{' '} {' '}
Limited time offer
SAVE % on your upgrade.

Page 1

S MECHANICAL A ENGINEER Nov/Dec 2019

Publication of the SA Institution of Mechanical Engineering, incorporating News of Associate Organisations

AN EFFECTIVE SACRIFICIAL BEARING INTERFACE ELECTRIC ALTERNATIVE TO PRESS BRAKES DEVELOPED


Your boutique business destination Surrounded by lush gardens in the hub of Johannesburg’s northern suburbs, The Peartree in Craighall Park caters for groups of fifteen through to 100 guests in three well-appointed and equipped business suites. Breakfast meetings, working lunches, indoor or outdoor dining, half-day and full-day packages including all welcome refreshments, teas and lunches are offered in Standard, Gold and Platinum packages. Secure parking, Wi-fi, lockable space, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.

www.thepeartree.co.za e-mail: info@thepeartree.co.za Tel: 011 781 1401 41 St. Albans Ave, Craighall Park

2

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019


AN ENGINEER’S VIEW

The Transition from Student to Mechanical Engineer Some would consider the years spent at university to be the steepest steps in learning in the overall career of a mechanical engineer. I would argue that the student years of an engineer only form half of the mountain that must be climbed towards the ascension to professional engineering status.

W

hile at university a mechanical engineering student typically only catches a glimpse of the engineering world through the lens of academia, with focused growth in the technical fields of thermodynamics, fluid mechanics, materials strength, calculus and the various forms of computer aided design. This focused technical growth typically culminates in a final year design project, whereby these new-found skills are applied to the design process of concept formation, detailed design, prototyping or testing and finally manufacture. Graduate engineers moving into the working environment will need to continue their steep learning ascension, this time mostly through the learning of the ‘soft skills’ required in order to be effective in the workplace. The discovery is soon made that a working engineer’s time is not their own and the priorities of clients and managers must be carefully balanced in order to produce an effective design that may pass the hurdle of financial viability. To achieve this, a graduate engineer must adopt the mantra of ‘keep it simple’, which must be uttered at the beginning of each new project. Nothing fuels the vanity of a graduate engineer quite like the belief that what is existing and proven in the market need not be considered. The benefit of using standardised and proven equipment and techniques is a significant reduction in cost and the use of the knowledge of the engineers who have come before you.

First principles

However, a working engineer must be able to identify the level of engineering required to solve a problem to within an acceptable degree of accuracy. It may be a priority to quickly solve a solution by using proven design and empirical formula, but for more complex problems the use of first principles and Matlab type calculations must be reverted to. Although simplicity is often the most revered solution in industry, it is often the most difficult outcome to attain. The newly graduated engineer must then extend themselves beyond the technical learning received in university and consider the more complicated variables of manufacturability, politics, material cost, trade-offs and HAZOPs. The intuition of what equipment must be procured from overseas, or what must be produced locally

cannot be taught in university. University also cannot teach the challenges Cameron Hofer involved with getting a construction crew’s equipment through the Zimbabwean boarder, nor can it teach the intricacies of identifying and managing potential risks in the execution of a project. Scenarios such as these can only be learned through experience.

The real world

It must be further considered that the product being designed will unlikely be used in the ideal world on which university models are based. In the real world, pipelines may become fouled with time, upsetting an engineer’s delicate pipeline pressure loss calculations. Instabilities in a process may be brought about by off specification material being fed into the factory. A good engineer must have the foresight to identify these potential “less than ideal” operating conditions and factor these into their calculations.

Although simplicity is often the most revered solution in industry, it is often the most difficult outcome to attain

To all the newly graduated engineers and those who are still studying, do not be discouraged. The world of mechanical engineering, especially within sub-Saharan Africa is an exciting adventure that presents many unique opportunities, that may not be known to those who are considering moving their careers abroad. My newly emerging career at a consulting engineering firm has seen helicopter rides to project sites in near uncharted regions of Africa, the comradery of a project team rallying against long odds to successfully meet a client’s requirements, and the dynamics of dealing with international projects. I have been exposed to projects ranging from ethanol plants to transformer oil production facilities to food processing factories. The notion that opportunities do not exist in this country for young engineers is only true if you believe it. My advice to those entering the work place is to be open to every opportunity that will be presented to you, any opportunity no matter how small or trivial will always have the potential to unlock further opportunities further down the line.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

3


High security welded mesh

Pallisade

Gates

Gate Automation

Razor wire and more ....

What is High Security Weld Mesh HIGH Security Weld Mesh is wire fused and welded at a Horizontal distance of 76.2mm and a vertical distance of 12.7mm also known as 35B/3510 where 3 denotes 3”(distance between vertical wires), 5 denotes 0.5” (distance between horizontal wires), and B or 10 denotes gauge of wire

Salient Features • Difficult to Climb: The spaces between the Horizontal wires are too narrow for fingers to have grip • Impregnable: Extremely difficult to cut with a hand cutter as the beak of a wire cutter will not be able to penetrate the horizontal wires • Excellent Replacement option to Solid Wall as: 1. More economical than a solid wall 2. Faster to install than a solid wall 3. CCTV Camera has a clear view • Further upgrade possible with electric security system • Anti-corrosive & low maintenance

Standards

• Manufactured according to BS EN 10016-2 • Wire Sizes in accordance with BS EN 10218-2 • Tolerance on Mesh Size in accordance wiht EN 10223-7 • Tolerance on Panel Size in accordance with EN 10223-4 • Welding Strength in accordance with BS EN 1461 • Zinc Coating in accordance with EN 10245-1 • Anti Corrosion in accordance with BS En 3900 E4/F4

Tensile Strength • Wire has a tensile strenght of min 550 MPA

MARK: 083 454 6488

Email: mark@palifence.co.za

www.palifence.co.za


S MECHANICAL A ENGINEER Nov/Dec 2019

Publication of the SA Institution of Mechanical Engineering, incorporating News of Associate Organisations

S MECHANICAL A ENGINEER Nov//Dec 2019  VOLUME 69

Contents AN EFFECTIVE SACRIFICIAL BEARING INTERFACE ELECTRIC ALTERNATIVE TO PRESS BRAKES DEVELOPED

On the Cover Combustion Technology Tel: (021) 715-3171 info@combustiontechnology.co.za www.combustiontechnology.co.za

Cover Story

Hydraulics

8

SA Institute of Tribology

26 Balls That Won’t Buckle Under Pressure

10 End of the Year SAIT Training Report

Ventilation 28 A Refreshing New Fan Design

SAIMechE

Power Transmission

12 Branch Golf Day

30 Motor System Efficiency High on the Agenda

All Aboard

Lubrication 18 Bearings of Choice

Power and Electrical

Bearing Focus

32 Locking Onto Efficiencies

20 An African Powerhouse

Maintenance

Regulars

22 Simplifying Asset Management

Robotics

3

An Engineer’s View

23 Clamping Down

7

Institution News

Health and Safety

33 Market Forum

24 Preventing Sick Building Syndrome

38 On the Move

Copyright

All rights reserved. No editorial matter published in “SA Mechanical Engineer” 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. Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123, Republic of South Africa Tel: (011) 781-1401, Fax: (011) 781-1403 Email: samecheng@promech.co.za, www.promech.co.za Managing Editor Susan Custers Editorial Contributors Liesl Venter/Patricia Holburn Advertising Sales: Louise Cresswell Cell: 071 886 1263 DTP: Sanette Badenhorst Circulation: Netta Janse van Rensburg Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/ Overseas. Disclaimer

PROMECH Publishing and The South African Institution of Mechanical Engineering as well as any other body do not take responsibility for the opinions expressed by individuals.

Printed by: Typo Colour Printing, Tel: (011) 402-3468/9 FSC (Forestry Stewardship Accreditation)

Official Publication of

THE SA INSTITUTION OF MECHANICAL ENGINEERING and endorsed by:             

CONSULTING ENGINEERS OF SA CORROSION INSTITUTE OF SA INSTITUTE FOR CERTIFICATED MECHANICAL AND ELECTRICAL ENGINEERS NATIONAL SOCIETY OF BLACK ENGINEERS NUCLEAR INSTITUTE SA ASSOCIATION FOR ENERGY EFFICIENCY SA CAPITAL EQUIPMENT EXPORT COUNCIL SA INSTITUTE FOR NON-DESTRUCTIVE TESTING SA INSTITUTE OF TRIBOLOGY SA PLASTIC PIPE MANUFACTURERS ASSOCIATION SA PUMP MANUFACTURERS ASSOCIATION SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION VALVE & ACTUATOR MANUFACTURERS CLUSTER OF South Africa

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

5


6

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019


SA INSTITUTION OF MECHANICAL ENGINEERING

Council 2018 - 2020

Company Affiliates

Office Bearers

President......................................................Prof D Blaine (Debby) Vice President....................................... H Makwarela (Hangwani) National Treasurer.............................Prof JL van Niekerk (Wikus)

Branch Chairpersons

Amoricom Autodesk as represented by Worldsview Technologies

Central ............................................................... A Celliers (Alicia) Eastern Cape........................................... G van den Berg (Gideon) KwaZulu-Natal ........................................ Dr J Padayachee (Jared) Mpumalanga Highveld ................................. M Mashele (Mishael) Vaal.............................................................. N Swanepoel (Niekie) Western Cape .................................................Dr G Erfort (Gareth)

Babcock Ntuthuko Engineering Pty Ltd Eskom Rotek Industries SOC Ltd

Osborn Engineered Products SA (Pty) Ltd Plant Design & Project Services (Pty) Limited (PDPS) PPS Insurance Co Limited Proconics

Esteq Group (Pty) Ltd

Redheads Engineering Services (Pty Ltd)

Exxaro Resources (Pty) Ltd

S.A.M.E Water (Pty) Ltd

Procedures.......................................................... SZ Hrabar (Steve) Communications and Marketing..................G Bartholomew (Bart) TBC...........................................................MAE Black (Malcolm) TBC..............................................................HG Bosman (Tertius)

Festo (Pty) Ltd

SA Power Services (Pty) Ltd

Fluor SA (Pty) Ltd

Sasol Technology (Pty) Ltd

Kelvion Systems (Pty) Ltd

Siemens (Pty) Ltd

Hatch Africa (Pty) Ltd

Spirax Sarco (Pty) Ltd

Chief Executive Officer..................... Vaughan Rimbault Digital Communication Specialist... Anisa Nanabhay

Howden Power (a div of Howden Africa)

Tenova Mining and Minerals SA

Howden Projects (a div of James Howden)

Thyssenkrupp Engineering (Pty) Ltd

MBE Minerals (SA) (Pty) Ltd

Vital Engineering (Pty) Ltd

Megchem

Weir Minerals Africa

Portfolios:

National Office Co-ordinator………....… Carey Evans

PO Box 511, Bruma, 2026 Tel: (011) 615-5660 Email: info@saimeche.org.za Website: www.saimeche.org.za Membership Email: membership@saimeche.org.za

Mod-U-Flow CC

Baker Baynes Talks Digital Transformation of the Process Plant On 7 November 2019 the SAIMechE Vaal branch, in longstanding partnership with Autodesk Gold Partner Baker Baynes and together with electrical and instrumentation engineering giant Proconics, gathered to talk about Digital Transformation of the Process Plant.

T

he meeting came about through numerous engagements with Proconics, which is a customer of Baker Baynes and the mutual relationship both companies have with SAIMechE. Of course there is also a shared interest in using technology solutions to drive innovation, save time and ensure more accurate cost saving outputs in the process plant environment. The event saw one of Baker Baynes’ specialist and industry thought leaders, Daneel Ballaram navigate attendees through the exploration and revolution of The Digital Transformation of the Process Plant, in which five main focal domains were discussed namely, design, control, fabrication, big-data analytics and work organisation. Proconics shared their digital transformation journey’s success, facilitated by the adoption of cutting-edge Autodesk Design Solutions with the support of Baker Baynes. info@bakerbaynes.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

7


COVER STORY

All Aboard! A ship’s engine room is a complex arrangement of machinery and systems carefully positioned for optimum performance. With an ever increasing emphasis on safety of ship and crew, fitting a boiler in these particular circumstances requires experience. “SA Mechanical Engineer” caught up with the team at Combustion Technology to find out about their latest marine installation.

U

nderstanding the maritime environment and its boiler needs is one thing. Delivering, installing and commissioning a boiler on a vessel another.

Cape Town-headquartered Combustion Technology can attest to this. Experts in the field of boiler installations and conversions the team is not new to the maritime sector. The company recently successfully completed the installation and commissioning of a new steam boiler on board the Desert Diamond, a vessel belonging to the largest fishing company in Africa, The Oceana Group.

Far more pro-active approach to maintenance and more cost-effective in the long run According to Combustion Technology CEO Riaan van Biljon the company has a long-standing relationship with The Oceana Group already responsible for the servicing and maintenance of boilers at their other processing plants. “Knowing our service level, our experience and what we bring to the table they asked us to look at the boiler on one of the vessels and find a solution for some of the problems they were experiencing,” says Riaan. “But, in the maritime industry it is not as simple as just going out to look at the old boiler and quote for an upgrade or a new one. We had to wait for the vessel to come into port before we could gain access to it.” After a thorough inspection it was agreed that a

8

THE SOUTH AFRICAN MECHANICAL ENGINEER

repair was not going to suffice and a new boiler was indeed required for the Desert Diamond. The decision was taken to install a Alfa Laval Model Aalborg OS 6500 Steam Generator, which allows for steam production of 6500kg/hr, plus 2000Kg/ hr from the exhaust boiler configuration on the vessel. With a total combined generating capacity of 8 500 kg/hr this would sufficiently address the steam requirement on the vessel.

Project planning

“When it comes to a successful installation on board a vessel the most important element by far is planning,” explains Riaan. “The vessels are out at sea for long periods of time and when they come into port they are only there for a set time during which numerous activities and upgrades have to take place. Also, the longer the vessel is in port, the less the revenue is for the fishing company.” Combustion Technology did not just install a new boiler, but also upgraded the entire system introducing the latest technology. “We installed the Autoflame Combustion Management System with data transfer interface (DTI) that allows us to now monitor the system’s operation remotely.” While land-based boiler systems can be accessed at any time, the operations on vessels can only be logged onto when the vessel is in port. “The decision to introduce this system, even though it cannot be accessed and monitored as often as is the case with boilers on land, is because the maritime environment is harsh. A remote monitoring system

VOL 69 Nov/Dec 2019


such as this ensures that the boiler is working at continuous levels of efficiency and allows us to pick up on any irregularities much quicker. It is a far more pro-active approach to maintenance and more cost-effective in the long run.” The system is monitored whenever the vessel is in a port anywhere along its fishing route and allows the Combustion Technology team to plan ahead to address any concerns when it returns to home port. A Riello P450PN ECO fully modulating burner with variable speed drive on the fan motor as well as water and oil flow metering with remote logging was also installed. In addition oil detection equipment for the feedwater tank, dual feedwater pumps, salinity and dissolved O2 detection with alarm equipment, a flue gas temperature measurement and transmitter, an Automatic Bottom Blowdown System, TDS Control System with automated top blowdown and an exhaust gas oxygen probe and interface were all part of the upgrade. Says project engineer Pieter Wentzel, “Planning for this installation began months ahead of the actual fitting. We knew we would have a limited time to do the installation on board the vessel and needed to ensure that everything to the last detail was ready and in place once the vessel came to port.” With no room for error every piece of equipment was pre-tested. “We could not take the risk of arriving at the installation phase to only see it was the wrong piece of equipment or that we needed something else. We had to have all of the elements including the assembly of the steam generator, the engineering and the electric panels ready.”

Vessel installation

The biggest challenge of the project, adds Pieter, was the actual installation. Working in extremely tight confines the team only had 25 days to install and commission the boiler. “We also had to wait our turn as there was an order of other jobs that had to take place and other contractors on board,” he says.

Measuring 7 metres long with a 2.8 metre diameter getting the 15 000kg vertical boiler into the vessel was a challenge and a detailed rigging study had to be performed. With hardly any manoeuvring room, Oceana opted to cut open the deck and lower the boiler into position using two 200 ton cranes, a process that took around 13 hours. Working long hours the boiler was commissioned on time on January 26 this year. “Our extensive experience in boiler installations really did contribute,” emphasises Riaan. “this is not the first time we have done something like this and we had a very good idea of what the challenges would be and could plan ahead of time to mitigate against it.” There are several benefits to the upgrade, says Riaan. “The decision to opt for the Alfa Laval Aalborg boiler with the Autoflame Combustion Management System was very intentional. Not only does it conform to stringent DNV marine regulations, but it is also robust enough to withstand the harsh conditions of operation at sea while delivering safer and more efficient operations to The Oceana Group while the Autoflame Combustion Management System will improve overall performance, efficiency, reliability and reduce operating costs” Brian Taylor, Marine Superintendent at The Oceana Group, commended the team for a job well done. “Combustion Technology was very professional in the acquisition, supply and installation of the boiler. The project went very smoothly and was completed on time. The Combustion Technology technicians went out of their way to make the project and commissioning successful,” he concludes. Combustion Technology Riaan van Biljon Tel: (021) 715-3171 Email: info@combustiontechnology.co.za www.combustiontechnology.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

9


TRIBOLOGY

End of the Year SAIT Training Report

T

he end of 2019 has been an excellent year for attendance at the SAIT five day “Lubrication Engineering” courses. The three venues used by the SAIT in Johannesburg, Durban and Cape Town give excellent, helpful and courteous service in comfortable surroundings. We have used the UCT Graduate School of Business at Breakwater Lodge at the Waterfront in Cape Town for many years, and Sica’s Guest House in Durban is a favourite venue. For the Johannesburg courses we have moved in more recent years from the SAIT office premises at Science Park to the more professional and convenient CedarWoods Conference Centre in Woodmead. Johannesburg is always well attended, Cape Town

10

THE SOUTH AFRICAN MECHANICAL ENGINEER

and Durban are popular but with fewer attendees. The six courses this year resulted in 27 distinctions, a mark of 75% and over, with the top score of 90%. The very highest over the years was 93%. One in-house course was held at the Palabora Copper Mine in Phalaborwa. In the small group of 12 who attended, four distinctions were achieved. We are looking forward to another great year, bookings from the February course at CedarWoods are already coming in – so don’t leave it too late to book if you wish to attend. Best wishes from Gill, Isabel and Berice at the SAIT. Gill Fuller SAIT

VOL 69 Nov/Dec 2019


THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

11


SAIMechE

Branch Golf Day The South African Institution of Mechanical Engineers (SAIMechE) Mpumalanga Highveld branch held its annual golf day on 25 October. Top tier professionals who are captains in their respective companies let their hair down by hitting the greens for a fun-filled round of golf. The event, with 18 teams in participation, was the biggest to date with Novus Sealing taking top honours being crowned the 2019 champions.

T

he SAIMechE Golf Day is an annual event on the SAIMechE calendar. Through the event, professionals in engineering are invited to participate with the intention to socialise and network amongst their peers. This provides a great platform for Mpumalanga’s great minds to share ideas on the current state of the industry and also conceptualise initiatives meant to uplift and drive engineering going forward. Apart from the golf day, SAIMechE also hosts monthly evening papers hosted by industry experts and community outreach programmes such as its World of Engineering Exhibitions.

Sponsorship

The Chairman of SAIMechE Mpumalanga Highveld Branch (MHB), Mishael Mashele said, “SAIMechE Golf 2019 day was a resounding success, thanks in part to the great number of sponsors. This year’s event also saw a record number of both sponsors and participants. PDPS represented by its director, Hannes Degenaar, MegChem represented by its Director, Andre Roos and PPS for Profes-

sionals and CCI Engineering & Projects represented by its director, Clifford Masus, each sponsored one of the four main holes and received Certificates of Sponsorships. The remaining holes were sponsored by Novus Sealing, Progo, SGB Cape, AZ-Armaturen and New Nation. At their information stalls the participants had the opportunity to learn more about the companies and the services they have to offer.”

Eighteen teams “On behalf of SAIMechE’s MHB committee, I would also like to thank all engineers who took time out of their busy schedules to honour the invite. A total of 18 teams from the afore-mentioned companies including Sasol, Eskom and SGB Cape braced the windy greens for top honours. Par-Tee-On from PDPS came in at 3rd place, The Wackos from SGB clinched 2nd position and Green Reapers from Novus Sealing took top honours claiming bragging rights as SAIMechE 2019 Golf Day Champions. Congratulations are definitely in order!”

Was a resounding success, thanks in part to the great number of sponsors. This year’s event also saw a record number of both sponsors and participants

12

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019


THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

13


SAIMechE

14

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019


THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

15


ALWAYS THERE, MAKING IT WORK. ��u �an trust BI t� �r����e the �ear�n�s an� ���er trans��ss��n s��ut��ns ��u nee� e�����ent�� an� ��st�e��e�t��e��. áƺȵƏȸɎȇƺȸɯǣɎǝɵȒɖƺɮƺȸɵɀɎƺȵȒǔɎǝƺɯƏɵِ Gear���es ��e� R�n�s Bushes ��ut�hes ��u���n�s �ha�n � ��r���ets Be�ts � �u��e�s A�r��u�tura� �r��u�ts

��e�tr�� M�t�rs �ar�a��e ��ee� �r��es �����s� �u�r��ants A�hes��es an� �ea�ants ���er an� �an� T���s ��eaners � �e�reasers Fasteners �a��es

ÁƺǼ‫׎׎׎׎חחז׏׏ואڷ‬ ǣȇǔȒ۬ƫƺƏȸǣȇǕɀِƬȒِɿƏ ɯɯɯِƫƺƏȸǣȇǕɀِƬȒِɿƏ

16

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019


SAIMechE

THE THESOUTH SOUTHAFRICAN AFRICANMECHANICAL MECHANICALENGINEER ENGINEER

VOL VOL69 69 Nov/Dec Nov/Dec 2019 2019

17 17


LUBRICATION

Bearings of Choice Custom-designed bearings offer greater protection against wear, tear and equipment failure

C

all it collaboration, partnership or customer service – when buyers, sellers and supply chains use the other’s expertise there is a better outcome. MechProTech, manufacturers of mineral processing equipment, are a good example. Using Vesconite bearings as their sacrificial bearing, their mills and scrubbers give customers a longer equipment life and lower the chance of total equipment failure.

The company has an innovative design approach to minerals processing “SA Mechanical Engineer” joined Vesconite’s Eddie Swanepoel on a visit to MechProTech for a closer look. MechProTech has been designing, testing and manufacturing mineral process equipment and solutions - anything that involves crushing, screening, grinding, classifying and liberating ores, for over 20 years.

Made in SA

“We’ve got good facilities (2 500m2), we do our own design, fabrication, assembly, commissioning and after sales service. Up to 85% of our product is made in SA. The only thing we don’t make are the gearboxes, motors and switchgear,” says Evan Bird, MechProTech MD. “Our job is to make the miner’s life easier. We ask - how can we improve existing operations. This can be very challenging in the traditional mining space as many mines use tech developed over 50 years ago.” There is often a reluctance to use something new. For any OEM, it means they have to prove their new designs and equipment works better than the existing solution.

Working better?

One reason is the use of Vesconite, which Evan says has operational and maintenance benefits.

18

THE SOUTH AFRICAN MECHANICAL ENGINEER

Processing run of mine (ROM) ore is a tough job and there will be wear on the component parts. “If you’re operating with time constraints, and in a remote area, this can be even more problematic. A solution is an extra layer of protection.” “We run Vesconite as a sacrificial bearing,” Evan adds. So if the equipment wears down, Vesconite acts as a barrier and there is no damage. “Our equipment runs on a hydrodynamic principle. As long as there is oil the bearing works, as soon as the oil film breaks down, there is contact with the steel journal, which causes damage. If the hydrodynamic equilibrium is not restored the bearing is compromised and we have to replace it,” Evan explains. “Vesconite is the sacrificial bearing interface between the journal and oil film.”

Time for maintenance

With Vesconite acting as the barrier, the equipment can continue operating for some time, giving the facility time for maintenance. Evan says that the mills and scrubbers operate

VOL 69 Nov/Dec 2019


Ready to fit is essential, because if possible, MechProTech transports their equipment as a single modular unit. “The mills and scrubbers are on a baseframe that encompasses the whole design. We pick it up, put it on a truck and move it to the client,” Evan says. The exception is particularly large units that need to be manufactured and moved in separate components.

For any OEM, it means they have to prove their new designs and equipment works better than the existing solution The net result is that when the equipment modules arrive on site they can be installed in a plug-andplay fashion and be operational within minimal installation time. Innovation is clearly a focus at MechProTech and Evan says that the company is designing more efficient bigger units that will process minerals more efficiently.

at 85% or more. “This is a big capital cost so we need to keep it going. When you stop going, costs are high. “With white metal bearings you need to scrap and recondition if the parts wear out, Vesconite is a lot more forgiving.” The cost impact is significant, and Evan notes that it lessens maintenance time as well. “The time to change a bearing on a big machine can be as short as six hours. “Vesconite has a high-load bearing strength, low friction and low wear,” Eddie points out. “And it does not require manual lubrication, even in harsh and dirty working environments.”

“We are pushing the boundaries. That’s what innovative technology does – it uses innovative designs to overcome shortcomings. In our game, failure is the opportunity to succeed,” he says. “We don’t see it as failure, we see it as R & D.”

Expertise

Using external expertise such as that on offer by Vesconite is one way MechProTech embraces innovation in its designs. “We had varying success developing our own bearings, so we went to Vesconite. They provide the bearings and tweak the design to meet our specifications and tolerances,” Evan remarks. MechProTech has had a long relationship with Vesconite. “They understand our financial ups and downs and what we need from a product.

Vesconite also retains its shape which is important in a design that requires flexible, malleable components.This makes it ideal for use in MechProTech’s designs.

“We know how important it is to work with supply chains and buyers who are looking to cut costs,” Eddie concludes. “Our product is suitable for a range of industries and we work with our buyers, tailor products and designs to make sure they get the best use out of our products.”

“The bearings come ready to fit and we have eliminated the quality issues so we give a better package to our clients,” Evan says.

Vesconite, Tel: (011) 616-1111, www.vesconite.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

19


BEARING FOCUS

An African Powerhouse BMG’s comprehensive range of bearings extends from precision miniature bearings used in machine tools and electronics applications, to giant size bearings that meet the demands of steel and mining industries.

T

he company - which has grown dramatically from a single bearings outlet, established in 1974 - now has 105 branches throughout Southern Africa and continues to expand on the continent. BMG has become Africa’s leading distributor of bearings, seals, power transmission components, drives and motors, as well as belting, hydraulics, pneumatics and filtration. The company also supplies valves, lubrication systems, instrumentation, fasteners and gaskets. An important area of growth for BMG, is in the tools and equipment sector.

Wayne Holton, BMG

“BMG’s specialist divisions have advanced technical skills to support the company’s commitment to applying technical knowledge and depth of experience to maximise the efficiency and profitability for every customer,” says Wayne Holton, Business Unit Manager, Bearings division, BMG. “The company has secured distribution and service agreements with some of the world’s most respected manufacturers of bearings, including NSK, NTN, Timken, IKO and Rollix. Our extensive bearings portfolio is carefully selected in terms of consistent quality controls, compatibility, standardisation, reliability and extended service life. “To enhance performance of bearings and for added protection, BMG has developed specialised sealing systems for bearing housings, to suit specific

Timken Blue Brute bearing housing unit

operating conditions. Added to this, associated bearing maintenance products include installation and removal tools, induction heaters, adaptor and withdrawal sleeves, as well as lubricants, lubricators and lubrication systems. “The company’s Technical Resources division is committed to enhancing process plant operating reliability in every industrial sector. Specialist services encompass technical applications consulting, product and system design, on-site process analysis, product quality control and assurance, as well as condition monitoring services.” On-site services, like product commissioning, conveyor belt splicing, product maintenance inspections and troubleshooting, are enhanced by large bearing and gear fitting. The BMG team is committed to working closely with customers in all industries to investigate the source of bearing problems and to provide cost-efficient solutions for optimum productivity of machinery, extended service life of the system and minimal maintenance requirements.

Linear motion systems

With the growing trend to move away from manual machine operation to specialised mechanisation as part of cost-saving programmes, BMG has made an investment in expanding its range to satisfy demand in economical and highly complex applications. The company’s IKO branded linear motion products have been carefully selected for excellent accuracy

BMG offers a complete bearing re-manufacturing and repair service

20 20

THE SOUTH SOUTH AFRICAN AFRICAN MECHANICAL MECHANICAL ENGINEER ENGINEER THE

VOL 69 69 Nov/Dec Nov/Dec 2019 2019 VOL


and smooth linear motion, easy integration, energy saving and environmental protection. BMG’s linear motion systems and associated products include linear guides, runner blocks, rails, ball screws, bushings and shafts, designed for high speed, high precision performance and to meet the rigorous requirements of technologically advanced engineering. This range is designed for use in diverse applications, including OEMs, the machine tool sector, automotive plants, design houses, packaging, beverage plants, robotics, brick and glass manufacturing, paper, pulp and wood industries, as well as for measuring systems. Key to precision instruments are linear guides, which are used in conjunction with compact ball screws that are locked onto a platform and linked to a servo motor, to produce linear motion. The primary function of the guides is to allow the platform to maintain high precision, high rigidity and high load motion. Standard components are suitable for machine tools, cranes and steel, as well as medical and laboratory systems, while specialised components are required for more demanding applications, like industrial robots, offshore rigs and aerospace.

Timken housed units

BMG’s portfolio of Timken housed units is designed for reliable sealing, ensuring enhanced bearing protection in harsh operating conditions, including debris-filled, contaminated or high moisture environments. The robust housed series includes plummer and solid block housing units. Timken uses the highest quality materials in the manufacture of these units, to meet the stringent requirements for cleanliness, machinability and performance required in demanding operating conditions. Timken Blue Brute, a spherical roller bearing with solid block housed units, is manufactured with cast steel housings that have three times the tensile

strength of cast iron housings. This is an important advantage in harsh applications where there are heavy loads and excessive vibration. These robust spherical roller housed units enable the bearing to be replaced into the same housing many times, which offers substantial cost savings.

Linear motion systems ball bushing flange unit

Without a properly aligned shaft, the service life of most housed units is reduced. However, this series is designed to run efficiently on misaligned shafts up to 1,5°. There are three standard sealing options available in the Timken Blue Brute range - teflon labyrinth seals, triple lip nitrile rubber seals and triple lip urethane seals. In steel, mining, pulp and paper, aggregate, cement and forestry, particulates are a challenge, hence the steel auxiliary covers are treated with black oxide for corrosion resistance and added protection against contamination.

Linear motion systems ball bushing block

Locating rings provide the flexibility to fix or float the roller bearings in the housing. Optional end caps, which are easy to install and remove, prevent damage to the bearing.

Re-manufacturing and repair

In partnership with Timken, BMG’s bearings division is able to offer a complete bearing re-manufacturing and repair service, where used bearings are reconditioned to original specifications for optimum performance and extended service life. This repair service includes a customised assessment, analysis, re-manufacturing and preventative maintenance programme for the bearings and auxiliary components used in all industries. The value of re-manufacturing is enormous in that it ensures substantial savings in downtime and reduced replacement costs. A reconditioned bearing can result in significant cost savings and time when compared with purchasing a new one. Efficient refurbishing options, using the most sophisticated processes and equipment, are offered for all brands, types and size of bearings. BMG works closely with a customer’s maintenance team to analyse the condition of bearings and to assess when a bearing needs to be serviced. When preventative maintenance programmes complement reconditioning, bearings are capable of reaching their fullest potential.

Linear motion systems Linear rail and block (slide units)

BMG Wayne Holton Tel: (011) 620 8428 Email: wayneh@bmgworld.net Web: www.bmgworld.net

THE SOUTH SOUTH AFRICAN AFRICAN MECHANICAL MECHANICAL ENGINEER ENGINEER THE

VOL 69 69 Nov/Dec Nov/Dec 2019 2019 VOL

21 21


MAINTENANCE

Simplifying Asset Management A new wireless vibration monitor uses embedded analytics to forecast when, how, and why assets may fail, freeing up resources while enhancing insight into operational performance.

T

he AMS Wireless vibration monitor is a low-cost, easy-to-deploy vibration sensor that performs prescriptive analytics on vibration data using native software to automatically identify failure modes and prevent potential problems involving rotating assets. The new compact device makes it economically feasible to fully monitor motors, pumps, fans and other critical plant equipment to reduce downtime and achieve more reliable operations.

Collecting data to create actionable information

Many organisations lack the analysis expertise to translate vibration data into asset health. The AMS monitor provides a solution by collecting and contextualising vibration data to generate actionable information. By applying Emerson’s patented PeakVue Plus technology, the device not only identifies when and how assets will fail, but also why. Technicians, regardless of expertise can quickly and clearly identify and prioritise common mechanical

Technicians, regardless of expertise can quickly and clearly identify and prioritise common mechanical issues such as bearing defects, gear wear, under-lubrication and pump cavitation, enabling them to focus more on operations-critical tasks

22

THE SOUTH AFRICAN MECHANICAL ENGINEER

issues such as bearing defects, gear wear, underlubrication and pump cavitation, enabling them to focus more on operations-critical tasks. “Thanks to the embedded prescriptive analytics, plant managers can add wireless vibration monitoring to their maintenance toolbox without having to train current staff to perform complex analysis,” says Robert Skeirik, director of machinery health solutions product management with Emerson’s Automation Solutions business. Users of Emerson’s Plantweb Optics asset performance platform can conveniently receive machinery health alerts anywhere with a mobile device. These alerts can also be aggregated with data and asset health information from other sensors and systems, allowing users to run analytics on all types of assets from a single application. This provides a more complete picture of the operation’s overall health while generating specific alerts when processes or performance are at risk. Plantweb Optics is part of Emerson’s Plantweb digital ecosystem, which leverages IIoT technologies, software, and services to expand digital intelligence throughout a workforce. Emerson Robert Skeirik www.emerson.com

VOL 69 Nov/Dec 2019


ROBOTICS

Clamping Down When people and machines stand shoulder to shoulder in production, safety at work is an important issue. A new clamp has been developed for energy chains and protective hoses on cobots.

velcro fasteners are flexible in shape and adapt to any robot arm. A slim design with rounded edges increases workplace safety by reducing the risk of injury when in contact with the robot.

obots continue to be a big trend in production and are used not only by major industrial players, but increasingly by small and medium-sized businesses. The automation of sub-processes ensures that companies can be competitive in the market. The collaborative robots work hand in hand with humans in close proximity. Sensors and cameras as well as an energy supply system ensure the safety of the process.

The lean robotics retaining fixture is attached directly on the robot in two steps, by simply placing the velcro around the robot arm and fixing it. “Thanks to the velcro fastener, the user has the opportunity to use the new retaining fixtures without any tools on any robot of their choice” explains Matthias Meyer, Head of Robotics Industry Management at igus. “Since we manufacture the clamps by injection moulding, they are very cost-effective.”

C

Quick to assemble and cost-effective

Free choice for safe cable guidance

The universal retaining fixtures with velcro fasteners are flexible in shape and adapt to any robot arm. Igus has developed the three-dimensional triflex R e-chain series to ensure that cables and hoses are reliably and compactly guided in cobots. For a secure attachment of the energy chain or the protective hose on robot, the user can now rely on the new lean robotics clamps. The universal retaining fixtures with

The new fixture will be available in three versions. The standard version has two continuously adjustable velcro straps in a universal size and a rubber lining inside. The second option is also available with a mounting bracket with and without strain relief. In a third option, the retaining fixture can also be equipped with a protector for additional security. Igus Email: ocyrus@igus.net Email: agoertz@igus.net www.igus.de

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

23


TRACE In is a glo antio leading party ri

TRACE due diligence solutions are based on internationally accepted best practices and our experience and familiarity with the compliance needs of multinational companies. Services range from a denied parties screening to enhanced due diligence, including TRACE Certified Due Diligence.

24

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019


nternational, Inc. obally recognized bribery business organization and provider of third isk management solutions.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

25


HYDRAULICS

Balls that Won’t Buckle under Pressure NSK ball screws from the advanced HTF (high tough) series are helping press brake manufacturers switch from conventional hydraulic drives, to electric drive systems, which offer a number of notable benefits

Electric alternatives becoming more popular

he ball screws have been delivered to NSK customer, Sangalli Servomotori. The customer is using the units in combination with its brushless servomotors to supply a complete system to a global manufacturer of press brakes.

Press brakes are a common type of machine tool found across industry, serving to bend sheet metal workpieces into pre-programmed shapes between top and bottom (punch and die) tool sets that close together. Traditionally, hydraulic drive systems have been used to create the required closing force but in recent years, an increasing number of press brake manufacturers have set about developing electric alternatives.

Electric press brakes are fast becoming the preferred option for fabrication shops that need to boost productivity, increase bending accuracy and safety, save money on energy bills, and improve their environmental credentials

Electric press brakes are fast becoming the preferred option for fabrication shops that need to boost productivity, increase bending accuracy and safety, save money on energy bills, and improve their environmental credentials, as the need for hydraulic oil usage and disposal is no longer nec-

T

26

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019


essary. Low noise and minimal maintenance are among further advantages. For many years Sangalli Servomotori has used NSK bearings in its motor production operations and, impressed with their performance and quality, made an enquiry about the ball screws in the linear product range. NSK’s team of experts assessed the application and recommended the company’s HTF series of high-load ball screws, which are ideal for the heavy loads and forces associated with press brake operations. The size of the balls and their special design configuration, along with the material used, are among the principal differentiators in favour of HTF ball screws.

demanding 60 tonnes of press force, an electric system featuring two HFT ball screws has also been developed.

The size of the balls and their special design configuration, along with the material used, are among the principal differentiators in favour of HTF ball screws In essence, the ball screw acts as a piston, and is controlled by the electric motor for high accuracy performance. As well as hydraulic machines, the system can be used to replace the connecting rod/ crank system found in press brakes with mechanical drives.

Under pressure A 63mm diameter HTF ball screw was selected to offer a press force of 20 tonnes. Together with a Sangalli servomotor, the ball screw formed the basis for a prototype that was successfully trialled on a customer press brake. In fact, for applications

NSK Govender Geraldene Tel: (011) 458-3600 Email: nsk-sa@nsk.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

27


“THE LINK FOR AFRICAN TRADING”

28

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019


TRANSNET FREIGHT RAIL

www.transnetfreightrail-tfr.net

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

29


POWER TRANSMISSION

Motor System Efficiency High on the Agenda With electric motors consuming almost 70% of industry’s energy, companies are always looking for better motor efficiencies. For many years, motor efficiency has been well defined, however, when driven by a variable speed drive (VSD), the VSD efficiency and the total efficiency of the VSD and the motor has not been well understood.

F

or many years, motor efficiency has been well defined. Choosing the right product combination can also be more difficult as manufacturers’ data is not always easily comparable. This is where the international IEC61800-9 standard comes to the rescue, according to global motor and VSD manufacturer, WEG.

The IEC61800-9 standard, based heavily on the previous EN 50598 standard, gives manufacturers a clear framework for grading a complete motor system irrespective of design and component selection Standards understood

The IEC61800-9 standard, based heavily on the previous EN 50598 standard, gives manufacturers a clear framework for grading a complete motor system. End-users can compare the overall efficiency

30

THE SOUTH AFRICAN MECHANICAL ENGINEER

of a manufacturer’s products, irrespective of design and component selection. The IEC61800-9 standard uses the extended product (EP) approach. This considers the efficiency of the motor system, which is comprised of the motor, the basic drive module (BDM) and the complete drive module (CDM). Together, these make up the power drives system (PDS), which also includes any switchgear and controls. This terminology sounds confusing but is just a technical way to say: Switchgear + VSD + Motor. The efficiency levels are defined by considering eight different operating points, covering low to high speed and torque. The user can easily compare a particular application load and speed requirements to the motor system defined speed and torque points.

Calculating efficiency

The EP approach employs a semi-analytical model to calculate the efficiency of each of the components at the operating points of the driven equipment. The calculations are also based on tested and verified values. This results in the most efficient component selection for the application. Using this standard, the user may be assured that a motor complies with the defined motor efficiency

VOL 69 Nov/Dec 2019


levels of IE1, IE2, IE3, IE4 or IE5, that a VSD complies with VSD efficiency IE0, IE1 or IE2 and that the manufacturer’s motor and VSD used in combination will meet or exceed a system energy standard of IES0, IES1 or IES2. Using this EP approach, the European Commission expects the increasing use of more efficient systems to help achieve its targets for carbon dioxide (CO2) reduction. In line with these efforts, WEG VSDs and IE2 motors in combination achieve IES2. Additionally, WEG’s VSDs and IE3 efficient motors exceed the highest system levels of efficiency and WEG has product lines that exceed even IE4 and IE5 classifications. Zest WEG Group Tel: (011) 723-6000 Email: info@zestweg.com www.zestweg.com

A WEG motor and drive combination

Power drives system torque, speed and efficiency

Extended product illustration showing the motor system, power drives system and complete drive module

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

31


POWER AND ELECTRICAL

Locking Onto Efficiencies Powermite recently expanded its Ampco product portfolio with the introduction of a range of plastic switched interlocked sockets which form part of a new series of plastic industrial plugs and connectors which are poised to raise efficiency, versatility and reliability.

T

he Gen 2 range is forged from Polyamide 6 and PC/ABS. The utilisation of these virgin grade plastic materials presents the range with several important advantages such as impact resistance combined with high robustness, high thermal stability (self-extinguishing), great

The utilisation of virgin grade plastic materials presents the range with several important advantages such as impact resistance combined with high robustness, high thermal stability

insulating qualities, high disruptive strength, UV resistance according to ISO 4892-2 as well as high abrasion and weather resistance. Furthermore, the material delivers exceptional resistance to a variety of chemicals and is free from cadmium and halogen.

At home on just about any plant

“Our new robust switched interlocked sockets are at home on virtually any plant or site where portable electrical equipment is used such as electric motor driven and heating machinery, welding, emergency generator supplies, IT installations, quarrying, mining, water purification as well as portable site and stage lighting,� confirms Donovan Marks, director at Powermite. The Gen 2 switched interlocked socket series, available from 16A to 125A, in 3 to 5 poles and comprises thirteen models. The range is available in IP44 splashproof and IP67 watertight rated versions as well as in nickel plated or brass with lam band contacts. In addition, the flanged version is ideally suited to distribution boxes and boards indoors and outdoors.

Connection ready

The compact and stable design of these switched interlocked sockets facilitates fitment even in confined spaces. Donovan explains that with all components mounted on the top or on the bottom, combined with a large connecting area and an enclosure built with shock-resistant thermoplastic material, these plug-and-play sockets are ready for wire connection. Powermite Donovan Marks Tel: (011) 271-0000 Email: donovan@powermite.co.za www.powermite.co.za

32

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019


MARKET FORUM

Rapid prototyping Johannesburg, South Africa, 6 August 2019 – RS Components (RS), is shipping the latest version of the MakerBot 3D which has been designed to bridge the gap between industrial and desktop 3D printing. The unit targets engineers and designers who use 3D modelling software and need to create product prototypes rapidly for a range of purposes, such as to accelerate product development or to ensure the viability of parts before moving to volume production.

heated chamber, which controls the heat of each layer and delivers a dimensional accuracy of ±0.2mm, as well as improved layer adhesion and greater part strength. The unit also has a structurally optimised ultra-rigid metal frame that runs the full length of the body, which leads to more consistent prints with better part accuracy and fewer failures, as well as offsetting flexing or warping of printed objects. The Method also comes with dual high-performance extruders, which offer lengthened thermal cores and optimised torque to maximise the material flow rate at high speeds. In addition, it has an industry-leading suite of sensors with a network of 21 intelligent devices embedded throughout to deliver enhanced control over the printing process.

A key feature of the MakerBot Method is its fast printing speed, which is up to two times faster than other popular desktop 3D printers, based on a range of tests using the same layer height and in-fill density settings. Use of the printer can save days or potentially weeks compared with the time taken to outsource prototyping via other additive manufacturing methods or CNC machining, for example. Another major advantage is the unit’s industrial reliability and precision: for example, the Method has a circulating

RS Components Tel: (011) 691-9300 Email: sakes.za@rs-components.com

SKF Multilog On-line System IMx-8

More data capture opportunities. Even in a limited space. Configure your IMx-8 and monitor your data wirelessly from your iOS or Android device. The IMx-8 can be fully configured via luetooth, and can use existing template configurations stored in the SKF Cloud. Machine data can then be viewed on your iOS or Android device. And with direct access to world-class software, analytics and support through SKF @ptitude or SKF Enlight, it’s the cost-effective route to high performance.

SKF South Africa (Pty) Limited Tel: +27 11 821 3591, Fax: +27 86 677 7876 Email: sales.za@skf.com, Web: www.skf.co.za ® SKF is a registered trademark of the SKF Group. | © SKF Group 2018

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

33


MARKET FORUM

Fully retractable frontage Barloworld Equipment has officially unveiled its unique new head office and Caterpillar Earthmoving Equipment showroom in Isando. The new development for the company consists of a head office and a world class showroom, housed in a series of elegant curved forms. The new campus, developed in conjunction with Eris Property Group, is currently under construction, with the showroom already completed and the head office opened in November this year. The most immediately noticeable feature of the new showroom structure, is its elongated front-facing bubble profile, inspired by the curved shape of the Caterpillar excavator tread, and which allows this huge machinery to be comfortably exhibited in the voluminous interior space.

Of course, this begs the question of how such huge apparatus can easily enter or be extracted from this space. Which is why the building can claim a never-been-done-before international breakthrough; with a staggering 8.8m x 5.5m piece of the prominent glass frontage being fully retractable, via intricate motor-driven automation. All the essentials are in place for a 3-Star Green-Star rating, including roofs that are purposefully strengthened to carry a variety of photovoltaic panelling, as well as water consumption and waste management systems. Barloworld Equipment Tel: (011) 929-0000 www.barloworld-equipment.com

RELIABLE ENERGY SOLUTIONS for the entire mining sector.

Renewable Energy: Wind & Solar Electrical Construction Standby/Emergency Generator Sets

LV Motors, Drives, Softstarters & Switchgear

Electrical Infrastructure Solutions

Motor Scan Power & Distribution Transformers

Invicta Vibrator Motors

Power Generation Solutions

Overhead Lines

MV Drives, Softstarters and Switchgear

Automation Control Room

Mobile Substations MV Slipring Motors Motor Control Centres, Panels & Distribution Boards Mini Substations

Zest WEG Group is able to offer a range of standard off-the-shelf products as well as end-to-end energy solutions by leveraging best practice engineering and manufacturing capabilities.

E-Houses and Containerised Substations

All products are engineered to facilitate a safe and reliable mine and plant with operational stability and the highest possible production levels as an objective. Reduced maintenance and ease of serviceability assist in lowering the total cost of ownership for the mine.

1 34ZWG_mining_130mmx180mm.indd THE SOUTH AFRICAN MECHANICAL ENGINEER

Tel: 0861 009378

VOL 69 Nov/Dec 2019

www.zestweg.com

2018/11/20 04:46


MARKET FORUM

Powering the world’s largest tidal turbine SKF has developed a power train for the world’s most powerful tidal turbine, capable of generating 2MW, being developed by Scotland-based Orbital Marine Power. SKF has been supplying bearings and components to Orbital since 2011 but has now taken a further holistic step in its technical capacity, by developing the full power train system. The Orbital is made up of a 73 metre long floating superstructure that will support two 1MW turbines at each end. With rotor diameters of 20m, it will have a total rotor area of 600m2, the largest ever on a single tidal turbine

to date and will be capable of powering more than 1 700 homes per year. The turbine will feature 360° blade pitching, which will allow the safe, dynamic control of its rotors and will enable power to be captured from both tidal directions, eliminating the need to rotate the entire platform. These controllers will also support the installation of even larger blades on the turbine in future. SKF, Tel: (011) 821-3500, www.skf.com

Trommel screen With large volume capabilities and a robust and simple structure, the Sag mill trommel is considered a viable alternative to vibrating screens in SAG mill scalping applications. Many designers and mill operators believe that the benefits of simplicity and the ability to handle throughputs in excess of 3 500 tons per hour of solids make trommels the preferred equipment for this application. “A key component ensuring optimal performance of SAG mill trommels is the screen panel, which enables this equipment to classify large volumes of mill product,” says Francois Fouche, senior screening specialist at Multotec. The company has developed a special range of rubber compounds that are used to manufacture the compression moulded rubber screen panels which are considered the highest wearing items in the trommel. “We have achieved excellent results from our compression moulded screen panels with wear life extending over six months in 4 500 tons per hour SAG mill applications,” Francois concludes. Multotec Tel: (011) 923-6000 Email: Marketing@multotec.com www.multotec.com Multotec has the process capacity to size SAG mill trommel screens with diameters up to 5.5 metres.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

35


MARKET FORUM

Industrial sectors Industri Tools & Equipment was launched in September as part of the Engineering Solutions Group (ESG) of Invicta Holdings Limited, to supply and support all industrial sectors in Southern Africa. Through the consolidation of six independent tooling companies, Man-Dirk, Tool Quip & Allied, SA Tool, Sibuyile Industrial Supplies, Gem Tool and F&H Machine Tools, Industri Tools & Equipment is well positioned to improve efficiencies and enhance productivity for a broad customer base. “The local market will benefit from a unified tools and equipment busiFrom left: Christo Badenhorst, Sales Manager, Pat Kearns, Product Manager, Kriban ness, which offers a comprehensive Govender, Managing Director, Sbu Qholosha, Operations Manager and Annel Hertog, Chief range of quality branded products, Financial Officer through the streamlined procurement of effective tools, via a broader distribution network. means increased value for customers.. This range extends from hand tools for the DIY handyman, INDUSTRI Tools & Equipment has a prominent online presto large-scale supply projects into mining, power generation ence, with an interactive website (www.industri.co.za) that and industrial sectors,” explains Kriban Govender, Managing provides relevant product and company information. The Director, Industri Tools & Equipment. company’s ambition is to launch an online ecommerce portal “What’s critical for customers, is dependable support from a within 12 months. highly-experienced team with combined technical skills and expertise. We have greater buying power for reduced costs INDUSTRI Tools & Equipment, Kriban Govender and this, coupled with the fast and effective supply chain, Tel: (011) 386-5801, Web: www.industri.co.za

36

THE SOUTH AFRICAN MECHANICAL ENGINEER BMG-COR18102019 - SAME

VOL 69 Nov/Dec 2019


MARKET FORUM

Highly affordable bearings A leading European supplier of high-quality, low-cost bearings for a range of industrial, agricultural, and automotive aftermarket applications is the latest international brand to be added to the product stable of Bearings International (BI), part of the Hudaco Group. With the local market increasingly price-sensitive as it strives to cut costs due to the prevailing economic conditions, BI decided to assist its customers by offering another brand at the lower end of the price spectrum. “It is often the case that premium brands do not have to be used in all applications. Craft bearings give end users the assurance of quality, tested bearings that are also highly affordable,” BI Business Unit Head Ross Trevelyan comments. BI Offer Marketing Manager Victor Strobel reveals that the new range will be introduced in a phased approach. Ball bearing units, the largest-volume sellers, will be introduced initially, and tapered roller bearings, cylinder roller bearings, and deep groove roller bearings at a later stage. The first consignment of stock is due from the European manufacturer in January 2020. CRAFT bearings is the only manufacturer at the lower end

of the price market that boasts a state-of-theart laboratory where product batches are tested in accordance with an acceptable quality limit. BI has been granted exclusive rights for South Africa, Swaziland, Lesotho, Namibia, Botswana, Mozambique, Zimbabwe, Zambia, and Malawi. “We anticipate significant sales volume growth from the South African market in particular,” Martynas Ruibys, Head of Business Development for Africa & Middle East at CRAFT bearings concludes. “This is mainly because our brand will be ably supported by BI’s extensive distribution network and value-add it is able to offer customers in the form of customer service and technical back-up. Our initial focus will be followed up by a concerted push into Africa, which is a region that we have not really focused on to date, and which represents major synergies for both CRAFT bearings and BI as we pursue growth opportunities here,” Ruibys concludes. BI Tel: (011) 899-0000 Email: info@bearings.co.za Web: www.bearings.co.za

Well-deserved Award Petrochemical giant Sasol has recognised Actom Turbo Machines with one of its top 2019 awards for exceptional service in repair, refurbishment and ongoing maintenance. The award in the ‘Top Performing Service Supplier’ : Large Enterprises category was recently made by Grace Nndwammbi, Sasol’s senior vice-president supply chain to Actom Turbo Machines’ managing director Chris Bezuidenhout at Sasol’s head office in Sandton. A division of Actom (Pty) Ltd, Actom Turbo Machines is the only large non-OEM business in its service category to win the award to date. Since its inception six years ago, it has become the largest non-OEM turbo-machinery and high-speed rotating equipment service provider in sub-Saharan Africa. Sasol is very OEM-reliant in terms of service backup and parts supply, according to Anton Hamman, Sasol’s principal specialist sourcing mechanical equipment. Nonetheless, ACTOM Turbo Machines has proved itself in service provision for turbo machines, where critical and complex skills are required. “We view turbo machines as the heart of our operations, so it is absolutely essential that the service provider has all the critical skills needed to ensure that the equipment is maintained to OEM specification,” Anton says. “If you use a non-OEM company for this work, you must be certain they have the required skills and competencies to perform this work to the correct standard every time and understand the associated risks.” Marthinusen & Coutts (Pty) Ltd Tel: (011) 607-1700 Email:support@mandc.co.za www.mandc.co.za

Anton Hamman (second from left), Sasol’s principal specialist sourcing of mechanical equipment, congratulates Chris Bezuidenhout, managing director of ACTOM Turbo Machines, on receiving the prestigious Sasol award. From left are: Leon Greeff, Sasol’s senior manager, oxygen electrical & instrumentation; Mervyn Naidoo, ACTOM’s Group CEO, and Nicholas Mokgosi, Sasol’s senior manager E,C & I sourcing, category management.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 69 Nov/Dec 2019

37


On the Move

MARKET FORUM

Rudi Rudolph

Kathy Shepherd

Leading supplier Bearings International (BI) has appointed Rudi Rudolph as Segment Leader – Manufacturing.

Leading supplier Bearings International (BI) has appointed Kathy Shepherd as Business Development Leader (BDL) – Wholesale and Retail.

John Tarboton John Tarboton has been appointed the Executive Director of the Southern African Institute of Welding.

Promech Publishing

wishes all its readers a good break over the holidays

Nylon ball and check valves Nylon ball and check valves designed and developed for irrigation and agricultural applications have been introduced by Incledon, a leading provider of quality fluid conveyance products and solutions. Featuring a nylon body with a steel ball and stem, Tekflo nylon ball valves are particularly suited for such arduous applications in that they are resistant to hydrocarbons and various harsh chemicals. The valves have a nominal pressure of 1.6 MPa, with a working temperature of –20°C to 120°C, and are available in sizes from 15mm to 50mm. Additional features include a low thermal conductivity, a higher corrosion resistance than traditional metal, a light weight for

38

THE SOUTH AFRICAN MECHANICAL ENGINEER

easy installation, high resistance to freezing and high temperatures, a high UV resistance, a low material cost compared with brass, and a BSP thread. With similar features and applications, Tekflo nylon check valves boast a nylon body, a polycarbonate disc, a SS304 spring, a BSP thread, and a working temperature range of –20°C to 120°C. Suitable for use where water is a medium, the valves are designed to handle a nominal pressure of 1.6 MPa. Incledon Charmaine Munian Tel: (011) 323-0800 Email: charmaine.munian@incledon.co.za Web: www.incledon.co.za

VOL 69 Nov/Dec 2019


dŚĞƐƐŽĐŝĂƟŽŶŽĨ ^ŽƵƚŚĨƌŝĐĂŶ YƵĂŶƟƚLJ^ƵƌǀĞLJŽƌƐ

QuanƟty Surveying… …at the heart of every successful construcƟon project

Find out more… info@asaqs.co.za

www.asaqs.co.za

T 011 315 4140/1 F 011 315 3785 P O Box 3527 Halfway House 1685 I Suite G6 • Building 27 • Thornhill Offi ce Park • Bekker Road Vorna Valley THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 69 Nov/Dec 2019 • Midrand 39


Who is Actually Managing your boiler right now?

How about a Boiler Expert takes care of it for you? How about a Company with a 30 Year Track record? How about the only Company that saves its Clients 8-12% off their Fuel Bills over their Competitors! Combustion Technology is your answer.

Introducing a 24/7 Boiler house Management by The Experts in Boilers and Combustion Systems for a very low cost!

How does it work? By Installing an Autoflame DTI, we are able to log on to any site equipped and see the boiler running in real time. Up to 10 boilers can be connected per site.

Contact us today to receive a presentation overview of the Combustion Technology Boiler Management system directly to your INBOX! info@combustiontechnology.co.za

Hands on Boiler Operation & Maintenance Training

Combustion Technology has developed training for

Duration - 3 days (9.30am – 4.30pm) Price – R19,000 + VAT per delegate

boiler operators, maintenance staff, plant technicians and engineers. This is an intensive course designed to provide a thorough grounding in the everyday operation and maintenance of boilers, burners and boiler auxiliary equipment. Additionally, we will cover burner combustion principles, fuel-air control and maintaining load demand efficiently. The course will also cover all relevant Health & Safety issues, fault identification and emergency situations. The ultimate aim of the course is to make sure that the plant can be operated safely, efficiently and economically.

MODULES Boiler in construction in respect of safety in operation n Boiler mountings n Water level control systems n Automatic TDS control systems n Thermal energy n Combustion n Combustion check lists n

n

Combustion practice and efficiency

n

n n

Fuel-air ratio control

Maintaining load demand n

n

Essential routines

Actions in emergencies

n

Operational efficiency

Remote boiler monitoring

Tel: +27 21 715 3171 Email: info@combustiontechnology.co.za

Profile for Promech Publishing

SA Mechanical Engineer  

SA Mechanical Engineer  

Profile for promech