to the Southern African Pulp, Paper Board and Tissue Industry

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BUYERS GUIDE

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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.

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Actom 13 BMG 23 CONEXPO-CON/AGG IBC CRI Fluid Systems 35 Enserve 7 Flowrox 43 Hidrostal 11 Integrated Pump Rental 37 Integrated Pump Technology 41 Invincible Valves 39 KV Controls 29 LVSA Group 9 Macsteel Fluid Control IFC Pleix-Quip Africa 17 Pamodzi Unique OBC Sam Engineering 27 Stewarts & Lloyds 21 Sulzer CS Transducer Technology OFC Vac-Cent Services 31 Verder 15

Pipes, Pumps and Valves Africa - Sept/Oct 2019

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COVER STORY

Transducer Technology are experts in flow, level & pressure measurement & control Established in 1983, Transducer Technology has grown into a focussed and specialised instrumentation company offering an extensive and diverse range of products to meet the application requirements across industry sectors. Pipes, Pumps & Valves Africa found out more about this company. Continuous expansion of its service and product offering has been at the core of Transducer Technology’s strategy from the get go. Initially only offering a few core products and services, this expansion drive has seen the company establish itself as specialists in the areas of flow, pressure, level, temperature and displacement measurement, says technical sales manager Mathew Battson. “Today we import, distribute and manufacture a very comprehensive range of instrumentation to suit almost any application need.” Ranging from flow, level and pressure sensors and controls for water systems and pump control systems, to mining process controls and measurement. High accuracy sensors used for research and development applications and cost effective sensors for high volume original equipment manufacturers. The approach to have suitable quality products at an affordable price as possible has served the company well throughout many industries. “We also supply sensors for Off Highway Vehicle management systems as well as sensors and controls used for military vehicle and underground mining machine applications. Sensors and controls for general industrial automation systems are also available,” says sales manager Brandon Houghton. The goal, he says, remains to be the one-stop, all-solutions provider to a variety of industries. Based in Benoni on the East Rand in Johannesburg the company has built up a solid customer base across South Africa.

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Pipes, Pumps and Valves Africa - Sept/Oct 2019

“We also have knowledgeable key sub distributors in all major centres as well as in our neighbouring countries,” says Houghton. Experienced team A well-trained, experienced team is on hand at all times to offer expert technical advice and assistance for the company’s complete range, says Battson. “Over the past two decades we have established ourselves particularly well in the water and waste sector with the design and development of our own submersible hydrostatic level sensor range, used to measure level in boreholes, dams, rivers and reservoirs.” He says the success of this product line has resulted in meaningful long term relationships within the water and waste industry. “This, to some extent, has put us in an advantageous position to offer a comprehensive range of bulk water meters, electromagnetic and ultrasonic flowmeters to the industry.” Growing business According to a recent international study the global pressure transmitter and transducer market is expected to register a compound annual growth rate of 4.1% between 2019 and 2024.


This research highlighted the growing demand for sensors that measure pressure, level, flow, and derivatives by physically responding to the changes in process conditions. Increased emphasis on industrial automation is also expected to drive the market.

This has also been the case in South Africa. Investment into its product range, services and experienced staff has been a driving force in the growth at Transducer Technology. This in turn has brought about competitive advantages. “With the continued growth of our business we have been able to invest in our own flowmeter test facility, where we can check and verify the accuracy and operation of any of our flow meters,” says Houghton. Both He and Battson emphasise that products are not just introduced for product sake. Quality is integral as is extensive testing to guarantee this to the client. “Our flow product offering continues to grow at a steady pace, but new products are only introduced after extensive testing and evaluation to ensure suitability in the South African market. We also have long term partnerships with many system integrators and can facilitate turnkey

Going forward Around the world there is a continued focus on the optimum utilisation of resources, says Houghton. As government reforms become tighter and economic slowdowns continue, industries across the board are under pressure to increase their efficiencies, while reducing cost as well as focusing on a cleaner, greener environment. “Over the years we have grown from strength to strength,” he says. “We have gained some serious traction in the water sector. Government clampdown on enforcing water usage legislation is driving the need for products such as flowmeters and level sensors to become essential to the industry.” Battson also is optimistic about the future and says with water users becoming increasingly water wise and aware in South Africa it bodes well for the sensor industry. “The ability to study, monitor and control water usage through automation only leads to the optimisation and increased efficiency of irrigation and farming operations,” he explains. “We have seen steady growth and only have confidence that this will continue well into the future. Our service, technical assistance and the quality of our products at competitive pricing assures us of this.”

COVER STORY

“With the concept of Industry 4.0 (4IR) and the Internet of Things (IOT) coming into the picture, industries have been evolving themselves to adopt the latest technological changes by investing heavily in development and automation,” reads the study.

solutions from simple monitoring and pump control to data acquisition and cloud based data logging systems. The possibilities really are endless,” says Battson.

• MAGNETIC FLOW METERS • ULTRASONIC FLOW METERS • TURBINE FLOW METERS • BULK WATER METERS • BOREHOLE & DAM LEVEL SENSORS • TANK LEVEL SENSORS • PRESSURE SENSORS • PRESSURE SWITCHES • DIGITAL DISPLAYS Transducer Technology +27 (0) 11 425 2094 sales@transducers.co.za www.transducers.co.za

Pipes, Pumps and Valves Africa - Sept/Oct 2019

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KSB Pumps and Valves recently tested an impressive pump set KSB Pumps and Valves recently tested an impressive pump set at the SABS.

PUMPS

Impressive scale “The test is unusual as components are usually tested individually and again on commissioning. This time, however, the units were tested separately - the pump in Germany pre-delivery to South Africa, the diesel engine by Mitsubishi in France and the gearbox by David Brown here in Benoni. Due to the nature of the project, further tests were then required of the entire unit including capacity, head, power, efficiency and net positive suction of the pump to ensure further conformity with specifications. “KSB usually performs these tests on our own standard equipment, but this time the size of the motor was a limiting factor and required us to use the SABS facility. Here, testing was done under the supervision of the customers, KSB and SABS personnel and ran for four hours before being deemed to meet all specifications and requirements,” says KSB’s test field manager, Norman Taylor

Powerful pump set tested Here the team lower the diesel engine into position on installed baseplate for alignment with gearbox and pump with 1350Kw of raw power produced by a massive V16 diesel motor, the SABS in conjunction with KSB Pumps and Valves has tested one of the most impressive pump sets to be assembled on South African soil in recent times. Due to the critical nature of the application to suppress toxic gases in an emergency situation, engineers took the unusual step of pre-testing the complete pump set to ensure the unit performs exactly as required. In this instance, even KSB’s own world-class testing facilities in Germiston were deemed too small to deal with the sheer size and power of the set. This necessitated the use of the SABS’ larger facilities in Pretoria. KSB contract manager, Geoff Havenga, explains the set, comprising a heavyweight KSB a RDLO 400-935A pump, V16 Quad-Turbo Mitsubishi motor and David Brownmanufactured gearbox, is part of Sasol’s Natref Hydrofluoric Acid Cloud Mitigation project and is required to rapidly produce a spray water to “knock down” any gas cloud that may form in an emergency spill situation. As a result, the pump set needs to be ultra-reliable and ready to spark in to action in an instant to pump approximately 770 litres of water per second at a head pressure of 13 Bar. 6

Pipes, Pumps and Valves Africa - Sept/Oct 2019

“These kinds of string tests are done to ensure the entire units work correctly considering that the diesel motor requires to produce a staggering 1015Kw of power just to handle the required absorb-power needed to produce the 2800 m³ of water needed per hour. Also, the forces at play when you consider this power is generated at 1500RPM and reduced through a reduction gearbox to 1000 which is the optimum range of the KSB a RDLO 400-935A pump.” Trusted type Geoff continues, “With the unit weighing in at an impressive 32-tons it is particularly impressive that we have facilities in South Africa where our customers can witness the performance of the equipment that they have purchased, in this instance by Worley Consulting Engineers on behalf of Sasol.” “The kind of pump used is widely operated in high volume applications in raw and potable water industries and is capable of reliably pumping high volumes on a continual basis. Well known for their reliable operation, they were deemed as the ideal pump for this critical operation. “We have a long relationship with both parties and proven service levels across our large installed base in Sasol and similar operations across the continent,” Geoff concludes. KSB Pumps and Valves, +27 (0) 11 876 5600, Annett.Kriel@ksb.com, www.ksbpumps.co.za


Vesconite wear rings offer pump operating advantage Vesconite Bearings’ casing wear rings are proving so popular that they are currently the company’s most important wear component for the pump industry.

PUMPS

The wear rings are used to restrict the pressure leakage of the fluid between the inlet of the impeller and the pump casing in centrifugal pumps. The wear rings are made from the thermoplastic Vesconite Hilube, which is a low-friction, wear-resistant polymer that replaces traditional metals such as bronze and stainless steel as well as other thermopolymers. Here are the benefits: •

They replace metal components that require large running clearances to avoid metal-on-metal contact. Metal-on-metal can result in galling and unwanted pump vibration, as well as severe damage to the pump;

They improve efficiency clearances can be applied;

They do not require pump redesigns, since they can fit into the same housings used by metal wear rings and, because they are press fit, do not require mechanical fitment or glue;

They can be easily machined from a variety of tube stock or they can be machined for use using Vesconite Bearings’ machining capability;

They are impervious to salt-water corrosion and thus are ideal for sea water and reverse osmosis pumps where galvanic corrosion may destroy stainless steel wear rings;

since

tighter

running

They resist cavitation, a problem often encountered with metal wear rings; and

Vesconite Hilube is approved, including by NSF61 and WRAS, for drinking water applications.

Vesconite, +27 (0) 11 616 1111, phillip@vexconite.com, www.vesconite.com

Enserve Group Enserve Engineering Services (Pty) Ltd are the proud sole sales, reconditioning, installation and commissioning agents for the world renowned Larner-Johnson® Valves manufactured by Blackhall Valves. Proud suppliers to the bulk water supply industry worldwide Enserve Engineering Services (Pty) Ltd

• Fixed Cone Hollow-Jet valves • Submerged Discharge Valves • Pilot-operated and plunger type control valves • Large bore parallel faced and wedge type gate valves

+27 (0) 16 971 3885

mail@enserve.co.za

www.enserveonline.com

Pipes, Pumps and Valves Africa - Sept/Oct 2019

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PUMPS

The life of any centrifugal pump is based mainly on the lubrication Don’t ever underestimate the importance thereof, says Andreas Vandré, Flowserve Regional Manager Educational Service EMA. Pipes, Pumps & Valves Africa finds out more. At least 43% of all ball bearing failures can be attributed to lubrication issues. This is according to Vandré, who says that mounting and fatigue together only make up about 36% of the issues clearly indicating the importance of lubrication for pump systems. Speaking at a workshop, hosted by Liquid Movers at their Johannesburg offices, Vandré says often lubrication is not a very high priority on the pump engineer’s list.

Grease lubrication on the other hand is a far more simple design and has no oil levels to maintain. It assists the seals to keep out dirt and moisture and is confined to the bearing, says Vandré. “Choosing the wrong lubricant for the wrong application can cause major issues,” he says.

“Bearing lubrication is necessary to reduce friction and wear by providing a load transmitting film at contact points. It also absorbs frictional heat and prevents rust,” he explains.

Considering that the average lifetime of a bearing is estimated at around three years’ lubrication plays a vital role in delivering optimum performance.

Arguably most people working with pumps know this, but fewer know that research has shown that two-thirds of all rolling element bearings in service, which had to be replaced, failed prematurely.

According to Vandré having chosen the correct type of lubrication it is also important that there be an oil film element present that does not touch anything at all.

There are two types of lubricant to choose from – oil and grease. Which one to opt for is an ongoing debate. The decision, however, should not be based on any personal preferences on which lubrication is superior but rather after careful consideration of the inherent components of each lubricant. Proper lubrication Oil lubrication are most common in high speed, hightemperature applications that need heat transfer away from working bearing surfaces thanks to the lubricants high

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temperature capability. Also, the amount of lubricant is easily controlled, it is easier to drain and refill and it flushes away foreign matter.

Pipes, Pumps and Valves Africa - Sept/Oct 2019

“It is much like dropping an apple on the floor. At first glance, there will be no damage, but later the dark-brown bruises will become visible,” he says. “If a rolling element touches one or the other rings in a bearing it is much like dropping the apple. There will be no damage to immediately see, but because of the touch, the oil film cannot swim around that easy and more and after a while the oil film will scratch off and the rolling element will soon resemble a golf ball as it will have so many dents.” Grease, on the other hand, is preferable in bearing applications that operate at moderate speeds and where


VSA

GROUP (PTY) LTD

YOUR PVF PARTNER

temperatures are not excessively high. It also provides protection from contaminant ingress and are often used when additional protection from dirt and/or fumes are required. Beware of water If opting for oil as a lubricant, says Vandré, it is essential to understand that the biggest enemy will be water. “Even the smallest amount of water in the bearing housing can cause premature failure. A concentration of just 0,05% water in the oil can cut bearing life by as much as 62%,” he says. “And anyone thinking but how on earth can water end up in the oil, it’s not that difficult.” Sources of water in lubrication can be from thermal expansion and contraction. “This draws moist air into the bearing housing due to temperature changes. Improper oil storage is another way. If it is open to atmosphere, exposed to rain and dew it can easily be passed. The other source of water is steam blowing against bearing housing or anywhere near oil storage.” Oil bath system This, say Vandré, is possibly one of the simplest methods available to lubricate bearings. “The bearing itself is partially submerged in a bath of oil so as the bearing rotates, it will accumulate a layer of oil.” Bearings should however, never be over- or under filled. “The correct level of oils is when half of the bottom ball is submersed in the oil.” He says sight glass should indicate the level to be in the middle of the sight glass. In an effort to ensure the right amount of oil is used constant level oilers are often used. Remember the viscosity When specifying oil for a bearing an important characteristic to keep in mind is the viscosity. This is the measure of a fluid’s internal friction or resistance to flow. Higher temperatures reduce oil viscosity Flowserve, avandre@flowserve.com, www.flowserve.com, www.liquidmovers.co.za

.

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


PUMPS

Reading a centrifugal pump curve does not have to be a daunting task According to Andreas Vandré, Flowserve Regional Manager Educational Service EMA. On a recent visit to South Africa he explained the process to Pipes, Pumps & Valves Africa. Knowing how to read pump curves are essential for the health of any pump system. According to Vandré it is all about finding the best efficiency point. Running too far out on the curve or in some cases too far back will ultimately result in poor pump performance, but it can also damage a pump. Pump curves are important for sizing of a pump and when troubleshooting problems on a pump. All pump charts will have a title box that provides a range of information such as the pump model, size, speed, and other identifying criteria specific to the pump. If checking the performance of an existing pump, confirm that you are matching the pump to the associated curve. Centrifugal pumps impart energy on a liquid. Dependent on installation it will have head and flow characteristics. Head is the height at which a pump can raise water up and is measured in either feet or meters. Usually the left-hand Y axis of the curve. The right-hand Y axis depicts the efficiency in percentage. Flow or the capacity of the pump is the amount of fluid the pump will move and is determined mainly by the diameter of the impeller and the shaft speed. Measured in gallons or litres per minute or cubic meters per hour (m3/hr) it is the X axis on the pump chart. The first curve on a pump performance chart to take note of is the head capacity curve. “This curve is also referred

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Pipes, Pumps and Valves Africa - Sept/Oct 2019

to as the performance curve. It represents the pump performance, or to be exact, the impeller diameter of the pump in question,” explains Vandré. “The head capacity curves are at a constant speed that will be indicated at the top of the characteristic curve.” According to Vandré the best efficiency point can be defined as the point where the pump shaft experiences the least amount of vibration. The duty point, he says, is always indicated with a small triangle on the head capacity curve. This is the point where the pump curve interacts with the system curve and is known as the best efficiency point (BEP. Flow rate at BEP can be taken when a line is drawn down from the peak of the efficiency curve to the rate of flow scale. Head at BEP can be taken when a line is drawn to the left towards the head scale 3, this line is drawn from the rated curve at the point where flow at BET interacts. Operating at low flow rates This is extremely back from BEP and is often an indication that the pump is oversized for the system. It is very inefficient and results in high head, increased radial load, shaft deflection, vibration and cavitation. A solution is to consider adding a recirculation line, says Vandre. Unstable flow is the result of flow reversal or recirculation at the impeller inlet or outlet or possibly even, both locations. It manifests as vibration, noise and cavitation. The severity of these undesirable conditions depends on the size and


design of the pump and its power leve3l. According to Vandre factors to consider when setting minimum flow include temperature, vibration and cavitation. Operating at high flow rates Operating out on the curve will be an indication of an undersized pump and cavitation, high rate of flow, high horse power and vibration will manifest. Net positive suction head, required for proper pump operation, issues will manifest and pump seizure cannot be ruled out. Understanding cavitation This is the formation and subsequent collapse of vapor bubbles in the liquid being pumped, explains Vandre. The force of the collapsing vapor bubbles causes pitting, vibrating, reduced pump capacity and noise. “Cavitation causes component damage, loss in capacity and the pump efficiency drops dramatically,� he says.

Flowserve, avandre@flowserve.com, www.flowserve.com, www.liquidmovers.co.za


KREBS® pumps excel in Africa

PUMPS

KREBS® slurry pumps have become leaders in mill discharge applications in Africa, with the latest Ultimate Mill Discharge (UMD) pump leading the way in these heavyduty applications. “West African gold mines and the copper operations of Zambia and Democratic Republic of Congo are among the areas where these robust pumps dominate,” says Andre Hall, FLSmidth Regional Product Line Manager — Pumps, Cyclones and Valves. ”Their popularity,” he says, “is based on their long wear life and high efficiency. “Ghana is a particular success story for our UMD pumps,” Hall adds. “‘Nearly all the gold mines there use our pumps to discharge slurry from their mills.” The KREBS UMD is popular at these mines largely because it lowers the total cost of ownership due to the millMax™ proprietary design that eliminates inefficient recirculation and grinding of slurry within the pump. Prior to the millMAX wear ring design, slurry pumps experienced two major problems: mechanical grinding of solids between the suction liner and impeller, and flow recirculating back to the impeller eye on the suction side. Both of these problems decrease pump life and increase power consumption. The wear ring stops recirculation by closing the suction-side gap, while still allowing for a large clearance between the impeller and the suction liner, eliminating the grinding of solids. Adjusting the wear ring while the pump is running restores performance and provides longer wear life and higher

continuous efficiency, in all, lowering the total cost of ownership. “The UMD’s casing symmetry also means less inventory for customers,” Hall says. “Mines that have pumps rotating in both left-hand and right-hand orientations must stock different casings, liners and impellers, adding to the operational costs.” The advantage of the UMD is that it uses the same casing, suction liner, wear ring and back liner. This reduces overall net working capital. The KREBS gravelMAX™ pumps continue to do well in Mpumalanga’s coal sector, where 14 of these pumps recently replaced competitor units on a single site. Commonly applied in a cyclone feed application within the dense medium separation (DMS) circuit, the pump’s wider passage allows pumping of larger solids. “We are also active in iron ore in South Africa with pumps in the DMS circuit,” Hall says. “A Lesotho diamond mine also operates KREBS pumps, which have demonstrated a four-fold increase in wear life compared to a competitor’s previous units.”As global leaders in sump pumps, FLSmidth dominates with the vMAX™ range, which features a recessed impeller design allowing the pumps to run dry. When the sump has been emptied of slurry, the recessed impeller allows the slurry to return safely down the

A KREBS UMD centrifugal slurry pump.

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Pipes, Pumps and Valves Africa - Sept/Oct 2019


PUMPS

The KREBS gravelMAX pump, designed for coal processing applications.

discharge pipe without contacting the impeller, ensuring that it does not vibrate when dry. Another recent innovation in the KREBS slurryMAX™ range of pumps is being introduced to the African market after an enthusiastic response in the US and Australia. With multiple liner and impeller material options, the slurryMAX splitcase pump can handle the majority of applications for any plant across multiple industries. FLSmidth KREBS pumps are designed using vast experience in pumping technology,

to meet the challenges with throughput, downtime, wear life and overall efficiency. The complete slurry pumping solutions optimise performance, maximise wear life and efficiency, and lower operating costs. FLSmidth (Pty) Ltd, +27 (0) 10 210 4820, willie.vanwyk@flsmidth.com, www.flsmidth.com

EFFICIENCY meets PERFORMANCE • • • •

Low Voltage TEFC frame Electric Motors to IEC60034 Ratings from 0,37kW up to 680kW at 400V, 525V and 1000V Premium Efficiency to IEC 60034-30 (IE3) IP66 & Class H Insulation

Pipes, Pumps and Valves Africa - Sept/Oct 2019

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IIoT enabled pumps are slashing maintenance costs and downtime

PUMPS

In every type of production facility, there are opportunities to deploy IIoT and digitalization to reduce maintenance costs, reduce downtime and improve profitability. Devices connected to the Internet of Things are growing exponentially. By 2025 it is predicted there will be over 100 billion devices connected to the Internet of Things. Smart Pumps Pumps are vital pieces of process equipment in almost every industry. In many situations, if the pump is not running the process is down. Even though they are some of the most vital pieces of equipment, they are some of the least monitored and analyzed components in most facilities. Adding pump monitoring tools can be accomplished by additional instrumentation and systems to help better analyze faults. Depending on the type of pump, pump curves can be embedded in the analysis to help improve energy efficiency

and improve process performance. In most cases, vibration monitoring will be added to monitor main bearing health, impeller wear and motor performance. If the pumps are equipped with a variable speed drive, then huge amounts of valuable data can be collected from there as well. Nearly 15 years ago, Flowrox developed the most revolutionary peristaltic pump in the global arena. This new design incorporates a single roller, rather than compression shoes. This single rolling design produces significant benefits to the user. The rubber hose is only compressed once every 360-degree revolution. With almost all other peristaltic pumps the hose is compressed twice every 360-degree revolution.

Flowrox manufactures a wide range of peristaltic pumps for numerous industries

Above is data provided by the city of Hamilton, Ohio, power plant on the costs of running a shoe pump for one year versus running a Flowrox rolling design peristaltic pump for one year. Flowrox was able to perform the same work with a 2.5� rather than a 4� shoe design pump. The costs for running the shoe design pumps was greater than R437,000 ($29K0 per year where the Flowrox operating expense was just over R135,000 ($9K). So, on only one pump the customer was able to generate operating expense savings over R300,000 ($20K) annually.

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Pipes, Pumps and Valves Africa - Sept/Oct 2019


Also, competitive designs use two metal shoes to compress the rubber hose. These shoes rub against the hose and cause huge amounts of friction and heat. This severely limits the continuous duty capacity of these pumps because if they’re run continuously, they get too hot and must be shut down to cool. The Flowrox rolling design generates nearly zero friction or heat. Many engineers assume the corrosive or abrasive medium is the main culprit in the destruction of the rubber hose. However, in reality, the number one determining factor on how long hoses last in a peristaltic pump is how many times the rubber hose is compressed. The number two factor is how high a temperature the hose is subjected to. Since Flowrox has half the compressions of other designs and generates very little heat or friction, the OPEX cost of running a Flowrox is typically a fraction of other designs. Flowrox has been manufacturing small peristaltic metering pumps for more than 10 years. Now with great excitement, Flowrox has introduced the first-ever fully IIoT-ready pump. Every single one of the pumps is IIoT capable right out of the box. By simply connecting an ethernet connection and registering the pump with Flowrox the pump becomes a full connected device. That given access will be able to see calculated flow rates, pump alarms, shutdowns due to tube failure, tube failure alarms and vital pump statistics. The pump has many impressive capabilities such as: • 5000:1 turndown • 4 – 20 mA

PUMPS

Typical cloud-based monitoring will allow 24/7 monitoring of pump condition anywhere with an internet connection. Each of the new FXM pumps come completely equipped with this capability directly out of the box.

Flowrox FXM IIoT Enabled Pump is IIoT capable right out of the box. With simple ethernet connection each pump that enables Malibu connection will gain: • Real-time status of the pump, Run/Stop/Alarm • Average run speed • Tube life in minutes • Access to stored Manuals & Data Sheets • The ability to fine-tune predictive maintenance • Ease of incorporating a metering pump into a larger monitoring package

VERDER INDUSTRIAL PUMPS For Wastewater Processing

VERDER PUMPS SOUTH AFRICA Tel.: +27 (0)11 704 7500 info@verder.co.za www.verder.co.za

Industry_Advert_Verderflex_SA_180x65.indd 1

07-10-19 10:11

Pipes, Pumps and Valves Africa - Sept/Oct 2019

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PUMPS

• IP66/NEMA4X enclosure • Non-contact capacitance tube leak detection • Non-contact flow verification • Multiple current capabilities • Tube life statistics • Predictive maintenance tools • CE/UL/CSA listings • Lightweight • Built-in handle for transport The Flowrox FXM pump allows for complete monitoring 24/7. Additionally, Flowrox understands some users may not want the cloud-based features, so users can simply not register the pump for Malibu access. In addition to Flowrox’s impressive peristaltic offering, Flowrox offers its progressive cavity and centrifugal pump series. These pumps are equipped with Malibu to provide ultimate performance and analytics to reduce maintenance costs, prevent downtime and improve profitability. The Flowrox CS progressive cavity pump provides several features that improve hydraulic efficiency and reduce wear and maintenance costs. The CS series features a patented mechanic seal that allows for removal and replacement of it without removing the motor and frame or the rotor and stator. This can save between eight to sixteen hours of maintenance. Also, the pump features both 2D and 3D elliptical rotors and stators. These rotors and stators have very tight tolerance which leads to significant benefits: • Less slip-on startup • Higher compression per stage and higher discharge pressure • Higher discharge pressures than conventional PC pumps

• Lower RPMs to deliver higher flow rates • An adjustable suction side port • Even-wall stator technology • Shorter end to end dimensions All of the benefits offer a longer life than conventional pumps. Flowrox CF series centrifugal pumps are designed for severely abrasive slurries. The pump features both hardened internal metal components or rubber-lined internals for abrasion resistance. This pump is most often used in hard rock mining, iron ore, energy, sand or aggregates. The maximum size Flowrox offers is a 56 cm (22”) diameter. When Flowrox’s competitors are offering 22 – 26-week deliveries for their pumps, Flowrox can often deliver their complete pumps within 10 – 12 weeks. Although Flowrox has no affiliation or partnership to Warman pumps, Flowrox’s CF pump spares are compatible with Warman AH pumps manufactured by Warman. Flowrox parts are fit, form and function acceptable in these pumps. Flowrox guarantees parts offered for replacement of Warman AH parts will be of equal or greater quality than the original equipment. New Flowrox CF series pumps are monitored by Flowrox Malibu smart pump monitoring which lowers the users operating costs and increases process availability. In today’s digitalized world just about any piece of the process, the equipment can be monitored and made smart. Flowrox is capable and ready to assist you in monitoring any asset. Flowrox’s monitoring capabilities are not limited to equipment that Flowrox manufacturers. The advantages are less downtime, reduced maintenance costs and greater process availability in any process. There is no reason to run your process facility blindly or with a lack of information. Dangerous, dark, dirty and hard to reach areas are ideal for digitalization. As well, areas, where

Flowrox PC pump delivers better hydraulic efficiency than traditional progressive cavity pumps which means less wear, higher pressures and flow rates.

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Pipes, Pumps and Valves Africa - Sept/Oct 2019


PUMPS Malibu’s dynamic and customizable dashboards allow users to see exactly what is important to them. From current data points to historical trends, get an intuitive look at how your process is running.

safety or compliance are at risk, are ideal opportunities to deploy digitalization. IIoT is going to help companies globally improve productivity which for many years has been stagnant. Early adopters are going to gain a competitive edge over their competitors. Diving into digitalization does not have to occur throughout your entire facility. Plan big, start small, then scale fast. A small start with specific pieces of equipment can be enabled by solution providers such as Flowrox. You can pinpoint your most important areas that create your greatest pain and add digitalization to improve your process results. Most of the inputs (instrumentation) are already in place in most facilities. What is lacking is a system to do complex analytics on the data that can help provide the increased production, lower maintenance costs and less downtime. Then scale fast, and see the benefits spread across your entire facility as time and budget allows. The scalability and flexibility fit every environment. A modern IIoT platform could be exactly what you need to pull all these systems and new sensors together. Plus, a cloud-based solution leverages powerful processors, provides data backup, and allows for in-depth analytics. Not to mention modern visualizations, with user experience and intuitive navigation prioritized. Flowrox Digital Services provides all these benefits, along with reporting, user permissions, maps, and more. If you have any valuable assets that need IIoT technology and optimization, now is the time to look into solutions. No two assets are exactly alike. Being able to tailor your service, maintenance, process, and control to your equipment will save time, resources, man-hours, money, and frustration.

Flowrox, todd.loudin@flowrox.com, www.flowrox.com

Pipes, Pumps and Valves Africa - Sept/Oct 2019

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BMG distributes Garlock Sealing Technologies PUMPS

BMG’s Garlock seals and sealing systems, which meet stringent safety and emission compliance standards in the hydrocarbon processing sector, are enhanced by customised solutions for efficient plant operation and maintenance. BMG – distributors in Southern Africa for Garlock Sealing Technologies – supplies and supports the full range of Garlock seals and sealing systems, including specialist fluid sealing products for the oil and gas industry. “BMG’s Garlock seals and sealing systems, which meet stringent safety and emission compliance standards in the hydrocarbon processing sector, are enhanced by customised solutions for efficient plant operation and maintenance. Sealing services extend from simple solutions to critical applications, ensuring safe, sustainable and dependable sealing integrity in every application,” explains Marc Gravett, BMG’s business unit manager, Seals and Gaskets division. “BMG’s Garlock products and technical expertise - including on-site maintenance, emission monitoring and repair programmes - ensure reduced operational costs, improved efficiency, minimal downtime and uninterrupted production.” Garlock products, which have been developed especially for the oil and gas industry include Klozure oil seals, Gylon and Gylon Epix gaskets, pipeline isolation products and Link-Seal modular seals. Garlock expansion joints and Klozure oil seals ensure that fluids run smoothly, making the transition of loading or offloading of gas and liquid safe and efficient in offshore buoy applications. Garlock Klozure oil seals and bearing isolators are designed to retain lubricants, but exclude contaminants, like moisture, dust and dirt, from penetrating the primary seal or bearing houses. These components play an important role in protecting bearings, preventing downtime and extending the service life of the system, even in arduous operating conditions. Klozure oil seals are available from BMG in numerous shaft sizes, materials and designs, including solid and split configurations. Seals with a reverse bevel lip allow installation in either direction without rollover and Stainless Steel garter and finger spring configurations provide tension to create an effective seal against the shaft. Klozure oil seals with a Gylon lip material offer reduced creep and cold flow, compared with the standard PTFE material. Gylon sealing products are used for many applications in hydrocarbon refineries, including flanged connections and tube and shell heat exchanger flanges. Gylon gaskets are suitable for media like hydrocarbons, acids, caustics and solvents. Newly-developed Gylon Epix gaskets are manufactured from the same PTFE material as standard Gylon products, but with 18

Pipes, Pumps and Valves Africa - Sept/Oct 2019

one universal thickness of 2,4 mm. The consolidation of two thicknesses into one product reduces the need for users to stock gaskets with multiple thicknesses. These colourcoded gaskets, which have been designed for increased compressibility and conformability, improve performance in misaligned flanges and are suitable for a broader range of applications than conventional PTFE gaskets used in worn and pitted flanges. This range features a hexagonal surface profile that combines the torque retention and blowout of a thin gasket and the conformability of a thicker gasket, for optimum sealing performance. The patented profile surface design reduces the contact area during initial compression to concentrate the compressive force of the flange for improved sealability. Various high-performance sheet materials in this range are suitable for use in different applications, including acids, steam, chlorine, water, solvents, gases, refrigerants and hydrocarbons.


BMG – distributors in Southern Africa for Garlock Sealing Technologies – supplies and supports the full range of Garlock seals and sealing systems, including specialist fluid sealing products for the oil and gas industry.

conformability of a thicker gasket, for optimum sealing performance. The patented profile surface design reduces the contact area during initial compression to concentrate the compressive force of the flange for improved sealability.

“BMG’s Garlock seals and sealing systems, which meet stringent safety and emission compliance standards in the hydrocarbon processing sector, are enhanced by customised solutions for efficient plant operation and maintenance. Sealing services extend from simple solutions to critical applications, ensuring safe, sustainable and dependable sealing integrity in every application,” explains Marc Gravett, BMG’s business unit manager, Seals and Gaskets division. “BMG’s Garlock products and technical expertise - including on-site maintenance, emission monitoring and repair programmes - ensure reduced operational costs, improved efficiency, minimal downtime and uninterrupted production.”

Various high-performance sheet materials in this range are suitable for use in different applications, including acids, steam, chlorine, water, solvents, gases, refrigerants and hydrocarbons.

Garlock expansion joints and Klozure oil seals ensure that fluids run smoothly, making the transition of loading or offloading of gas and liquid safe and efficient in offshore buoy applications. Garlock Klozure oil seals and bearing isolators are designed to retain lubricants, but exclude contaminants, like moisture, dust and dirt, from penetrating the primary seal or bearing houses. These components play an important role in protecting bearings, preventing downtime and extending the service life of the system, even in arduous operating conditions. Klozure oil seals are available from BMG in numerous shaft sizes, materials and designs, including solid and split configurations. Seals with a reverse bevel lip allow installation in either direction without rollover and Stainless Steel garter and finger spring configurations provide tension to create an effective seal against the shaft. Klozure oil seals with a Gylon lip material offer reduced creep and cold flow, compared with the standard PTFE material. Gylon sealing products are used for many applications in hydrocarbon refineries, including flanged connections and tube and shell heat exchanger flanges. Gylon gaskets are suitable for media like hydrocarbons, acids, caustics and solvents. Newly-developed Gylon Epix gaskets are manufactured from the same PTFE material as standard Gylon products, but with one universal thickness of 2,4 mm. The consolidation of two thicknesses into one product reduces the need for users to stock gaskets with multiple thicknesses. These colourcoded gaskets, which have been designed for increased compressibility and conformability, improve performance in misaligned flanges and are suitable for a broader range of applications than conventional PTFE gaskets used in worn and pitted flanges. This range features a hexagonal surface profile that combines the torque retention and blowout of a thin gasket and the

ElectroStop monolithic isolation fittings provide a positive leak-proof, long-lasting block against the flow of electric current in all piping systems. ElectroStop fittings, which eliminate short circuits, provide a maintenance-free welded in-line isolation joint in below-ground pipe systems.

PUMPS

Garlock products, which have been developed especially for the oil and gas industry include Klozure oil seals, Gylon and Gylon Epix gaskets, pipeline isolation products and Link-Seal modular seals.

Garlock pipeline isolation products include new ElectroStop fittings that complement PSI/Pikotek isolation joints, to ensure the security of flange connections by providing electrical isolation, extreme temperature electrical isolation and high integrity seal.

Many applications involve connections, where the pipe is penetrating a wall, floor or ceiling and sealability, is required between the pipe and the penetrated surface. In these through-wall piping applications, BMG recommends the use of Link-Seal modular seals. Link-Seal - suitable for ductile iron, pre-stressed concrete and metal or plastic pipe, conduit and cables - will affect a hydrostatic seal capable of holding 20 PSIG (40 feet of static head) between the pipe and the penetration cylinder through which the pipe passes. BMG’s full range of Garlock seals and sealing systems include metallic and Gylon gaskets, oil seals, bearing isolators, expansion joints and butterfly valves. Components extend from a standard sealing ring, available from BMG’s stock and ready to install, to customised designs, which are fabricated to specific requirements. Garlock sealing products, with a user-friendly design and advanced materials, ensure dependable sealing in all sectors. These industries include chemical and petrochemical, pulp and paper, power generation, electronics, food and pharmaceuticals, as well as steel mills, mining and OEMs. All Garlock seals and sealing systems undergo stringent field and in-house testing to ensure safe and reliable use, as well as extended service life in all industries.

BMG, +27 (0) 11 620 1575, marcg@bmgworld.net

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Slurrysucker helps farmer save water PUMPS

A large Northern Cape farming operation recently moved to drip-irrigation to conserve water. This required cleaner water from its dams – a challenge that Integrated Pump Rental could help to solve. Using its specialised SlurrySucker desilting solution, Integrated Pump Rental desilted the first of four dams to prove the concept to the customer. Less silt meant not only cleaner water, but higher storage capacity in the dam. “The customer was so pleased with the result that they have asked us to tackle the other three dams as well,” says Ruaan Venter, rental development manager at Integrated Pump Rental. “Dirty water would have clogged their drip-irrigation pipes and prevented the whole system from working.” Venter highlighted that this was the first time that the company’s robust SlurrySucker equipment had been used in an agricultural application. “Our traditional focus is in the mining industry,” he says. “But our experience in removing silt from process ponds on mines was ideal for this work in the agricultural sector.”

across liners.” There was also vegetation rooted in the silt, which had the potential to clog the suction heads. With its extensive experience and product range, Integrated Pump Rental applied its vortex impeller solution to deal with this. The efficiency of the SlurrySucker meant quick work. At 80 metres long, 25 metres wide and about two metres deep, a dam could be desilted in just one week. And this is despite a high slurry content of about 60%. “Using one 37 kW submersible slurry pump on the barge, we were able to pump at about 250 cubic metres an hour through a six-inch pipeline,” says Venter.

The SlurrySucker is mounted on a floating barge facilitating desilting.

Integrated Pump Rental’s specialised SlurrySucker desilting solution made quick work of cleaning a dam for an agricultural operation

“This converted to between 50 and 60 dry tonnes an hour.”He adds that the customer has also entered into a maintenance contract with Integrated Pump Rental to ensure that the dams are regularly desilted for optimal system efficiency.

In these applications, the SlurrySucker is mounted on a floating barge that is pulled back and forth across a dam. A dewatering pump feeds the surface water down to a dredge-head, which agitates the silt using seven bar of pressure through 16 nozzles. The thick, agitated material is then pumped out of the dam using a fit-for-purpose slurry pump. One of the key advantages of the system is that it does not damage the clay lining or geomembrane that lines the dam. Previous efforts to desilt these dams had been conducted with tractor-loader-backhoes (TLBs) and this punctured the lining and was unsuccessful. “We make sure that our agitation heads are operated at a suitable distance from the floor of the dam,” he says. “We also use specially designed hose floats to keep the hoses and electrical cables on the water surface. This avoids any possible damage caused by submerged hoses being dragged 20

Pipes, Pumps and Valves Africa - Sept/Oct 2019

The SlurrySucker being lowered into the dam.

Integrated Pump Rental, admin@pumprental.co.za, +27 (0) 11 894-2906


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PUMPS

Responsiveness to pit dewatering needs differentiates IPR Pit dewatering remains a vital activity for all opencast operations, as groundwater not only poses an operational challenge but can also become a safety hazard if not attended to appropriately. Interestingly, it is not a simple case of one pump fits all dewatering application requirements and it is advisable to deal with a reputable pump supplier to ensure that the most appropriate solution is selected. Lee Vine, managing director of Integrated Pump Rental, explains that there is no such thing as a standard pit dewatering system as each instance requires a site-specific solution. “There are numerous options available in terms of the actual pump and ancillary equipment, as well as the choice between rental and outright purchase,” he says. “The differentiator that our team offers is the ability to assess a given application and provide a pit dewatering solution with the correctly sized pump.” Several factors can have an impact on the pump selection, and this includes available power sources, the volume of water to be pumped, the condition of the dirty water including size and type of particles in the water.

Responsiveness to pit dewatering needs has set Integrated Pump Rental apart from its competitors.

“What adds complexity to pit dewatering applications is that, and in many cases, the need to dewater a pit can be urgent and customers are forced into making an incorrect pump selection or tying themselves into a contract that does not work in the longer term,” Vine says. He says that while the decision to hire or purchase is an important commercial one, so is the actual selection of the pump itself. “If the pump is not sized correctly for the dewatering application at hand, it will not perform as required. This, in turn, leads to further operational challenges including production losses and sometimes even the need to change the pump resulting in further costs.” One of the most important factors to consider is the available energy source, and if there is no access to power options such as diesel-driven or pumps fitted with hydraulic power packs must be explored. When selecting the pump, it is also important to understand the specifics of the water ingress conditions and whether this is a long-term issue or simply a short-term challenge. This scenario will dictate the pump size, its rated output and what ancillary equipment is required. As an example, Vine points to a recent dewatering application on a mine in Lesotho where a constant flow 22

Pipes, Pumps and Valves Africa - Sept/Oct 2019

When selecting a pit dewatering pump, it is important to understand the specifics of the water ingress conditions.

of water into the mine’s pit area demanded that water be urgently and reliably pumped out. Over time the pit depth had increased, and the groundwater level had been exacerbated by the winter snowfall in the highlands of Lesotho. As a result, the total dynamic head for the duties of the installed dewatering pump installation changes and the mine required an urgent solution. Initially, a Sykes XH150 diesel driven pump was deployed, pumping at 120 litres per second at the 150-metre head.


After this, a second Sykes pump was dispatched to the site to ensure that the level of water remained at an acceptable level. With the two Sykes pumps on-site, the mine was assured of sufficient pumping capacity, should the groundwater level increase. Commenting on the responsiveness exhibited by Integrated Pump Rental in this instance, Vine says this is not unusual at all. “While not a standard across the industry, our teams are known for this, and the primary reason why we can respond rapidly is our comprehensive fleets of pumps that are capable of handling varying dewatering applications.”

Sykes diesel driven pump sets are ideal for pit dewatering.

PUMPS

He sketches the scenario where the call from the mine came in and with 24 hours, the first Sykes pump was installed onsite. “This is very significant when one considers that the mine is situated some 500 km from the company’s front door and across the border into a neighbouring country.” “More often than not, and this was indeed the case here, our teams have existing relationships with the customers that have been built up and maintained over time. Our repeat customers know they can rely on us,” he continues. Integrated Pump Rental not only rents out Sykes diesel driven pump sets, but the company is also responsible for the sale of these robust dewatering pumps across southern Africa. The robust units are designed for reliable performance, under even the harshest operating conditions. Vine concludes by saying that operating in Africa requires a certain mindset and skillset, and most importantly suppliers need to be responsive to customer requests. “Many mines are situated in outlying areas and this calls for a very customer-focused approach, particularly when groundwater in a pit becomes an issue.”

Sykes dewatering pumps are designed for reliable performance, under even the harshest operating conditions.

Integrated Pump Rental, +27 (0) 11 894-2906, admin@pumprental.co.za, www.pumprental.co.za

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Pipes, Pumps and Valves Africa - Sept/Oct 2019 BMG-FT07102019 - P&V

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Solutions available whenever and wherever needed from one access point www.sulzer.com Sulzer Pumps (South Africa) (Pty) LTD www.sulzer.com E10513 en 3.2018, Copyright © Sulzer Ltd 2018 9 Gerhardus Road This brochure is a general product presentation. It does not provide a warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our products. Directions for use and safety will be given separately. All information herein is subject to change without notice. Elandsfontein 1406


INDUSTRY NEWS

Monitor water levels and flows from mobiles

A new water monitoring station that measures levels, flows, flumes and stage discharge via cloud networks has been launched to assist in the mitigation of the effects of floodwaters, stormwater, and protect against compromised storage dams. Distributed by local technology integrator, Euca Technologies, on behalf of one of the world’s leading logging and monitoring system specialist companies, Onset Computer Corporation, the HOBO MicroRX Water Level Station delivers near real-time water level and flow alerts. The new cellular, web-enabled station uses the same 4G cellular technology widely adopted for mobile devices, to provide fast, reliable communications. Pre-programmed water flow formulas for select weirs, flumes, and a stage discharge table result in an easy and intuitive configuration.

Flume flow measurement

Euca Technologies managing director, Ernest Campling, says the new water flow and accumulated rainfall calculations, which are performed directly on the station at time of measurement, trigger immediate notifications of critical water level conditions, combined with Onset’s ceramic water level sensor, delivers calculated water level and flow data through the powerful cloudbased HOBOlink software for remote reporting and management. Fingertip information “As a result, hydrologists and others can access their water level data via any web-enabled device to get timely information whenever and wherever they need it. Designed to withstand the harshest conditions, the tough, compact station is available with built-in solar power or battery power. He explains that the monitoring of water level can be particularly challenging, especially with the need for immediate access to critical data in what are often severe weather conditions. The compact and durable station, together with the non-vented water level sensor, enables harsh condition deployments and reliable monitoring. The optional integrated solar panel or battery power, with a wide range of plug-and-play smart sensors, supports flexible environmental monitoring. Supported measurements include absolute pressure, barometric pressure, leaf wetness, light intensity, PAR, pulse input, rainfall, relative humidity, soil moisture, temperature, water level and wind Features • Stormwater monitoring – and wetlands monitoring • Floodwater mitigation – providing an alert system for potential flood situations 26

Pipes, Pumps and Valves Africa - Sept/Oct 2019

Water flow measurement

• Irrigation control – delivering accurate water usage data for conservation, water use records, and water rights issues • Hydrological studies – monitoring surface water systems and aquifers, to support water quality and environmental studies • Station-side alarms for water flow and accumulated rainfall triggered at time of measurement The system includes a non-vented ceramic water level sensor with a choice of four ranges, interchangeable, Kevlar-reinforced water level sensor cables, integrated barometric pressure sensor and a compact IP66/NEMA 4X enclosure. The unit includes a built-in LCD which confirms proper setup and operation and can be powered via solar power and lithium battery packs. It also has inputs for five plug-and-play smart sensors. Euca Technologies, +27 (0) 10 007 5278, ernest@euca.co.za, www.euca.co.za


Sulzer introduces wireless condition monitoring 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.

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The system includes wireless sensors attached to a pump, agitator, motor or any rotating equipment. The sensors measure temperature and vibration and send the data to the Cloud. This means that the operating status of the equipment can be remotely monitored 24 hours a day, seven days a week. Sulzer Sense devices are battery-powered and operate in a wireless mesh network, making them simple and cost-efficient to deploy and operate.

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AVK Valves quality endorsed by large local mining company VALVES

“Since mid-May 2014, AVK Valves Southern Africa became my preferred supplier of all valves for compressed air, portable water and service water applications. I would recommend any of their products because I’ve commissioned their valves with no failures to date.” The letter continues by inviting interested parties to visit the mine and “witness a product that works and will save you money, time and resources.” The letter was signed by the Senior Mechanical Foreman from a mine plant in the Limpopo Province. The ever-expanding 30+ year old mine, which operates under a mining right that covers a total area of 31km², produces around 160 000 ounces of platinum a year. It has estimated reserves of approximately 24.6 million ounces of platinum and also produces palladium, rhodium and gold. During the course of 2014, AVK was contracted to replace some of the mine’s valves. Based on the valves’ operating performance; the fact that they remained leak-free in severe applications; and that no maintenance was required, the mine made the decision to replace all damaged and obsolete valves with only the AVK product family. “The valves are used to manage the flow of liquid and air through a spider web of piping inside the shaft, which has operating depths of between 30 and 1 250 metres, and a network of pipes to and from the shafts,” says Riaan

Kloppers, Director – Industrial, AVK Southern Africa.” Locally manufactured AVK isolating valves and non-return valves, and Wouter Witzel butterfly valves, part of the AVK stable, are used within the mine’s infrastructure. They are used for numerous applications including ventilation, potable and process water, as well as hydrant lines. Each of the AVK range of valves used on the mine has a standard 10-year warranty and the Wouter Witzel butterfly valves a five-year warranty. “Our typical warrantees exceed the industry norm of a one-year product warrantee by far,” Kloppers points out. “In addition to standard cover, our warranty includes our “zero leakage, zero maintenance” declaration. When one takes this into account, along with the facts that no spare parts are ever required and no downtime is incurred due to our valves, the overall cost benefit compared to competitor products is obvious.” The letter of endorsement was penned in September 2017, and in 2019 AVK reports that all its valves installed on site continue to function optimally, with zero replacements required. “The author of the letter is now overseas,” says Kloppers, “but the mine is continuing with his legacy of converting all valves to AVK valves on an as-and-when required basis.” “Bragging about product durability and its ultimate longevity is something most manufacturers do,” Kloppers comments in conclusion. “Proving the accuracy of these claims using SANS and ISO measurement standards is one thing. Having your client quantify these statements is another.” AVK Southern Africa offers a wide range of products and services for all industrial sectors, having acquired and invested in well-known South African brands, Premier Valves, Gunric Valves, Baker Valves, Cementation Engineering and IPV (Industrial Petroleum Valves).

Locally manufactured AVK isolating valves and non-return valves, and Wouter Witzel butterfly valves, part of the AVK stable, are used within the mine’s infrastructure for numerous applications including ventilation, potable and process water, as well as fire lines.

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Pipes, Pumps and Valves Africa - Sept/Oct 2019

AVK Southern Africa, +27 (0) 11 908 3760, sayuri@avkvalves.co.za, www.avkvalves.co.za


VALVES

Finding the right partner for control valve solutions in the pulp and paper industry can be challenging With applications often extremely difficult due to erosive, corrosive and high cycle services, expert product knowledge and a high level of service are non-negotiable. Pipes, Pumps and Valves Africa spoke to Fred Venter, Director at KV Controls, about this industry’s demands. Not only does KV Controls have a range of specific products for the pulp and paper industry, but they also have solid experience. This is critical for servicing this industry where one cannot take a one-size-fits-all approach, says Venter. Not only are the applications demanding considering the variety of chemicals used, but different mills have very different requirements at times and precision control is of utmost importance. “The chemical processes put a real strain on the equipment meaning they need robust valves, but at the same time careful product selection is just as important to ensure that the right application is used in the right circumstances.” According to Venter mills are very specific in their needs. More so, it is an industry that demands reliability from its service providers while it also has to be cost-competitive. This can be a tall order for a supplier. “It is also not all that easy to find the right expert for a particular component in the pulp and paper industry,” says Venter. “It is an industry that has been impacted by the economy and plants are operating with slimmer staff components. The reliance on salespeople and consultants has increased.”

But, too often sales only want to sell a product, while engineers come at a price. “We advocate a solid partnership built on mutual trust and good communication between equipment vendors and paper mills,” says Venter. Know your client According to Venter to service the pulp and paper industry well, vendors of the equipment that run mills need to have an integral understanding of the processes at the plant. “Furthermore they also must have the know-how to apply specific valves in very specific applications,” he says. Far too often sales are made just for sale’s sake. “Just buying an application without considering an overall solution for the mill can become a costly endeavour,” he says. “We place a lot of emphasis on our relationship with our clients. Not only do we do weekly site visits to ensure all of our equipment is in optimum form, but we are constantly looking at ways to deliver total solutions, ensuring that the overall cost of ownership is affordable, that the applications are correct and the equipment is maintained to deliver the longest possible lifespan.” For Venter, it is critical to delivering bespoke solutions to every client. “We know and understand the processes of each of the mills that we service and we find solutions that work in the specific circumstances.” Standing the test of time Venter says all valves manufactured for the pulp and paper industry are done with special materials such as Alloy 317L, a molybdenum-containing, low carbon austenitic stainless steel that offers better corrosion resistance and increased resistance to chemical attack for sulphurous, acetic, formic, citric, and tartaric acids. “Some of the most demanding applications include medias such as calcium carbonate, lime, slurries and white-, greenand black liquor.” At KV Controls the decision was made to opt for 2205, duplex stainless steel, that has a significantly improved corrosion resistance than 317L.

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Pipes, Pumps and Valves Africa - Sept/Oct 2019


VALVES

“This product is far more superior and while it does come at a higher initial cost, the total cost of ownership in the longterm is far lower.” There is no denying that the pulp and paper industry has hit some hard times in recent years, he says, but mills still require valves to keep things going. “It is our experience that mills want to purchase high-quality valves backed with the knowledge of where they are best suited and how to apply them properly.” The better the product and application, the longer the mill can run between shutdowns. According to Venter short lead times to deliver materials – be it for new sales or after-sales service parts – are critical. “It is all about reducing downtime to a minimum.” Industry trends For a long time mills have been operating using vendors they know, but with most industries under pressure due to the economic circumstances in the country, there is a definite move away from this approach. “Mills are increasingly looking for valve suppliers that can deliver an overall solution. Not only do they want to see problems solved, but they also want superior quality products that are price competitive.” According to Venter, there is also a lot of emphasis on good service delivery. “The days of just selling a valve and leaving until the next valve is required are long gone. There has to be an ongoing service, a partnership with the mill, where any of their needs can be addressed immediately.”

KV Controls, Fred Venter, +27 (0) 16 100-4592, fred@kvcontrols.co.za, www.kvcontrols.co.za

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Local content inspires AVK’s international expansion VALVES

South Africa’s local content directive has provided opportunities for AVK Southern Africa to export key valve solutions to Europe and the Middle East. The company’s range of locally manufactured resilient seated valves – an industry niche – coupled with an investment into local foundries to produce lost-foam castings for its production lines, has paved the way for it to almost double in size with regards to technology, manpower and turnover. AVK is the only local valve manufacturer that currently exceeds the directive’s local content requirement of 70%, reaching an above-average 84% within its production processes. This means that AVK qualifies to supply product to SOEs and municipalities, giving the company an edge in providing valve solutions to South Africa’s water distribution networks. Additionally, AVK is the only South African valve manufacturer that has the knowledge and capacity to manufacture high pressure large diameter valves – up to 3 m. “Local content is of benefit to our country, and also to companies that not only comply with the directive but also embrace it,” says Patrick Jantjies, AVK Southern Africa Managing Director. “It promotes both skills development and resource expansion, which lead to skills transfer and job opportunities. At AVK we have the technical abilities to provide practically any valve solution. Our greenfield developments and brownfield expansion projects have provided us with the infrastructure to build solutions according to specific customer requirements.” “We view local content not only as an opportunity but as an added value. It promotes the growth of our manufacturing industry which may, in turn, serve as a draw card to recall some of our engineers who have emigrated. This contributes to enhanced skills transfer.” He adds that these factors will enable increased local production to the extent that export

opportunities for manufacturers across South Africa will increase. It was with this in mind that AVK made an investment into locally produced castings that would not only service the company’s requirements, but could also be used for export to Europe and the Middle East. With the bulk of its castings originating in the Far East, AVK had established a lost-foam castings facility in that region. It simultaneously identified two local black-owned foundries and transferred their intellectual property gained from its foundry in the Far East to the local foundries along with an R8-million investment. “The quantity of lost-foam castings that AVK uses exceeds that produced by our local foundries,” Jantjies explains. “This necessitates continued casting imports from the Far East for many manufacturers. However, we are confident that our local industry will rapidly rise to international competitor status. That would be a cost-saving to South African manufacturers while providing employment and increased skills levels for our country’s labour force.” Jantjies adds that companies in Europe and the Middle East have become reticent in ordering castings and other products from the Far East due to economic and other challenges. “This creates an opportunity for the South African industry to target these two markets and, when one takes the exchange rate into account, it will be a costeffective approach to order castings from South Africa.” He says that it is essential that South African manufacturers compete with the quality standards expected by overseas markets. This is not only achievable but already in place – especially with regards to lost-foam castings for the valve industry,” he says. “AVK gives product warranties that far exceed the international norm, and that is because the quality of the products we produce are unsurpassed.” With local casting companies producing world-class products, the likelihood of penetrating the European and Middle Eastern markets seems extremely positive. AVK Southern Africa’s exports would rise, as would lost-foam castings for other production processes. Local manufacturing of previously imported resilient seated valves and high pressure large diameter valves; the investment in local castings; products that meet international standards; export opportunities to the Middle East and Europe; and an exchange rate that is favourable to the customer, bodes well for AVK to meet Patrick’s vision of doubling turnover, manpower and technology in the next five to 10 years. AVK Southern Africa, +27 (0) 11 908 3760, sayuri@avkvalves.co.za, www.avkvalves.co.za

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Allmech – sole authorised agent for Runxin Valves Allmech, leading South African manufacturer of boilers and supplier of water treatment components, is the sole official agent for Runxin water treatment system valves in the country.

VALVES

Lionel Maasdorp, General Manager at Allmech, says the company has been South Africa’s only authorised agent for Runxin for 11 years. “The valves are produced by Wenzhou Runxin Manufacturing Machine Co, a global company founded in 2000, based in China, which distributes its products into 117 countries around the world,” he says. “We partner with Runxin because we’ve found their valves to be reliable, easily available and user-friendly. They are also easy to service and have proven to be more chemical resistant and robust than other brands on the market. Furthermore, they are a cost-effective option.” Maasdorp says Runxin has collected various valve models that have been in service for 10 years or more, which are on display at their manufacturing plant. Similarly, Allmech has a softener valve displayed that was in use for a full 10 years without a single service, and still functioning perfectly.

“We have a test bench and host training sessions regularly, and pride ourselves in our technical support and spares supply capabilities,” says Maasdorp. “We really work hard to provide an end-to-end solution for our water treatment clients, whether they are business owners, engineers or downstream distributors. They know they can come to us for expertise on which valve to use for a specific application, for repairs and maintenance, and for other technical input.” Allmech supplies Runxin valves with flow rates ranging from 4 500 l/hr, such as the F56A1 manual filter valve and the F63B/C automatic filters, right through to 30 000 l/hr F112A softener and F112B filter valves.

Allmech, which is headquartered in Johannesburg and has an office in Pinetown (KwaZulu-Natal) and distributors in the Western Cape and Free State, supplies Runxin control valves to both domestic and industrial water treatment clientele throughout the country, as well as in neighbouring states.

Paul Van Der Walt, sales and procurement manager of East Midlands Water Company SA, a leading supplier of water filtration products, says that the range of Runxin valves supplied by Allmech are a perfect fit for their application in whole house water filtering systems. “The valves perform as required, they are of good quality and the support and technical advice from Allmech is much appreciated. Allmech has always provided excellent service to us and in receiving great service, our customers also receive great service.”

Allmech stocks Runxin manual and automatic valves with a range of flow rates, as well as the Runxin ceramic ball range. Its water treatment division also supplies chemicals, reverse osmosis and demineralisation plants, softeners and filters.

Allmech, Lionel Maasdorp, +27 (0) 11 849 2731, lionel@allmech.co.za, www.allmech.co.za. Pipes, Pumps and Valves Africa - Sept/Oct 2019

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World’s largest gate valve

VALVES

With an ever-growing population in Dallas, Texas, it is expected that more than 13 million residents will need water by 2060. This is more than double the population served by authorities today. A partnership was formed to execute the $2 billion Integrated Pipeline Project (IPL) which enables an increase in water supply by 1.59 billion litres per day. The project involved the construction of over 240 kilometres of pipeline which extends from and integrates multiple lakes. It involved the construction of 3 lake pump stations and 3 booster pump stations. Blackhall Valves played an essential role in this mega project having regulated the water in the largest and longest segments of the pipeline. This involved the design and manufacture of high-pressure DN2800/108-inch Parallel Faced Metal Seated Gate Valves, considered to be the world’s largest gate valve. It weighs over 100 tons and is a majestic 12 meters tall. Tarrant Regional Water District placed the order after evaluating Blackhall’s award-winning design expertise, capability, utilisation of manufacturing technology and project management skills. Furthermore, Blackhall’s proven track record of manufacturing 100-year asset life valves matched perfectly with the water district’s 100-year sustainability promise on the IPL project. Design and Manufacturing Blackhall Engineering aims to be at the forefront of embracing advancements in computational technology for the development of their products, thus delivering improved performance and efficiencies for its customers. These Parallel Faced Metal Seated Gate Valves are an excellent example of a world-class product that has been designed with these advancements fused with the experience of the design team. Theoretical knowledge and empirical data have been comprehensively used to simulate and to predict both the structural behaviour of the valve during its operation and its capability of sealing under various flow and pressure conditions. The geometry of the components has been optimized for enhanced stress distribution. Results were validated by performing ‘strain gauge’ testing on the valve. Testing of the design also incorporated external loading

factors to ensure the sustainability and robustness of the valve during earthquakes and similar calamities. The success of any highly engineered product depends not only on the design but equally on the manufacturing and assembly processes. Advanced Casting Simulation Programme was employed to optimise the casting process to ensure the castings manufactured were free from any residual stresses that could potentially develop during the solidification of the metal. 34

Pipes, Pumps and Valves Africa - Sept/Oct 2019


By employing all of the methods above, Blackhall aims to provide its customers with the ultimate peace of mind over the life cycle of their assets. Highly reputed and technologically advanced machining facilities were sourced for machining of the valve components to achieve dimensional and geometric accuracy which are critical for the functioning of the valve. The complete valve was assembled with the utmost care and diligence by employing Blackhall’s trained and highly experienced

personnel to ensure the exceptional reliability of the valve build.

VALVES

This prevents any over stressing of the components during operation and helps in ensuring the prolonged life of the valve. Extensive NDE and inspection techniques are also used to guarantee that the valves are manufactured to the highest quality standards.

The first valve to be installed on the pipeline successfully passed all hydraulic tests. A further five valves were manufactured for this impressive pipeline scheme. Blackhall Valvologists take great pride in delivering the ultimate valve solution. Blackhall is proudly represented in South Africa by Enserve Engineering Services. Enserve Engineering Services (Pty) Ltd, Steve Bannister, +27 (0) 16 971 3885, +27 (0) 83 610 0367, steve@enserve.co.za, www.enserveonline.com

Pipes, Pumps and Valves Africa - Sept/Oct 2019

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VALVES

Digitisation of water processes saves almost 40% in costs

Key plant processes within the water and wastewater operations can now be digitised, which can generate 20-40% in cost savings. This is good news, especially for an industry under pressure to both lower operating expenditure (OpEx) and manage an ageing workforce. “Trends such as the Industrial Internet of Things (IIoT), cloud computing and ‘edge’ control are emerging as technology engines that present cost-effective options for modernising operations,” explains Jacques Squire, Water and Wastewater Segment Leader at Schneider Electric South Africa.

and securely; generating high-quality output in a manner that adheres to regulations. Ageing facilities is not the only problem. A full 38% of utility employees will be eligible to retire within the next decade. The expertise they have nurtured over the years will disappear.

“It is estimated in South Africa that almost 50% of existing wastewater treatment infrastructures are not functioning adequately and require some form of intervention. As water systems’ physical assets age, the cost of maintenance rises exponentially, and instances of downtime increase in frequency. Maintenance is often performed in a reactive mode; only once equipment breaks down. During such instances, stress levels are high, productivity is lost and costs accelerate.

Workforce considerations

“These plants depend heavily on a pool of experienced workers to ensure that operations are run efficiently, safely

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Pipes, Pumps and Valves Africa - Sept/Oct 2019

“The combination of an ageing workforce and ageing infrastructure, along with current cost control measures, mean that these issues need to be addressed quickly. Workers should be supported by tools that enable them to make better operational decisions. Fortunately, new technology trends, such as IIoT and artificial intelligence (AI) present themselves as opportunities for the industry to reinvent itself. Proper implementation of digitised solutions can both address operational costs while addressing some key workforce evolution issues.


Upgrades reduce Capex worries “Very few municipalities have the funds to engineer wholesale infrastructure improvements. Fortunately, many of these new technologies are designed to operate within open architectures, which allows for easy ‘snapon’ upgrades to existing infrastructures. This avoids the need to ‘rip and replace’ to achieve modernisation and corresponding operational benefits. Using fully integrated SCADA and Telemetry systems, remote sites with limited internet signal can be connected reliably. “An example is England’s Anglian Water company, which covers a geographical radius of 16 100 kilometres, 12 000 remote stations and 630 000 telemetry data points.

The company has also had 25 years of data since the time an old system was installed in the 1970s. To complete its modernisation project successfully, it needed to migrate this data and integrate it with existing systems, while still maintaining operations. The result is that it has achieved a leakage rate at 4.97 m/3km/day, one of the lowest levels in the UK. “Workforce mobility technologies that utilise mobile Human Machine Interface (HMI) technologies, such as smartphones, tablets, portable wireless devices and wearables are also expanding capabilities and are improving operator experience. Australia’s Yarra Valley Water company saved 80% in external support costs and reduced faults by 66% thanks in large part to its SCADA system and mobile data access.

VALVES

“These technologies will both enhance knowledge retention and provide more flexibility when managing a changing workforce – another crucial part of the modernisation puzzle, which requires careful consideration. Digital technologies will be key for attracting and training new workers now and into the future. Such tools also enhance the ability of the plant to capture the knowledge of the more experienced workers so that it can be shared with the new generation of incoming workers.”

“At Schneider Electric South Africa, we look forward to sharing our global knowledge and local expertise with the water and wastewater operations around the country,” concludes Squire. Schneider Electric, www.se.com/za.

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Nuclear technology remains lucrative for valve manufacturers VALVES

Europe remains reticent about nuclear technology, whilst in Asia, numerous new nuclear reactors are being built. The bottom line is that the nuclear reactor business remains lucrative for valve manufacturers. Ten years ago, it would have been perfectly correct to speak of a global boom in nuclear energy. But since the Fukushima major disaster at the beginning of the decade and the rise in renewable energy in recent years, the tide has been turning, especially in Europe. The use of atomic energy also divides opinion. So now it is more of a regional speciality – and how! It is unloved in Germany and Switzerland, in France it is declining, but gladly accepted worldwide. So atomic energy is complicated – one way or another – it doesn’t seem to leave anyone cold. Even some experts are not sure whether the construction of new nuclear facilities will prevail in the long run – concerning the high costs of nuclear technology and cheaper alternatives with renewable energies. The fact is that, at least for the foreseeable future, above all in Asia, nuclear power plants will be on the rise. Increase in nuclear energy The increase in nuclear energy is supported by figures from the International Atomic Energy Agency (IAEA). According to these, there are currently around 450 nuclear power plants in operation in 31 countries. They produce a little more than 380 Gigawatts annually. But it won’t stay that way. The IAEA expects an increase in capacity of more than 1.9 per cent by 2030. And if the global economy continues to grow as it is currently, an increase to almost 600 GW is conceivable.

The reason for the growth is the thirst for the energy of the emerging economies. This is why China is planning 40 new nuclear power plants, Russia 25 and India almost 20. Europe is reticent about building new facilities. However, Poland will soon start using nuclear technology in several power plants. According to the World Nuclear Association, 164 nuclear power plants are already under construction worldwide and another 350 are planned. Also, some countries will have longer-term extensions. China as an important market “The music is playing loud and clear in China,” emphasizes Dr Tomas Hahn, member of Framatome GmbH’s management committee and responsible for clients, politics and innovation. “For example, we brought an EPR reactor with a Framatome design onto the grid for the first time.” Overall, the focus of new construction activities is in China. So, this market is, of course, interesting for Framatome. “But we should not only look at new-build areas. The service market is very important too,” according to Hahn. And here all countries are interesting for nuclear power plant operation. For Framatome in Germany, these include Switzerland, Sweden, the Netherlands, Finland, Hungary and Brazil and Argentina, as well as many other countries. From Schroeder Valves’ point of view, the issue of nuclear maintenance becomes more relevant. “The valves used are inspected and maintained at regular intervals during review times,” says Axel Mücher, Managing Partner of Schroeder Valves. Here usually only worn parts would be replaced and new ones obtained from the manufacturer. “The general service life of valves is 20 to 30 years and does not differ significantly from non-nuclear facilities.” 20,000 valves for each nuclear power plant The German phase-out in 2011 had led to a drop in orders at Framatome, as the affected plants were customers of the company. But the decline in orders is gradual. Because, in a nuclear power plant, safety requirements remain high even after a shutdown. “Also, we were able to offer preparatory services for dismantling, such as chemical decontamination of the primary circuit.

In June 2018 the nuclear power plant Taishan 1 in China was connected to the power grid for the first time. 38

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But that does not change the fact that we will be gradually losing the German market in the coming years. Because of this, we have been driving exports since 2011,” says Hahn. So, since Fukushima. Fortunately, this works well because nuclear skills from Germany are still recognized and in demand worldwide. “This allowed us to stabilize sales at around R12,3 billion (750 million Euros).


Invincible Valves (Pty) Ltd was established in 1982 and since has grown to a medium sized enterprise located in Knights, Germiston Invincible Valves prides itself on service excellent and flexibility by striving to enhance our customer’s bottom line. Our 6,500m² facility in Knights is made up of 4,500m² under roof being our stores and workshop. The facility is fully equipped to offer a one-stop resource for valves and ancillary equipment which we transport globally. As an approved BBBEE Level 2 supplier to all major industries within South Africa, we maintain expertise and experience across a broad spectrum of industries and applications with a wide range of products. We offer a comprehensive range of local and imported valves and accessories for the mining, petro-chemical, power generation, water, sewerage and general industries. We have agents in all major centres around the country and service all four corners of the globe. We offer an in-house rubber lining service for valves, pipes, fittings and vessels which is utilized by many of the country’s major valve manufacturers. In addition we offer complete service, repair and valve reconditioning services for all types of valves. Our Core Values: We believe in treating our customers with respect. We grow through creativity, invention and innovation. We integrate honesty, integrity and business ethics into all aspects of our business functioning. Our Mission Statement: Build long term relationships with our customers and clients, to provide exceptional customer services by pursuing business through innovation and advanced technology. Our Purpose: To be a leader in the Valve Industry by providing enhanced services, customer service and profitability. Our Vision: To provide a quality service that exceeds the expectations of our esteemed customers. Invincible Valves is a proud supplier of quality valve products and ancillary equipment backed by service excellence around the globe. It is the combination of these values that allows us to form lasting business relationships.

Invincible Valves (Pty) Ltd Your BBBEE Level 2 partner

If it's not INVAL®, it's not Invincible 33 Shaft Road, Knights, Germiston TEL: +27 (0) 11 822 1777 | FAX: +27 (0) 11 822 3666 EMAIL: enquiries@invalve.co.za | WEB: www.invalve.co.za


Suppliers of valves for nuclear reactors, of course, are following developments with eagle eyes, as nuclear plants have a great need for valves. “In one nuclear power plant there are around 20,000 valves, of which around a third are large valves, so in practically every area of the plant,” explains Hahn. Different types are used, for example, those with electric or magnetic drives, manual drives or even passive constructions. In certain cases, these shut down independently, and perhaps permanently, should certain parameters such as temperature and pressure change. In this way, they ensure that the media in the pressureenclosing valve are held securely.

VALVES

Safety valves are key Naturally, safety valves are of paramount importance. The demands on them are high, but they differ according to their purpose. Many industrial facilities are subject to classic industry standards, which are also used in other power plants. Hahn: “For the entire primary circuit, but also all safety-relevant functions, the requirements of the nuclear technology regulations apply, so the KTA in Germany or the ASME Direction III from the USA. Here there are precise specifications concerning the material properties, calculation complexity or mode of operation. Also, we

pressure surges and forces that exceed the permissible limits of material strength. “Thus, the closing behaviour of check valves after a breakage in pressurized piping has special significance,” explains the company. The Sempell design was developed to prevent pressure surges which can result from double pipe breaks in the feedwater pipes in the nuclear power plant. The damper check valves absorb pressure shocks that could cause other damage in the pipework. “As new nuclear power plants have to operate in a broad load range, the Sempell design also fulfils the demand for a stable, fully-open position – adjusted to the minimum load case. At the same time the valves are optimized concerning pressure loss,” explains Sempell. As proof that damped check valves are suitable as a safeguard against pipe breakage in feedwater systems, blowdown tests were carried out in the experimental power plant Kahl HDR with a DN 350 valve. In these tests, the malfunction “double-ended pipeline breakage” was realistically reproduced. Pilot valve solution In 2021 Sempell will also supply six Pressurizer Safety Relief Valves (PSRV) for Blocks 1 and 2 at Hinkley Point C. The valve manufacturer has concentrated on a pilot solution according to the relief principle with the controlled safety valve VS99. Three blow-off lines with pressurizer safety relief valves were directly installed on the pressurizer. For each blow-off line, the inlet of the pressurizer valve to the pressurizer dome is connected with a DN 150 nozzle. The outlet is connected via a DN 200 pipe with the discharge collector. The three pressurizer safety valves are connected to the pressurizer relief tank via the discharge collector. A renaissance? Not yet

The new construction project Flamanville 3 in France: A worker closes a valve as part of testing have to provide numerous proofs in advance, to qualify the components for use in nuclear power plants”. Framatome is involved in the construction of numerous nuclear plants. Including, in fact, facilities in Europe. In France and Finland for example. Above and beyond that there is a huge project in Great Britain, where two new plants are to be built at the Hinkley Point location. “We from Germany are involved in all these projects. We have an order backlog of around R41,1 billion (2.5 billion Euros),” reckons Hahn. Check valves for Hinkley Sempell got the order to supply eight damped check valves (Main Feedwater Damped Check Valves MFDCV) for the nuclear power plant Hinkley Point C in Great Britain. The damped check valves were manufactured for the main feedwater system, according to the valve manufacturer, to protect its piping and the connected steam generator. With the help of the check valves, this is to prevent: Rapid changes in mass flows in high-pressure lines that can cause 40

Pipes, Pumps and Valves Africa - Sept/Oct 2019

Even so: Although two new blocks are emerging at Hinkley in Great Britain, the idea of an atomic energy renaissance in Europe is far removed. It is, as is often said, somewhat complicated. “The absence of broad and sustainable international consensus about the long-term use of nuclear technology and its low and unpredictable future social acceptance in individual markets considerably reduces its appeal,” remarks Axel Mücher, Executive Partner at Schroeder Valves. The company supplies pump protection valves for the nuclear market as special free-wheel check valves. These valves – on average eight per power plant – are used in various cooling and emergency feedwater systems in the plants. A look behind the scenes shows that manufacturing the valves for the nuclear market is done through a certified quality system, “that is strictly monitored internally and externally by qualified personnel. Subcontractors who supply materials and services are also part of this quality system,” Mücher emphasizes. The regulations in force specify all the requisite quality measures, depending on the conditions of use and their safety relevance. Involving local partners in China “Implementation of the regulations begins straight away with the development, construction and calculation of the valves and with the choice of materials, all conforming to the regulations.” This compliance with the regulations is ensured


with a preliminary check of the complete documentation by notified bodies. “Then the production process starts, with numerous interruptions due to compulsory productionrelated inspections that are carried out by qualified internal and external personnel,” explains Mücher. A final, appropriately monitored function and strength test by the experts concludes the production process.

field for a long time. The company has been providing valves like shut-off valves since the mid-1960s. The sensitive area of application requires “the highest safety standards and elaborate documentation,” emphasizes Persta StahlArmaturen. Naturally, users like to rely on the experience of such companies who have long been established in the nuclear power business.

But China has its regulations. Involving local partners is playing an ever more important role, since value-creation, particularly with large-scale projects, should remain incountry. “So, our task is to buy in China, for China, but in doing so not compromise our quality and process requirements,” explains Dr Tomas Hahn of Framatome GmbH.

The future is open

For example, Sempell landed a major order in China. The company supplied a total of 236 valves for the KKW Tianwan blocks 3 and 4. Blocks 3 and 4 are pressurized-water reactors VVER 1000/428M and were fitted out by the Russian company Atomstroyexport. The different shut-off valves and flaps are used in the emergency cooling system, and the live steam and sprinkler systems. The order includes, for the high-pressure area, 84 GPS5 DN 300 sliders and 52 HKS5 DN 300 valves made of forged steel, and for the mid-pressure area another eight GPS5 DN 600 sliders, 68 GPS3 DN 300 sliders and 24 HKS5 DN 300 valves. Velan is one of the valve manufacturers that serves the nuclear market on a large scale. A company that was supplying components to the sector in the early days of the nuclear industry in the 1950s. Velan supplies several hundred nuclear reactors worldwide. Persta Stahl-Armaturen has also been active in the nuclear

“The number of countries using nuclear power plants will increase, there will be more nuclear power plants worldwide than there are today. And Framatome keeps on collaborating on new construction projects, supplying servicing and modernization for commissioned facilities and supplying fuel elements,” says Dr Tomas Hahn, member of Framatome GmbH’s management committee.

VALVES

Experience is appreciated

Experience, that has been needed for a long time. How much – that is difficult to assess. Framatome, as a supplier of nuclear technology, naturally sees its future in an optimistic light.

But others have doubts about competitiveness, safety and the nuclear waste disposal issue. As I said, the issue continues to divide thinking – but still holds great potential for valve manufacturers. Innovations in the fields of valves and pumps will be presented at VALVE WORLD EXPO, No 1 fair for industrial valves, from December, 1 to 3, 2020 in halls 1, 3 and 4 at Düsseldorf Fairgrounds. Valve World Expo 2020, www.valveworldexpo.com

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Electra Mining Botswana 2019 PUMPS

Electra Mining Botswana took place at the Gaborone Fairgrounds from 10-12 September. This niche trade show is designed to support business growth in Botswana.

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Pipes, Pumps and Valves Africa - Sept/Oct 2019


Vac-Cent Services (Pty) Ltd, a Level-5 BBBEE compliant company, is the only supplier of Gardner Denver Nash Vacuum Pumps in Southern Africa. The company manufactures a large range of NASH pumps locally, under a license agreement and to ISO 9001:2008 standards. Providing Nash liquid ring vacuum pumps and related equipment to make paper at a lower cost and higher quality is a Gardner Denver Nash speciality. Their reputation as an industry leader in engineered vacuum systems and water removal for paper machines is well known. In today’s climate, Nash Vacuum Pumps has shifted its focus to seal water and power saving and thus offering various pumps that comply with these demands. Not only do they manufacture liquid ring vacuum pumps and compressors, but they also represent quality products to provide an all-round solution to various process areas in the modern paper mill today.

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T: +27 (0) 11 820 6000 F: +27 (0) 11 820 6206 E: CSSEnquiries@sulzer.com W: www.sulzer.com

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

Pipes, Pumps and Valves Africa - Sept/Oct 2019

T: +27 (0) 11 823-4250 F: +27 (0) 11 823-4943 E: sales@sameng.co.za W: www.sameng.co.za

APE Pumps

APE Pumps

T: +27 (0) 11 823-4250 F: +27 (0) 11 823-4943 E: sales@sameng.co.za W: www.sameng.co.za

SAM Engineering

MAGNETIC PUMPS

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

CENTRIFUGAL PUMPS

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

ASSET MANAGEMENT

AES PUMP SA T: +27 (0) 17 631 1003 F: +27 (0) 17 631 1002 E: craigg@aespump.co.za W: www.aespump.co.za MULTISTAGE PUMPS

APE Pumps Mather & Platt T: +27 (0) 11 824-4810 F: +27 (0) 11 824-2770 E: info@matherandplatt.com W: www.matherandplatt.com

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

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

T: +27 (0) 11 723-6500 E: info@franklin-electric.co.za W: www.franklin-electric.com

Mather & Platt T: +27 (0) 11 824-4810 F: +27 (0) 11 824-2770 E: info@matherandplatt.com W: www.matherandplatt.com


VALVES

PUMPS MULTISTAGE PUMPS

SLURRY PUMPS

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

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

T: +27 (0) 11 873-8620 F: +27 (0) 11 825-1401 E: wme@mweb.co.za W: www.versaflo.co.za

VERTICAL TURBINE PUMPS

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

Stewarts & Lloyds (Pty) Ltd ™

ASSET MANAGEMENT

AES PUMP SA T: +27 (0) 17 631 1003 F: +27 (0) 17 631 1002 E: craigg@aespump.co.za W: www.aespump.co.za PLUNGER PUMPS

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

T: +27 (0) 11 917-0778 F: +27 (0) 11 917-0769 E: peterk@sltrading.co.za W: www.stewartsandlloyds.co.za TRASH PUMPS

SUBMERSIBLE PUMPS

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

C.R.I Pumps S.A. (Pty) Ltd Hawk High Pressure Pumps T: +27 (0) 031 274-8555 +27 (0) 10 010-0144 F: +27 (0) 31 205-4332 +27 (0) 11 822-2868 E: sales@hawkpumps.co.za W: www.hawkpumps.co.za PISTON PUMPS

Franklin Electric T: +27 (0) 11 723-6500 E: info@franklin-electric.co.za W: www.franklin-electric.com

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

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

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

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

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

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

AES PUMP SA

T: +27 (0) 11 826-6111 F: +27 (0) 11 826-6162 E: sales@uniqueeng.co.za W: www.uniqueeng.co.za

AES PUMP SA

WELL PUMPS

ASSET MANAGEMENT

Unique Engineering

ASSET MANAGEMENT

Integrated Pump Technology

VERTICAL SUMP PUMPS

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

WASTEWATER PUMPS

Integrated Pump Technology Hawk High Pressure Pumps

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

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

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

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

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

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

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

Pipes, Pumps and Valves Africa - Sept/Oct 2019 45


VALVES KNIFE GATE VALVES

BALL VALVES

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

Valcon Valve & Controls T: +27 (0) 11 453-7537 F: +27 (0) 11 453-6056 E: valconsa@iafrica.com W: www.valcon.co.za

T: +27 (0) 11 736 4994 F: +27 (0) 11 736 6130 E: tiaans@pleixquip.co.za W: www.pleixquip.co.za

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

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

T: +27 (0) 11 838-4028 C: +27 (0) 82 823-7703 E: thanesh.padayachee@macsteel.co.za W: www.macsteel.co.za

Mine Track & Tools (Pty) Ltd

K

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

Valcon Valve & Controls T: +27 (0) 11 453-7537 F: +27 (0) 11 453-6056 E: valconsa@iafrica.com Web: www.valcon.co.za

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

Invincible Valves (Pty) Ltd

Macsteel T: +27 (0) 11 838-4028 C: +27 (0) 82 823-7703 E: thanesh.padayachee@macsteel.co.za W: www.macsteel.co.za VALVE RECONDITIONING

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

Pleix-Quip

CHECK VALVES

CY

CMY

SAFETY & RELIEF VALVES

GATE VALVES

T: +27 (0) 11 736 4994 F: +27 (0) 11 736 6130 E: tiaans@pleixquip.co.za Web: www.pleixquip.co.za

MY

Macsteel

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

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

Y

CM

PINCH VALVES

DIAPHRAGM VALVES

BUTTERFLY VALVES

M

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

Pleix-Quip

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

C

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

CONTROL VALVES

T: +27 (0) 11 736 4994 F: +27 (0) 11 736 6130 E: tiaans@pleixquip.co.za W: www.pleixquip.co.za

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

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

ACTUATORS

Macsteel T: +27 (0) 11 838-4028 C: +27 (0) 82 823-7703 E: thanesh.padayachee@macsteel.co.za W: www.macsteel.co.za PIPES

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

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

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

C.R.I Pumps S.A. (Pty) Ltd Invincible Valves (Pty) Ltd T: +27 (0) 11 822-1777 F: +27 (0) 11 822-3666 E: enquiries@invalve.co.za W: www.invalve.co.za 46

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

Pipes, Pumps and Valves Africa - Sept/Oct 2019

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

Atlas Copco T: +27 (0) 11 821 9000 E: wendyb@za.atlascopco.com W: www.atlascopco.co.za


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Manufacturers of Double Diaphragm, Positive Displacement & Borehole Pumps

Different operations producing great results 100% South African

Support and save with local manufacture

BEE Compliant Level 2 Proud Manufacturer

Range of ECO Progressive cavity pumps and spares including explosive emulsion dispensing pump units. Wilflo DD25 and DD50 Eco friendly, non-hazardous lube free double diaphragm pumps and spares. The ECO BG Deep Lineshaft Borehole pump range including spares for agricultural, municipal and dewatering on mines. With our innovative technical design team on hand, any pump solution idea can be made a reality.

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