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June 2011

Contents

Featured on the cover: FLSmidth (Pty) Ltd Tel: 010 210 4820 Fax: 010 210 4800 www.flsmidth.com

Cover Story 5

31 Market Forum

Integration is Now Complete

Endorsing Bodies

Lifting

‡ CMA (Conveyor Manufacturers Association)

9 Innovative Lifting Design 13 Monster Crawler Crane Lift

‡ LEEASA (Lifting Equipment Engineering Association of South Africa)

Earthmoving

15 Processing Meets Earthmoving

‡ RFA (Road Freight Association)

Project Management

‡ SAIMechE (SA Institution of Mechanical Engineering)

19 A Novel Growth Strategy

Power Transmission

‡ SAIMH (SA Institute of Materials Handling)

23 Time is Money 27 Conveyor Belt Tensioning Systems

Copyright

All rights reserved. No editorial matter published in “Bulk Handling Today” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

The monthly circulation is 4 016

Our e-mail address is bulkhandling@promech.co.za Visit our website on www.promech.co.za

Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 E-mail: bulkhandling@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editor: Kowie Hamman

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CONVEYOR MANUFACTURERS ASSOCIATION

From the Chairman’s Desk

Members and their guests were treated to a most enjoyable evening last month at the CMA Annual Dinner, which was held at Bryanston Country Club. Abbott and Crabb are wonderful entertainers and had us alternately creased up with laughter and singing along to their catchy music.

I

Simon Curry

t has become customary at this event to honour people who have made an outstanding contribution to the excellence of belt conveying technology. This year the award was made to Wilton Monnery. Wilton has spent over twenty years in the industry and is passionate about service – particularly aftersales service. Well done, Wilton: recognition of your valued contribution to our industry is well deserved.

Two-year wait until the next one! Preparations for Beltcon 16 are gearing up and before we know it, the doors will be open for this most important international

Simon Curry, Chairman with award winner, Wilton Monnery

CMA Members List as at June 2011 All members subscribe to the CMA Code of Ethics ABB Industry Afripp Projects Actom Atlanta Manufacturing Bateman Engineered Technologies Bauer BMG Bearings International Belt Reco Bonfiglioli Power Transmissions Bosworth Brelko Conveyor Products CKIT Conveyor Engineers Conveyor Watch CMG Electric Motors South Africa CPM Engineering CPI Technologies CT Systems David Brown Gear Industries Delras Engineering DRA Mineral Projects Dunlop Belting Products Dymot Engineering Company ELB Engineering Services Facet Engineering Fenner Conveyor Belting (SA) Flexible Steel Lacing SA FLSmidth Roymec Hägglunds Drives South Africa Hansen Transmissions SA Hosch - Fördertechnik (SA) Iptron Technology Joy Global (South Africa)

Lesa Mining Equipment and Conveyor Belt Lorbrand M & J Engineering Martin Engineering Melco Conveyor Equipment Moret Mining MS Conveyor Pulleys SA Nepean Conveyors OE Bearings Oriental Rubber Industries SA Osborn Engineered Products PH Projects Holdings Read Swatman & Voigt Rema Tip Top South Africa Renold Crofts RSV ENCO Consulting Rula Bulk Materials Handling Sandvik Materials Handling SA Schaeffler South Africa Secrivest SENET SET Agencies SEW Eurodrive Shaft Engineering Shaw Almex Africa SKF South Africa ThyssenKrupp Materials Handling Transmission Components Transvaal Rubber Company Unitek Engineers Veyance Technologies Africa Voith Turbo Zest Electric Motors

Dries van Coller of Rema Tip Top and Dunlop with Ute Bormann from SEW

materials handling conference. Delegates wanting to take advantage of the early bird discounts are registering and exhibitors are getting ready to build their stands. The organisers have secured extra space for exhibitors, allowing the five companies on the waiting list an opportunity to exhibit to this prestigious audience. All information including registration forms for Beltcon 16 can be found on the website www.beltcon.org.za. Don’t miss the leading conveyor event this year – it is a two-year wait until the next one! The CMA’s website home is www.cmasa.co.za. Here a visitor is able to view a list of member companies, their products and services, contact details, etc. The Code of Ethics that all members subscribe to, industry standards such as those on Safety and Geared Reducers, as well as all the Diploma holders in the Design it and Operation of Belt Conveyors can be found, so it is well worth a visit. Simon Curry, Chairman


COVER STORY

Integration is Now Complete Circular stacker/reclaimer at Mafube Colliery

Following FLSmidth’s acquisition of engineering and material handling specialist Roymec in November 2010, all Roymec personnel have now moved over to FLSmidth’s South African headquarters in Constantia Kloof, Roodepoort creating a staff complement exceeding 400.

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he physical integration of the two companies is now complete and we are fully up and running as the new FLSmidth Roymec,” Rudi Pieterse, the company’s sales and marketing manager, says. “With the strengths the two companies have brought to the table, the new entity is strongly positioned to support the current growth being experienced in the local and regional mining industry.

and MVT’s bulk material systems include stackers and reclaimers as well as ship loaders. “Former Roymec staff are enjoying having access to the FLSmidth material handling technology centres in Spokane and Boise in the USA, Wadgassen in Germany and Chennai in India,” Rudi says. “We are finding that these centres not only provide world class information to enhance our offering, but that

The new entity is strongly positioned to support the current growth being experienced in the local and regional mining industry “FLSmidth Roymec is now in the enviable position of having access to a broad spectrum of equipment and capabilities to complement its project execution competencies, while retaining its B-BBEE credentials.”

Rest of the continent

FLSmidth Roymec represents the FLSmidth material handling business in South Africa and on the rest of the continent, incorporating well known brands such as FLSmidth Rahco and FLSmidth Koch MVT. FLSmidth Rahco systems include mobile bridge boom stackers, mobile conveyor systems, portable conveyors and radial stackers, while Koch

Zibulo crushing plant and overland conveyor


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COVER STORY

we can also contribute to their knowledge base from our own experiences.� Rudi adds that the acquisition of Roymec has greatly strengthened FLSmidth’s capabilities to provide complete material handling solutions such as heap leach and spreader systems, stockyard systems, ROM tips, overland conveyors, rail loadout stations, crushing and screening and complete plant conveyor systems.

Environmental gantries prevent spillage into waterways

Withdrawal from the 6000 t silo

Heap leach and spreader systems

FLSmidth Roymec supplies spreader systems for heap leaching, overburden and waste material including mobile bridge boom stackers, mobile conveyor systems, portable conveyors and radial stackers. The new company has the expertise to design stockyard systems – either as LSTK or EPCM options. The range of products here includes stacker/ reclaimers, bulk material loading/unloading systems for barges and ships and conveying solutions, as well as complete material handling facilities.

ROM tips

The FLSmidth ROM tip is strong, absorbs impact, manages dust pollution and allows large lump size material to flow freely through the system. It offers several options for retaining wall construction, including concrete and reinforced earth. FLSmidth Roymec has built several rail loadout stations and provides after-sales service to keep the stations operating. Weigh flask and volumetric systems are available, depending on the material handled and the accuracy required.

Crushing and screening

FLSmidth brings 50 years experience in the manufacture of feeding, sizing, crushing and screening equipment. The company has designed and built several crushing and screening plants (including in-pit crushing stations), and has extensive experience in the application engineering of equipment, allowing it to design efficient plants. In the past five years, Roymec has built several long overland conveyors, including the 15.9 km long Zibulo overland conveyor – the longest single flight overland conveyor on the African continent. It features three horizontal curves and several convex and concave vertical curves. The design necessitated comprehensive static and dynamic analysis of the entire system, which can all be managed within the FLSmidth Group.

Mafube ROM tip

FLSmidth was awarded the contract (through Anglo Coal) to supply three reclaimers and four stackers to the project, while Roymec supplied and commissioned the yard equipment, two rail loadout stations as well as the overland conveyors.

The longest single flight overland conveyor on the African continent As a sub-contractor to Roymec Materials Handling, FLSmidth supplied feeders, minerals sizers and circular stacker reclaimers to the Mafube Project – a 3 mtpa export steam coal and 2 mtpa power station coal project located in Middleburg. Roymec supplied the ROM tip, rail loadout station and overland conveyors to the project.

Future

“FLSmidth Roymec’s strong regional footprint, combined with FLSmidth’s global products and expertise, will ensure an effective single source for all material handling needs, firmly establishing the “One Source� concept in our markets,� Rudi continues.

Prior to the acquisition, the two companies worked on several major material handling projects together, including the Phola coal processing plant project and the Mafube coal project.

“With offices also in Botswana and Mozambique, FLSmidth Roymec believes in the future of mining in southern Africa. We have now set our sights on establishing a local presence in Zambia and Namibia, where we’re currently working on several material handling project,� he concludes

The Phola coal beneficiation plant in Mpumalanga is a 16 mtpa coal washing facility servicing coal from two mines, Klipspruit and Zibulo.

Marinda Kerr, FLSmidth (Pty) Ltd, Tel: 010 210 4820, )D[(PDLOPDULQGDNHUU#Ă€VPLGWKFRP ZZZĂ€VPLGWKFRP

Recent projects


LIFTING

Innovative Lifting Design

A custom-built system that now makes underground battery changes an easy routine

Underground machinery is more often than not driven by electric motors using large rechargeable batteries, a system similar to that of electric forklift trucks used in warehouses.

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nlike the warehouse environment where there’s enough headspace to lift and exchange heavy batteries, the underground environment usually has very limited headspace, making it impossible to exchange large batteries at operational sites.

A custom-built system that now makes underground battery changes an easy routine Lifting batteries

This is the challenge the engineers at Raytoko Electrical & Mechanical, a lifting specialist company in Benoni, faced when a mine requested them to find a lifting solution to enable below ground battery changes. All standard cranes and hoists need considerable space, not just for the beam on which they are mounted, but also for the actual hoist. In general, mine shaft roofs are too low for this function. “Bulk Handling Today” speaks to Wayne Lloyd of Raytoko on how they solved this problem using a custom-built system that now makes Wayne Lloyd of Raytoko underground battery changes an easy routine. “We had 460mm space below the

beam to play with and a standard hoist with the load hooked onto it, would simply not fit,” he explains. “We designed a system where a movable custom-made trolley traverses the I-beam and, to balance the weight lifted on one side of the trolley, we fitted counter weights on the other. “Consequently, the trolley has arms extending 90 degrees on both sides of the rollers traversing the I-beam. On one side are the counterweights and on the other the hoist is fitted. The rope, or chain, then runs down over a lower block and back up over another block to provide enough length to achieve maximum height for the lift,” explains Wayne. “This means we gained the space the I-beam and hoist would have needed in a normal situation. The maximum lifting point now is literally at the same height as the top edge of the I-beam touching the roof of the mine shaft. This provided just enough space to lift the battery clear of the machine before the trolley is pushed to fetch a fresh battery and lift it into place.”

Other services

As the solution was a huge success the mine ordered several more which are currently under construction. Besides innovative design, Raytoko’s services include maintenance, servicing, and refurbishing of all types of overhead cranes, hoists and mechanical lifting equipment, including new cranes and modernising existing ones.


LIFTING

Before: A hoist from an acid plant in for refurbishment

“We regularly get involved in special projects involving bespoke engineering designs,” says Wayne. “This is undertaken by a team of highly skilled engineers with extensive experience in the lifting industry and knowledge of the regulations governing safe lifting practices. We provide integrated solutions for the conception, design and manufacturing of systems to individual customer requirements. As a registered LME (lifting machine entity) with registered LMIs (lifting machine inspectors) we also do the required annual load testing and mandatory regulatory inspection on all lifting equipment.

Many people don’t know how much weight they’re actually lifting, in spite of load limiting switches

After: After the refurbishing the hoist is as good as new

“To support this we supply spare parts for all brands, do inspections and are very active in both upgrading and the conversion of any kind and make of lifting equipment,” adds Wayne. “In addition, we have several teams of fully apprentice-trained service engineers on call 24-hours a day, 365 days a year. Each service engineer has a fully equipped vehicle to respond to any emergency event or to fulfil our offering of a complete service and maintenance programme, managed by properly trained and equipped management staff.”


LIFTING

A new Demag hoist in stock

from all corners of the world. “People should be careful where and what they buy,” warns Wayne in conclusion. “If the price is too good to be true, then it’s bound to be cheap imports that cannot be traced back to the original manufacturer as regulations require. End users should remember that, according to law, they’ll be held directly responsible if something goes wrong with a lift. The rule of thumb is to deal with reputable companies that can show certificates of compliance for the lifting equipment they sell.” Wayne Lloyd, Raytoko, Tel: (011) 914-5334

The Powalift hoist

Remote control

Radio remote control of overhead cranes is growing in popularity, not only for safety reasons but also because of its many advantages. “We are agents for Teleradio remote control units made in Sweden,” says Wayne. “We also have a wide range of joysticks and recently launched a new model that displays the load of the lift on the control unit. This system can be retrofitted on most cranes by making one of several different modifications to the overhead crane’s shaft or by affixing the system to the crane’s rope.

Weight monitoring

“Many people don’t know how much weight they’re actually lifting, in spite of load limiting switches, which can damage the crane,” explains Wayne. “With this system they’re assured they are within the specifications limits to operate the crane safely. With end-users becoming increasingly safety conscious, this option has grown steadily since its launch.” Raytoko is also an agent for the Powalift range of electric chain hoists. “This range come in capacities from 500kg to five tonnes and is widely used across all industries,” Wayne says. “We even have a small single phase version in this hoist that plugs straight into a normal 220 volt outlet.”

Beware!

The lifting industry in South Africa is highly competitive with lifting equipment entering the country


LIFTING

Monster Crawler Crane Lift

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his was the third heavy lift task carried out by the new crane — the only one of its kind in Africa — since the Liebherr LR 1750 750-ton was commissioned into Johnson Crane Hire’s fleet in mid 2010. The other two operations were mining related. “The new crane’s versatile capabilities in tight, congested areas makes it ideally suited to the Sasol job,” Johnson Crane Hire’s Grant Parker, who was project manager on this assignment, says. “The crane can reduce superlift radius while it is operational, which not only makes for ease of use, but also saves time. The LR 1750 is able to move while fully assembled and rigged from one location to the next and can handle higher lifts and heavier loads to further radii than any other crane currently available locally.”

Underfoot conditions A new lattice boom crawler crane was rigorously put through its paces recently when Grinaker-LTA called on a crane company to lift a massive gasifier from its offsite laydown area in Secunda and set it in position in a gasification plant at the nearby Sasol Synfuels operation.

The ground pressures reduced lattice boom crawler crane is equipped with additional driving gears with four drive motors on the crawler tracks which facilitate smoother travel, even in poor underfoot conditions. It features a 245 t machine counterweight and an additional 95 t central ballast counterweight. When used for lifts requiring its maximum capacity, the crane can be fitted with a maximum of 400 tons of super lift counterweight which

An example of 3D drawings used during the planning stage


LIFTING

is mounted on a suspended super-lift tray. The crane features a massive 133 metre main boom, but when in luffing fly-jib configuration, it has a main boom length of 84 metres, a luffing fly-jib length of 70 metres and is able to reach a height of 150 metres. With tracks 1.5 metre wide and the use of specialised crane mats, ground pressures are substantially reduced and the crane can perform single lifts up to a height of 130 metres. It is powered by a Liebherr eight cylinder turbo diesel 400 kW engine and can travel at a maximum speed of 1.65 km per hour.

Only once all three companies had given their go-ahead, could the project proceed Gasifier lift operation

A nine-man Johnson Crane Hire project team was involved in the Sasol gasifier lift operation, managed on site by Danie Earle, who is the Johnson specialist on the Liebherr LR1750. Prior to lifting the vessel, which weighed in at just under 140 tons, the company submitted a comprehensive technical rigging study outlining how the operation would be carried out. This study was scrutinised by Grinaker-LTA, the Linde Group and Sastech Technology who supplied the gasifier. “Only once all three companies had given their go-ahead, could the project proceed,” says Grant. The crane crew began by mobilising the crane to move it to the Sasol site, configuring it for the task and conducting load tests. Grant adds, “It took about 40 truckloads of components to complete the complicated configuration.

Quick thinking

this adjustment, we boomed out to a radius of 35 metres over the port into which the gasifier had to be lowered and then slewed and lowered the boom.

Awkward operation

“The next task was to do the main lift, which involved lowering the vessel down into the port and holding 50% of its weight while the Grinaker-LTA team secured it to its foundation,” explains Grant. Johnson Crane Hire was also tasked with installing a 70 ton waste heat boiler at 33 metres in the same plant, which Grant says was an awkward operation owing to jutting nozzles and steelwork. Ultimately, the crane crew had to remove some steel beams before the boiler could be lowered into place.

Tight timeframe

Safety was a primary priority during the operation, which took place over a live plant. In addition to Sasol’s stringent safety procedures, Johnson Crane Hire conducted daily Toolbox Talks and risk assessments and obtained the entire crew’s buy-in to the lifting plan. “Although we were given a tight timeframe in which to complete the task, we managed to come in comfortably within the time allotted,” Peter Yaman, general manager of Johnson Crane Hire’s projects and heavy lift division, says. “This operation has clearly positioned us as a company to offer a total turnkey solution on a diversity of projects within different engineering environments. On the Sasol project we supplied all our own equipment, including an imported 300-ton capacity main lift shackle and a 125-ton tailing shackle, as well as a variety of smaller cranes, to meet the client’s requirements.

“We used two heavy lift cranes — a 550 ton and a 275 ton — to load the gasifier and supplied a multi-axle trailer to move it on site. “The vessel was offloaded in a horizontal position using the 550 ton crane and the LR 1750, and then maneuvered into an upright position, balancing the weight between the two cranes.

“One of our main strengths derives from our network of 13 branches throughout South Africa. Each branch — notably our Trichardt branch on the Sasol operation — has built up excellent relationships with local suppliers and its personnel draw from an in-depth knowledge of local conditions in their areas of operation.”

“We had to do some quick thinking during this delicate operation, when we found that the actual weight of the gasifier was less than originally specified to us. This meant we had to remove some ballast from our superlift tray to get the balance back within specification. Once we had attended to

Johnson Crane Hire has successfully completed several contracts for Grinaker-LTA over the past 12 months and was the biggest supplier of cranes for Sasol’s maintenance shutdowns in November 2010. Lalith Senarathne, Johnson Crane Hire, Tel: 011 455 9203, Website: www.jch.co.za


EARTHMOVING

Processing Meets Earthmoving You’re staring at an open pit – in front of you are yellow mining machines and nearby some mobile processing equipment. So, it makes a lot of sense for the suppliers of this equipment to join forces, especially as mobile mining processing equipment is increasingly being utilised in mining operations. This is exactly what Barloworld Equipment has done by establishing Metso Mobile.

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edicated specialists

“Bulk Handling Today” meets with Andrew Stones, the sales manager and mining process engineer, heading up the Metso Mobile section of Barloworld Equipment based in Isando. “This business unit was started off with a staff of eight originally, but with the expansion we’ve now grown considerably. We’ve stocked up with mobile crushers and screens held in our inventory yard and a dedicated warehouse stocking all the Metso crusher spares required to

Delivering the lowest, sustainable, cost per ton in the most demanding mining and construction environments

Andrew Stones, sales manager and mining process engineer, at the Metso Mobile section of Barloworld Equipment

offer the Southern African market full support,” he says. “In addition, our field service engineers are able to service our increasing mobile crushing and screening customer base.” Metso is a global supplier to the mining, construction and general industry and this equipment is sold and supported by the southern African Caterpillar dealer, Barloworld Equipment. “As with all Metso machines, the design philosophy from the ground up is on delivering the lo lowest, sustainable, cost per ton in th most demanding mining and the co construction environments,” says Andrew. An “Metso has gained extensive experience ex in this field and was the fir company worldwide to start the first serial se production of mobile crushing and an screening plants back in 1985.

Built on experience B

A cone crusher spare component in the yard in Isando

“S “Since then more than 5 000 Lokotracks, Metso’s mobile crusher ko machine, have been sold globally m while ongoing research and develw opment continues to be based on op the extreme hard rock conditions th typically found in Finland and the ty surrounding Nordic region, making su this equipment particularly suitable th for South African conditions,” adds fo Andrew. “Innovative features such An as Metso’s IC (Intelligent Control) software systems refine this offering so still further with full plant automation st capabilities and real-time diagnostic ca feedback.” fe


EARTHMOVING

Extra wear plate spare parts imported to stock for the growing customer base in South Africa

More options

Crushing equipment particularly suitable for South African conditions

Automation has brought with it several advantages, not only in reducing the risk of human error, but also to protect machinery should something go wrong. “It assists the operator to keep an eye on the machine at all times, as sophisticated software ‘recognises’ that something’s amiss and automatically shuts down the machine,” explains Andrew.

If a lubrication system fails, for example, the cone crusher could be damaged and therefore the system will shut down “If a lubrication system fails, for example, the cone crusher could be damaged and therefore the system will shut down when the lube pump fails. Not only does the automation protect the unit, but it also assists with running the plant at an optimal production level.”

Metso Mobile’s comprehensive Lokotrack crushing and screening series has now been expanded following the recent introduction of three additional models built to meet the high tonnage demands and different customer application challenges of the local market. The new models, which comprise the Lokotrack ST3.5 and ST272 mobile screening units, and the Lokotrack LT110C mobile primary crusher, are all produced at Metso’s manufacturing facility in Tampare, Finland while all spares and replacement wear parts are stocked at the warehouse in Isando. “The ability to field a broad range of Metso Mobile solutions integrates well with our Caterpillar product line,” explains Andrew. “This means that we can structure packaged solutions for our customers that include Metso machines along with Cat excavators or wheel loaders as the loading tools. In addition, since Metso has decided to standardise on Cat engines across its entire mobile range, we are well-positioned as the local Cat dealer to provide comprehensive after-sales support.”

Primary crusher

Designed for primary crushing, Metso’s new Lokotrack LT110C is built around the world famous Nordberg C110 jaw crusher, which has a feed opening of 1100 x 850mm. Power is supplied via a 310 kW Cat C13 diesel engine and the machine has an overall operating weight of 58 tonnes.


EARTHMOVING

“Sold locally with a 9m3 feed hopper this is deep jaw configuration and large feed size is ideal for crushing hard and abrasive materials, s, making it well-suited and well proven in our ur local conditions,” Andrew explains. “A key feature of the LT110C is its crushingg efficiency since the feeder’s grizzly screen n deck ensures that you only crush what needs ds to be crushed. With a mesh setting of 53mm, m, around 30 to 50% of the extraneous material al passes through the grizzly, which optimallyy lowers the cost per tonne.”

Scalping screen

From efficient primary scalping to the accurate screening of fine end materials, such as natural gravels, crushed rock, soil or recycle materials, the new Lokotrack ST272 is well equipped for the task, with the unit driven by its Cat 4.4 engine. With an overall weight of 34 tonnes, the ST272 is built around a heavy-duty two-deck two-bearing screen design. The screen box dimensions are 4 866m x 1524m with a screening area per deck of 6,6m2.

Sand production

Joining the ST272 in southern Africa, the Lokotrack ST3.5 mobile screen is a new global release by Metso with units reaching the market for the first time from the fourth quarter of 2010. Locally it is expected to prove especially popular with sand producers. “Metso’s simplified LT and ST naming policy now clearly identifies the performance profile of each mobile crusher or screen,” says Andrew. “On the ST3.5, for example, ‘S’ stands for Screen, ‘T’ for Track-mounted, ‘3’ for the number of discharge

conveyors, and ‘5’ for the screen area per deck to the nearest whole number in square metres. On the mobile crushers, “LT” stands for Lokotrack followed by the model number of the crusher.

Locally it is expected to prove especially popular with sand producers “From the outset, profitable operation is the overriding design factor for all Metso crushing and screening systems to ensure that targeted product throughputs are achieved while keeping processing costs to a minimum,” Andrew remarks in conclusion. “The three new Metso models joining our current line-up are manufactured to do just that, with the added assurance for customers of excellent aftersales support via Barloworld Equipment’s extensive branch network throughout southern Africa.” Alastair Currie, Barloworld Equipment, Tel: (011) 9290000, E-mail: acurrie@barloworld-equipment.com or Andrew Stones, Tel: (011) 929-0677, Email: astones@ barloworld-equipment.com


PROJECT MANAGEMENT

A Novel Growth Strategy

Hennie Read, founder and CEO of RSV

Strength in numbers is a term which is often bandied about and in the current economic climate it becomes so much more important as it allows the market to access a wide range of services.

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his is exactly where our linked enterprise strategy comes to the fore,” Hennie Read, founder and CEO of RSV says. RSV’s linked enterprises include K’Enyuka, EHL Consulting Engineers, RSV Enco, RSV (SA), RSV Australia and RSV USA. He points out that all linked enterprises are essentially independent entities which operate autonomously, with each linked enterprise maintaining a focus on its own disciplines and portion of the market. “However, it is because of this very diversity that the sum of the parts is so strong and successful.

Essentially independent entities which operate autonomously Vast resources

“We are able to access a vast amount of resources within the linked enterprises and we, in turn, give all stakeholders in the linked enterprises a common set of standards, systems and access to invaluable

K’Enyuka’s expertise covers project and construction management in both EPCM (engineering, procurement, construction, management) and LSTK (lump sum turnkey).In addition, the company has specific expertise in preparing high level feasibility studies ranging from conceptual studies through to bankable feasibility studies. “K’Enyuka’s project capital cost estimating capability is considered to be world class,” Mike Symonds, managing director of K’Enyuka, says. Project services across the whole project spectrum are provided including project management, construction and safety management, procurement, planning, capital cost estimating, project accounting and Hazop/Risk/Value engineering facilitation. Engineering disciplines offered include metallurgical engineering in hydropyrometallurgical and mineral processing; mechanical engineering in piping and materials handling sectors; civil and structural engineering and electrical and instrumentation engineering. K’Enyuka is a BBBEE, medium sized hydro-pyrometallurgical and mineral processing engineering and project management company which undertakes multi-commodity process plant projects including coal and uranium.


PROJECT MANAGEMENT

EHL Consulting Engineers operates as a single discipline electrical consulting company registered with Consulting Engineers South Africa (CESA) and adheres to ISO 9001:2000; the Safety, Health and Environmental standards as well as Occupational Health and Safety Act. “For almost 30 years we have had an established position in the market providing electrical, control and instrumentation (E,C & I) services to predominantly mining houses with a smaller focus on the industrial sector,” Fred Knoetze, managing director of EHL, says. “We can offer customers services ranging from conception right through to delivery of specific customer requirements” Fred adds.

Over the years, depending on the economy, we have expanded and retracted while still maintaining a core of skilled and experienced people The company provides a full range of engineering, procurement and construction management (EPCM) skills within the E,C & I engineering discipline across the gold, platinum, chrome, copper and coal mining industries. “Our focus is on process plants, vertical and decline shafts power reticulation, winder projects, furnaces, associated data communication networks and project management,” says Fred.

Large divisionalised organisation are often plagued by inherent inefficiencies data. This concept differs from the one-stop shop since a broader exposure is brought to the market with far greater operational efficiencies, cost efficiencies and experience base,” Hennie adds. “While each entity concentrates on core specialities

in the industry, there is a natural cross pollination which provides the total solution to the client,” He explains. “Depending on the individual client requirements, various aspects of each entity will come to the fore in varying degrees. So in spite of the underlying speciality of the contribution from each linked enterprise, each enterprise has a project management capability using common systems and procedures.


PROJECT MANAGEMENT

Service commonality

“The shift towards linked enterprises came when RSV started growing but we were reluctant to develop a large divisionalised organisation. Unfortunately, such organisations are often plagued by inherent inefficiencies so we needed to create a model where other parties in the industry, with complementary businesses, aligned their services with RSV’s service offering to engender a spirit of customer service commonality,” says Hennie. “In essence, RSV’s linked enterprises are businesses in related market sectors and through them we offer clients the benefit of combined proven experience across the full spectrum of mining, metallurgical, mineral processing, industrial plant and infrastructure design, installation and commissioning,” Hennie clarifies.

Remaining independant

RSV itself is involved in the engineering and project management of mining projects in the hard rock sector. “We are one of the world's foremost mining, engineering and project management companies in this and the industrial markets, offering solutions for individual client needs from resource estimation to final commissioning and production ramp-up,” Hennie adds.

“By remaining independent of any supply chain providers, RSV offers an entirely independent, impartial and professional service to our clients through our three divisional entities,” he says. “The Projects Engineering and Management Division encompasses project clusters across the RSV business while Administration and Technical Services incorporates business administration; human capital management; information technology; the environmental, health and safety cluster, and the project services cluster. Strategic Business and Global Technology is responsible for business analysis services, the engineering and technology cluster, all international businesses as well as being the strategic interface with all the RSV ‘linked enterprises,” Hennie explains.

Takes the hassle factor out of the project equation for customers Hassle factor The company has become a forerunner in the African and global mining industries and offers all, or any combination of, multi-disciplinary services from independent technical assessments, scoping, pre- and bankable feasibility studies to overall engineering, project management, commissioning, ramp-up and facility handover.


PROJECT MANAGEMENT

RSV ENCO is the linked enterprise focusing on the energy – in particular coal and uranium mine development – and infrastructure sectors. “We have in-house mining experience in the platinum and coal mining sectors,” Allan Wingrove, corporate executive/project principal of RSV ENCO, says. “However, we place emphasis on energy and coal and from a mining perspective we have the in-house capability to develop a project opportunity from a conceptual level through to final commissioning and handover. This inhouse capability includes the early assessment of the mineral resource, financial modelling and production of Competent Person’s reports as may be necessary for listing purposes,” Allan adds. With a focus on project and programme management, RSV ENCO’s foundation is built on world class engineering, the inherent mining intellectual capital across all disciplines coupled with proven project management systems and procedures; a blend of technical and practical operational experience is carried through into the design, procurement, construction, management and commissioning of the full spectrum of mining activities, from exploration through to full production. “We have discerned that in the energy field, we are better focused on supporting infrastructure as opposed to competing in the supply specialist technology,” Wingrove says.

“In addition, project support in the form of document control, estimating, procurement, cost control and planning takes the hassle factor out of the project equation for customers,” Hennie elaborates. “I would suggest the formula for success would be for mining houses to entrust the project management – not just during the planning and commissioning stages, but beyond, to full ramp-up – to service providers who have an appropriate level of project maturity. This will ultimately lead to the overall success of any project,” Hennie says. “Ultimately, through the interaction between the linked enterprises, the experience base is expanded with efficiencies and cost benefits to the client,” he concludes. Harry Nieman, RSV, Tel : +27 011 373 8200 Contact Surita Marx Tel (011) 781-1401, Fax: (011) 781-1403 or E-mail: bulkhandling@promech.co.za to book your advertising space


POWER TRANSMISSION

Time is Money A bearing in a plumber block housing is usually placed on a shaft that runs in between large components such as the motor and the gearbox, or between the gearbox and the mill. To replace this bearing after it’s been in operation for many years is a nightmare, not only in terms of getting it off the shaft, but mainly because the whole gearbox and/or motor has to be removed to get it out.

Warwick Steinhobel, managing director of OE Bearings

what spilt bearings are all about, “Bulk Handling Today” speaks to managing director, Warwick Steinhobel. “Split bearings have been around for many years, but in the beginning the plumber block housings for split bearings weren’t compatible with those of standard bearings, making it tricky to swap out a standard bearing with a split bearing system,” he explains. “This turned out to be a huge drawback for split bearings at the time because it required painful modifications to do the swap out. In conjunction with Revolvo, a bearing manufacturer in the UK, OE Bearings subsequently developed a plumber block housing for the SRB which is compatible with the standard range supplied by any of the major bearing manufacturers. Warwick explains, “This dramatically revolutionised SRBs because they are now interchangeable with bearings in the field, so it’s no longer a case of having to make elaborate modifications in order to replace a standard bearing with our SRB plumber block system.

The unique brass bearing cage has clips that can only clip on the right way

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his takes time, and time is money! In critical applications like a mine ventilation fan system, for example, the cost of changing a bearing escalates into millions by the hour, let alone the life- threatening aspect of not having ventilation underground. This is why most mines today have split bearings installed in critical applications like the ventilation fans. Split bearings can be changed quickly and easily, ensuring the absolute minimum downtime because none of the surrounding large components have to be removed.

It’s no longer a case of having to make elaborate modifications in order to replace a standard bearing with our SRB plumber block system Compatibility

OE Bearings, based in Booysens, Johannesburg are split roller bearing (SRB) specialists and to explore

Undeterred

“Having tested the plumber block design to ensure and confirm that it complies with the required standards and specifications for the split bearings we manufacture, the new SRB system became so successful that we soon started exporting our product to the UK,” says Warwick. “End-users liked our product and the demand grew rapidly, leading to others copying the design in order to compete. “Originally we only had one range, the light series which has since been copied,” elaborates Warwick. “However, we’ve since developed a medium series which no-one has copied yet. The medium series is unique to our product range, allowing us to convert heavier standard bearings in the market to SRBs as well. It has proven to be a popular move as we’re now converting 70% in the interchangable new series while only converting 30% with the old original design that wasn’t interchangable with standard plumber blocks.”

Cat out of the bag

The popularity of the medium range has prompted Warwick to take the SRB product development even further, but he doesn’t want to let the cat out the bag yet. “We’re in the process of developing


POWER TRANSMISSION

Assembly can’t go wrong because there are offset guide pins that only allows parts to fit together the right way

another range, but it’s still pretty much on the drawing board,” he says. “All I can say right now is that we have made prototypes and the results are good, but we’ll officially launch the series at the Beltcon conference later this year.” One of the main advantages of installing split bearings is speed, explains Warwick, “More often than not, the gearbox or motor gets damaged during the tedious stripping process required with conventional bearings. It can take anything from eight hours to a week to get up and running again. With the SRB plumber block system, it takes no more than an hour to change out the bearing and with the self-alignment system built into the housing, there are no finicky alignment procedures to go through.”

Installation is much simpler and you can’t make the mistake of not properly aligning the bearing Seeing is believing

To illustrate just how the system works, the company has a desktop model they use to show prospective clients just how easy it is to assemble the SRB system. Every component of the plumber block, the support, the housing and the bearing itself is numbered, the parts also have offset pins on each half of the component. This means you simply can’t put it together the wrong way round because the pins won’t allow it. Even the unique brass bearing cage has clips that can only clip on the right way. Similarly there are grooves on one side and not the other side of the housing, for example, also preventing fitting the wrong way round. This is particularly handy when the light is poor where the bearing is being assembled. The clever engineering of the alignment system is particularly impressive. The housing unit can swivel to a certain degree in the clamped support unit which means there is no strain on the seal which often results in dirt entering the bearing roller, as is the case with rigid standard plumber block arrangements.


POWER TRANSMISSION

Here the bearing housing is straight in the lower section of the plumber block

And here it shows just how much the housing can swivel to allow for misalignment

Correct installation is key

“There are many sceptics out there who don’t have faith in assembling a plumber block bearing from loose parts, but once converted, they never go back to conventional systems,” Warwick says in conclusion.

All sizes, in metric and imperial sizes are stocked to ensure availability

“Besides, our system has proven over and over that it lasts longer than standard systems not because it’s necessarily better but because installation is much simpler and you can’t make the mistake of not properly aligning the bearing. The biggest mistake made with conventional plumber block bearing failure is alignment and correct installation. We’ve eliminated alignment and installation risks with our products which is why they last longer.” Warwick Steinhobel, O.E. Bearings, Tel: (011) 493-4463, Email: warwicks@oebearings.co.za


POWER TRANSMISSION

Conveyor Belt Tensioning Systems Integral to long conveyors is the belt tensioning system where traditionally a dynamic counterweight mechanism maintains the tension on the belt during operation. On large overland conveyors, the counterweight in the tensioning system can be as much as fifty tonnes to compensate for the stretch in the belt as it starts up and the slack created as it builds up speed. Of course this high tension is exerted continuously to the belt.

T

his puts a huge strain on the belt and has a direct influence on belt life, often weakening already damaged areas even more. One of the biggest drawbacks of the dynamic counterweight system is that, if the belt breaks, it

Mike Redmond, a director of Hägglunds Drives South Africa

can pull a large section of the belt off the system, costing more downtime as the belt is refitted. In underground situations the space needed for counterweight systems increases costs enormously and usually prohibitively.

The solution

Direct hydraulic drives, meaning drives without the need for gear reducers, on conveyor systems have over the past decade earned their rightful place not only as a good option for the main drive, but also as a separate solution to control the belt tensioning on the conveyor system. “Bulk Handling Today” has an exclusive interview with the UK’s Mike Redmond, a director of Hägglunds Drives South Africa and ex mining engineer.

The technology has also been widely accepted in South Africa with conversions steadily growing year on year “Hagglunds direct drive motors and systems were introduced into mining and bulk materials handling applications in the 80’s on haulage systems, mine locomotives, apron feeders, chain conveyors, bucket wheels and belt conveyors. The growth over the years has been impressive for example, since converting the first electro-mechanical bucket wheel drive to a hydraulic drive in the mid-nineties, we today have over 400 installations on bucket wheels across the globe,” he says. “The technology has also been widely accepted in South Africa with conversions steadily growing year on year.”

Efficiency and power to weight ratio Hydraulic drives are popular on apron feeders

“Direct hydraulic drives are increasingly being


POWER TRANSMISSION

Belt tensioning systems

driving force available, even at very low speeds, providing a very reliable drive system” Mike adds. “Today, direct hydraulic drives are used in a wide variety of applications however, recently we have seen applications growing strongly with conveyors.”

The challenges

Drives on belt conveyors

As the hydraulic motor’s mechanical efficiency remains constant, the torque applied to the winch rope and hence the conveyor take up trolleys also remains constant used in the mining and materials handling industry mainly due to engineers recognising the advantage of the typical hydraulic drive versatility and the high power to weight ratio they deliver in many applications, let alone the high torque efficiency available from starting to full speed. This allows for the adjustment of speed while always having full

While tensioning is considered critical by conveyor designers for reliable trouble-free conveyor operations, the effects of the inadequate, poorly-maintained or inappropriate application of tension devices by some end-users or contractors often proves costly. “There are many methods used to tension the belt but the main functions should include adequate slack side tension at the drive drum to prevent belt slip, particularly during start up. The tensioning system should also accommodate changes in the length of belt due to its elastic behaviour, especially during the starting/stopping acceleration and various load conditions.

Belt storage

“It’s important to maintain a minimum constant tension in the belt at all times avoiding belt sag.


POWER TRANSMISSION

Tough and reliable drive solutions for heavy-duty applications

Drives on scraper chain conveyors

Over-tensioning and stressing of the belt and the conveyor components during starting and stopping should also be avoided,” explains Mike.

“There is no need for load cells because of the high efficiency of the drive, the pressure control is tension control so monitoring pressure is effectively monitoring torque or tension” says Mike. “However load cells are sometimes installed purely to cross reference data and for calibration.

“Another important role for the tensioning system is to provide belt storage for advancing/retreating type conveyor systems. When these requirements are reviewed, it’s worth considering how the features of a direct hydraulic drive might well benefit a conveyor when applied to a live tensioning device such as a winch.”

Tension control

The Viking hydraulic motor is really like a large, extremely efficient hydraulically driven ball bearing, providing a high torque, fast acting, low inertia drive which supports one end of the winch drum. The cable is connected to the take up trolley often with a number of sheaves to give the needed tension. “The hydraulic motor torque and therefore the winch tension is controlled by pressure, controlled by the pump package. The tension is directly proportional to the pressure, a highly efficient mechanical process,” states Mike. “As the hydraulic motor’s mechanical efficiency remains constant, irrespective of direction of rotation, starting position or speed, the torque applied to the winch rope and hence the conveyor take up trolleys also remains constant. By using a simple solenoid valve the tension can be switched to a high level for starting the conveyor and then when running be switched back to a lower tension thereby reducing wear on the belt, improving the life. This is important especially as on some conveyors, the difference between start, stop and running tensions is in the order of 50%.”

No load cells “The winch unit incorporates a fail-safe springapplied, hydraulically released brake which is applied on stopping and operates in a power loss situation to ensure the tension is held whenever the system is de-energised”. The hydraulic power unit runs continuously, automatically maintaining belt tension by sensing pressure and therefore the load within the system.

Automatic and manual

“Normally the system is fully automatic but a manual mode is provided,” clarifies Mike. “In automatic mode, the pump is set to haul in and a mooring function in the pump package is engaged. Any line pull greater than the preset tension will cause the winch to ‘payout’ while any pull less than the preset tension, will cause the winch to ‘haul in’ the slack, automatically and actively self tensioning and maintaining a constant belt tension for all operating conditions. “In the manual mode, the system allows for operator intervention by facilitating manual ‘haul in’ and ‘payout’ to accommodate belt maintenance,” adds Mike”

Share the load easily and inherently compared with tricky synchronising electro-mechanical systems Proven its worth

The direct hydraulic drive concept in general has offered substantial additional benefits in a number of conveying applications such as multiple drives that share the load easily and inherently compared with tricky synchronising electro-mechanical systems. “Although not specifically promoted as such, there are numerous conveying applications around the world successfully applying this technology,” Mike says in conclusion. “With installed powers from 30 to 2500 kW, belt lengths from 30 to 3700m and production flows from 400 to 8000 tph on a variety of materials, on both conventional and tube conveyors, direct hydraulic drive technology is well proven. Understandably direct drive features are not required with all conveying applications, but when appropriate, this technology is worthy of serious consideration.” Michael Gullick, Hägglunds Drives, Tel: (011) 454-4933, Email: michael.gullick@za.hagglunds.com


Market Forum and clean coal stacker conveyor, a 152cm refuse collecting conveyor with 107cm sub-refuse conveyors, and a 183cm belt width train load out conveyor. All surface conveyors have been operating since May 2010. Conveyor systems for all underground operations are also part of this project and will be installed as mine plans are implemented. Joy Mining Machinery, www.joy.com, Lou Boltik. E-mail: lboltik@ joy.com

‘Pulleying’ ahead

MS Conveyor Pulleys SA was formed in 2004 with the main emphasis being the design and marketing of conveyor pulleys. During 2010, the company continued to grow into a leading manufacturing of high quality engineered pulleys. Over the past few years Max Schenck, company founder, took an active role in the writing of SANS standards in collaboration with the CMA and many client specific pulley specifications. These included Eskom and Anglo American.

84 inch belt with underground 171 degree conveyor transfer

Installation completed

The installation of two 213cm belt width slope conveyors for M-Class Mining’s new Sugar Camp Energy underground coal mine located in the state of Illinois (USA) was recently completed. Both are rated at 10 000 tons per hour. The Slope A conveyor, 1 060m with 145m of vertical lift, comprises an 8 000 hp four pulley remote drive with a 150hp constant tension vector winch electric take-up. The take-up is installed near the Slope A tail end which is half the distance from the surface to the coal seam. The Slope B conveyor, 1 143m with 391m of vertical lift, comprises a 6 000hp four pulley remote drive with a 150hp constant tension vector winch electric take-up. The take-up is located near the tail end in the coal seam. The Slope B conveyor discharges onto the Slope A conveyor midway down the mine slope at a 171 degree transfer angle. Both slope conveyors include 183cm diameter by 236cm face width drive and discharge pulleys weighing up to 28.7 tonne each. The take-up and tail pulleys are 152 cm in diameter by 236cm face. All of the surface conveyors at Sugar Camp Energy were included in Joy’s scope of supply. The surface conveyors include a 213cm belt width raw coal stacker, a 152cm plant feed conveyor, a 183cm clean coal collecting conveyor

“We firmly believe that the reason behind this success,” says financial and business development director, Magda Jansen-Schenck, “is primarily the result of 25 years experience in the pulley industry, the partnerships we have forged with our clients and the continued improvements to the engineering, design and manufacture of our pulleys. “We have seen significant growth in our client data base,” she continues, “which proves to us that our customers have the utmost faith in our product and our abilities to deliver on time.” The company’s mission is to continue the successful growth of their business by means of partnerships with their clients based on high values, morals, work ethic and professionalism, and it is an accredited level 5 BBBEE contributor. Tel: (011) 894-4900, Fax2mail: 086 540 3158, Email: quotes@ mscpsa.co.za, www.mscpsa.co.za


Market Forum Hot and cold responsibility

Wade Walker has secured the contract for the E&I work at Adamas Resources’ Nzema Gold Project in Ghana, a project managed by Lycopodium out of Perth. The scope of work comprises labour, supervision, installation and commissioning of free issue material for the gold operations at Nzema mine which is located in south-western Ghana. Michael Hanna, project manager at Wade Walker responsible for this contract, says that it includes both the HV and LV substations, primary crushing and grinding areas, conveyors, gold and elution, CIL and CCD leach and thickening plants, reagent plant and lime storage facility. “What is significant on this particular contract is that Wade Walker will be responsible for both the cold and hot commissioning, and while this is not standard practice in South Africa it is something which we have done on numerous occasions on projects in Africa,” he explains. The EPCM contractor on this project is Lycopodium, and Michael says that Wade Walker has undertaken several successful contracts with this Australian-based engineering and project management organisation.

A section of the Nzema plant where Wade Walker is working

The company has had a dedicated operation in Ghana since early 2004, which underscores the level of commitment which the company has to the West African region. 7LP:DNH¿HOG7HOZHEZZZZDGHZDONHUFR]D


Market Forum Celebrating mileage Saving fuel

In order to emphasise the broad range of fuel-saving measures available, Volvo Trucks is presenting a philosophy called “Every Drop Counts”. It is a concept that aims at reducing fuel consumption and environmental impact. At www.volvotrucks.com/everydropcounts the company shares examples of both big and small ways of achieving fuel savings. “Fuel consumption can be significantly reduced via relatively simple measures. Lower fuel consumption is good for our customers and good for the environment, and that’s a message we want to make sure gets through in our campaign to increase knowledge about fuel efficiency,” says the company’s president and CEO Staffan Jufors.

It is not often that you find two trucks that have clocked up a combined two million kilometres of trouble-free running, with no breakdowns and no repairs – not even a clutch replacement. They are not extra-heavy duty long haul models, but freighters in the heavy truck category. This is the situation with Eray Freight which celebrated this achievement with two of its Hino trucks. One of them has covered almost 1,1-milliom kilometres with the same driver at the wheel, Elias Kgaladi who has driven the 15-257 freighter since it was delivered in 2003. The other truck has 998 000km on the odometer and has had many drivers behind the wheel, but it has also been reliable and trouble-free.

“We have now adopted a holistic approach based on customers’ operations, aiming for optimal energy usage and minimised environmental impact. It’s all about big and small steps in harmony,” he says. Driver training is one of the most effective means of cutting fuel consumption. In Europe, Riau Botha, founder and (almost) single-handed operator of Eray Freight with the drivers of her Hino 15 000 drivers have 15-257 “million kilometre” trucks, Elias Kgaladi (left) and Edward Matlou, pictured at their depot in Kempton Park already taken Volvo Trucks’ driver training course. The overall range of measures includes major Eray Freight has grown from having two four-ton trucks in technical innovations such as hybrid technology and 1999 to a fleet of 15 now. They have all been eight-ton gas-powered engines, as well as accessories and services freighters but now a 13-ton 17-26 freighter with a tag axle such as choice of equipment, vehicle maintenance, has joined the fleet and will be driven by “millionaire” Elias traffic planning systems and fuel consumption analysis. as a reward for his excellent treatment of the Hino eight Correct wheel alignment and appropriate choice of tonner over the past eight years. tyres can cut fuel consumption by as much as 14%. Eray Freight is virtually a one woman business with Ria “In other words, we’re not talking about a vision for Botha the powerhouse behind its success and expansion the future but rather about concrete steps that are over the years. She does have the support – both moral and already happening. With all these pieces of the puzzle practical – of her husband Pat. falling into place, we feel the time is ripe for reaching The trucks are all serviced on the company premises after out in this way and talking about our philosophy and the warranty expires. There is a dedicated technician and our long-term aims,” says Staffan Jufors. the trucks run 20 000km between services. Fuel consumpJenny Björsne, Volvo, E-mail jenny.bjorsne@volvo.com, tion is considered very good at about 6km/l with the fitment Web: www.volvtrucks.com/everydropcounts of extra fuel tanks ensuring that most round trips can be completed without refuelling. Ignatius Muthien, Hino, Tel: (011) 809-2064, Email: imuthuen@ hino.co.za


Market Forum Achieving growth in hostile terrain

The power and reliability of HPE Africa’s exclusive range of earthmoving equipment is helping to ensure that plant hire company, SJM Industrial, continues to meet the demanding challenges of its clients, who operate in remote and hostile terrains across South Africa. Heidelberg-based SJM Industrial, which supplies a wide range of heavy-duty machinery to industrial applications nationwide, purchased its second Hyundai R210LC-7 excavator from HPE Africa. SJM Industrial director Clive Fraser says the company purchased its second Hyundai R210LC-7 excavator, which has an operating weight of 21,7 tons, after the first model SJM Industrial director Clive Fraser and co-director Steven Fraser with their new Hyundai R210LC-7H proved itself to be highly-capable of operating in environments ranging currently boasts a fleet of 14 heavy-duty machines, which from construction and mining, to demolition. are all supplied to clients with a fully-trained operator. “SJM Industrial decided to purchase the additional Hyundai .LUVW\'HQKROP7HO  (PDLONLUVW\#KSHDIULFDFR]D R210LC-7 this year, following a highly-successful trial run of the same excavator a year ago. The first excavator is currently contracted to a major energy project in the Limpopo province, where it is being used with an attached hydraulic jackhammer and, if needed, a bucket too,â€? he explains. SJM Industrial co-director Steven Fraser notes, “SJM Industrial

Driving up figures

The commercial vehicles market is slowly returning to its pre-recession glory, reflecting a mounting confidence in the business world as industries reliant on trucks continue to boost sales. “With a year-on-year increase over the past four months of 41.7%, we are very encouraged by the performance of the Mercedes-Benz South Africa (MBSA) share of extra heavy segment of the commercial vehicles market increase,â€? says Kobus van Zyl, vice president, commercial vehicles. This follows on positive year-end 2010 results at MBSA, climaxing in a strong position with a market share of 28.1% in the over 3,5t GVM segments. Ian Riley, divisional manager at MBSA for Freightliner and Fuso brands comments, “Our year-to-date figures are very encouraging, with Freightliner showing growth of 31.5% over last year and Fuso up by an impressive 116.4%.â€? The Mercedes-Benz truck brands represented in this segment also showed good results for the first four months of 2011 over the same period in 2010. Mercedes-Benz Axor sales increased by 41.7% while the Mercedes-Benz Actros is ahead by 31.5% year-on-year. /\QHWWH 6NULNHU 7HO    HPDLO O\QHWWHVNULNHU# daimler.com


Head Office & Manufacturing Facility: WEARCON (Pty) Ltd, 16 Industria Road, Vorsterskroon, Nigel, GAUTENG Tel: +27 11 814 2983 - Fax: +27 11 814 2984 - E-mail: andre@wearcon.co.za - Website: www.wearcon.co.za


Market Forum Complete solutions

SKF’s Lubrication Application Centre (LAC) is equipped to offer complete lubrication solutions to diverse industry applications. The SKF Solution Factory Africa in Witfield, Johannesburg, positions the company as the ultimate solutions provider for rotating equipment by integrating its knowledge and capabilities in its core technologies. SKF formally launched its Solutions Factory in July 2009 and the company continues to invest in additional equipment in order to deliver exceptional service and product support to customers. “The Solutions Factory has undoubtedly opened doors for the LAC,� says Sarel Froneman, SKF’s Manager of Lubrication Solutions. “The Solutions Factory concept combines technical innovation with business model innovation by offering complete solutions aimed at solving customers’ underlying problems. This opens new markets and creates opportunities for us�. SKF Lubrication is an SKF value offering that combines understanding of the bearing and bearing technology as well as the specific need of an application. “With the acquisition of two leading lubrication brands (Vogel and Safematic),� says Sarel, “SKF acquired what is unquestionably the best lubrication technology in the world.� The SKF Lubrication Application Centre is an autonomous business unit within the SKF Solutions Factory. Lube Solutions has 30 000 product lines while the SKF bearing portfolio also counts some 30 000 products. “It was simply more practical to consolidate the lubrication stock under one roof and to use dedicated, trained and experienced technicians to do justice to this vital part of the SKF portfolio. We have organised our stock holding into a manageable area our people understand and have the know-how to work with the products and more to the point, they know how to read a lubrication designation,� Sarel concludes. 6DPDQWKD-RXEHUW7HO(PDLO6DPDQWKDMRXEHUW# skf.com

Speculation put to bed

Regarding speculations on a possible combination between MAN SE and Scania AB, MAN SE comments as follows: “It is well known, that MAN and Scania are seeking a closer industrial co-operation in order to realise considerable synergy opportunities. Both companies are in discussions in this regard. Both parties are focused on creating value for their shareholders and other stakeholders and are pursuing this with mutually friendly intentions. At the same time, both sides are committed to maintaining the operating businesses and the unique brand values of the respective companies. This would be the basis for any possible option pursued by MAN. At this early stage of the discussions, the outcome is still open and no decisions have been taken.� 0DUMD%UXQQLQJHU7HOHPDLOPDUMDEUXQQLQJHU# za.man-mn.com

2011 Conveying Guide “Bulk Handling Today�, will be publishing the first ever CONVEYING GUIDE in July 2011. The guide will be distributed together with “Bulk Handling Today�, at various seminars and conferences throughout the year. We are offering you a golden opportunity to put your product or service on the map.

T

he guide will advise industry users on how to choose, use and maintain conveying equipment. But any equipment is only as good as the person who operates it, so we will also discuss training, proper maintenance, health and safety requirements, inspections and much more. If you would like your product or service to Surita Marx feature in this definitive lifting guide, I will be happy to provide you with further information so please do not hesitate to contact me. Make sure you’re in this comprehensive reference publication!

Kind regards, Surita Marx, Advertising Sales Consultant, Bulk Handling Today, Tel: (011) 781- 1401 / 083 281 5761, E-mail: bulkhandling@ promech.co.za

Engineer Placements Professional opportunities Our job board continues to display a wide variety of excellent job positions that you can review and apply for on- line. Keep your credentials on our secure and FRQÂżGHQWLDOGDWDEDVHXSGDWHWKHPDWDQ\WLPH We keep in touch with you. www.engineerplacements.com


Market Forum Minimising damage

Becker Electronics manufactures belt protection systems which automatically detect tears or rips in conveyor belts used in diverse industries. “This belt rip scanner system type BRS-01, which is used to detect longitudinal rips on steel cord and fibre conveyor belts, also prevents further damage to the belt by stopping the belt drives in the event of a rip,� says Albert Bower, managing director of Becker Electronics. “This system works on the principle of secondary rip detection – rips are only detected after they have occurred. This scanner minimises damage to short belt distances, typically 50m, thus preventing further damage to the belt.� At installation, the system carries out an identification run and the processor of the belt rip detection system unit (BRS/CU) stores the necessary data in the EEPROM. Parameters include the succession of coils in the belt, belt speed and start up time of conveyors. Stored values are protected against power loss and can Installation of the Becker Electronics belt protection system be entered or changed when necessary. the BRS/SI cannot measure any analogue values from the The belt rip sensor that is embedded in the belt operates destroyed coil. like a bridge between transmitter and receiver of the belt rip scanner sensor interface (BRS/SI). If a belt is ripped, $OEHUW%RZHU7HO  (PDLOLQIR#]DEHFNHUPLQLQJFRP

Index to Advertisers AST Pyroscan Barloworld Metso

Inside Front Cover 8

Bateman

18

Bauer

25

Bearings International

22

BMG

10

Bonfiglioli

26

Clyde Bergemann Africa

32

Dunlop FLSmidth Hagglunds Horne SA

25 Outside Front Cover, 20 Inside Back Cover 14, 19

Melco

24

Quadrant

28

Rema Tip Top Sandvik

11, 34 Outside Back Cover

SEW

12

Silver ‘A’ Power Transmission

24

Sovereign Steel ThyssenKrupp

6 30

Transmission Components

38

Voith

21

Wearcon

36

WearWestweigh

35


Tough demands have met their match.

With a hydraulic drive system from H채gglunds, you get compact, durable power - without foundations or gearbox. A full range of rugged motor types and complete solutions for monitoring and control give you total assurance, even in the most demanding applications. Let us know your demands.

H채gglunds Drives South Africa (Pty) Ltd P.O.Box 2851, 1610 Edenvale, Johannesburg Phone: + 27 (0)11 454 4933, Fax: +27 (0)11 454 5088 E-mail: info@za.hagglunds.com, www.hagglunds.com

Our drive is your performance.



Bulk handling Jun11