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S MECHANICAL A ENGINEER Apr 2015

Publication of the South African Institution of Mechanical Engineering, incorporating News of Associate Organisations

M&V REPORTING ACCURACY YOUNG WELDER OF THE ENGINEER YEAR VOL 65 THE SOUTH AFRICAN MECHANICAL

April 2015

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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 65

April 2015


AN ENGINEER’S VIEW

Innovation and Action I believe that the real crisis in our base load system has not yet been reached, and the inevitable worst case scenario is to come if the period over the next 10 years is analysed. If we make an assumption (as naïve as this may be) that the economy grows over the next 10 years at an average of 3% per annum, then the demand on the installed base load system will grow by 34% by 2025. If the effective available base load now is 40GW, we will need to add some 14GW capacity but that is only on the assumption that the existing fleet of units does not suffer incremental attrition through ageing and hard running that stresses the system over its design limits.

B

ut let’s look at the equations on the assumption that in this period Medupi and Kusile actually come Chairman of the Working Committee: Communications on line and add 9,6 GW, and the (SA Institution of Mechanical oldest of the 6-pack units now running Engineering) meets the end of its useful life. The net gain would be say 2,5GW capacity. The chances are, over the next 10 years, that more attrition is likely.

Chris Reay

In the event that say 12GW of new base load capacity is needed, this is equivalent to 2,5 new Medupis or 6 Koebergs. We know that SA cannot build Medupis very well – so far double the initial cost and 4 years late with just the first unit. So don’t let’s kid ourselves that we will just hurry up building some new six-pack fossil stations, and the likelihood of 6 Koebergs or the equivalent in nuclear would take a minimum of 12 years for the first unit to be ready.

If any funding for another fossil station is ever available, rather re-direct it to providing solar water heating and PV panels for every home in SA National bankruptcy

Add to this the dismal record of state planning and financial control, and we can envisage the scale of the challenge ahead. It simply is not possible to quickly correct 20 years of perpetual inert policy and insufficient action. A necessary condition would be the affordability given that SA is currently near junk investment status. With the commodities market in decline and on which SA has historically depended via foreign investment in mining, we have to realise that unless we jack up manufacturing and are competitive in world trading, we are heading for what could be national bankruptcy.

tories with the best technologies that can take all low-order water heating, ie, hot water geysers out of the base load system. Enable the PV panels to work both on-line back-feed to the grid and for charging of the batteries in a one-stop package with inverters, switching etc. Train up Engineer and Technician teams to be able to install, commission and maintain the complete system. Do it all on a massive scale with private sector skills and sufficient competitive organisations as was done with the wind and solar projects. The technology must have SABS certification to avoid the bandits in it for a quick kill. This will require constructing an attractive long term cost to the user with the capital cost being tied to the asset value of the home via a structured debt note that stays with the home or building. One can argue that this process of using renewables is happening, but the scale and focus is minimal.

Playing the blame game

Who then knows when and if electric car fever will hit SA? Could we take a leaf out of Elon Musk’s USA initiatives – SolarCity and Tesla, and if possible, license their technology? Tesla has, and is developing, a battery based on their current market leading Lithium-ion pack design for the Tesla, to be provided to homes together with the solar energy systems, and where their car batteries, once they lose their initial high energy density performance, can be used for home use. So material sustainability is also achieved. If a smart South African can go to the USA, invent and build SpaceX, Tesla and SolarCity, then come on guys, what are we doing about solving our challenges? And ours are not even rocket science which SpaceX certainly is. We tend to spend too much time looking for reasons that ideas won’t work and playing the blame game. Can we boere maak a plan?

The current climate makes us more risk averse than ever. How innovative can we be? Some ideas. If any funding for another fossil station is ever available, rather re-direct it to providing solar water heating and PV panels for every home in SA. Invest in the best PV panel, solar water unit, battery and grid inter-connect device facTHE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 65

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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April 2015


S MECHANICAL A ENGINEER On the Cover

April 2015  VOLUME 65  NUMBER 4

Regal-Beloit South Africa Tel: (011) 453-1930 www.regalbeloit.co.za

Contents Cover Story 8 New Products for a New Year

22 Commercial Heat Pumps: A Retrospective M&V Case Study

10 Letter to the Editor

POWER GENERATION TODAY

Careers 11 Prominent Professionals:

Thys Horn

Solar Power 12 UKZN’s Solar Car

Materials 13 Cutting Edge Services

Business 15 Sustainable Employment in Madagascar

Exhibition 17 Platform for Frank Debate

Pipes, Pumps & Valves 19 Special Protection Against Slurries

25 Pitch Control on Turbines 27 Power Generation News

Oils & Lubrication 29 The Right Stuff 33 Responsible Management of Used Oil

Food & Beverage 39 Competition Challenge

Awards 41 Young Welder of the Year 2015

Regulars 3 An Engineer’s View 6 Institution News 37 SAIT 42 Market Forum

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.

The monthly circulation is 3 947 Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, Official Publication of 2123, Republic of South Africa THE SA INSTITUTION OF MECHANICAL ENGINEERING Tel: (011) 781-1401, Fax: (011) 781-1403 and endorsed by: Email: samecheng@promech.co.za, www.promech.co.za  CORROSION INSTITUTE OF SA Managing Editor Susan Custers Editorial Contributors  SA PUMP SYSTEMS DEVELOPMENT ASSOCIATION (SAPSDA) Advertising Colleen Cleary Liesl Venter and Andrea Müller  SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION Circulation Catherine Macdiva  THE SA INSTITUTE OF TRIBOLOGY DTP Zinobia Docrat / Jacqueline Nene  NUCLEAR INSTITUTE Subscriptions Please email us at accounts@promech.co.za  SA INSTITUTE FOR NON-DESTRUCTIVE TESTING if you wish to subscribe to “SA Mechanical Engineer” at R510,00 (excl  NATIONAL SOCIETY OF BLACK ENGINEERS postage and VAT) per year; R1 280,00 per year for Africa/Overseas.  INSTITUTE FOR CERTIFICATED MECHANICAL AND Disclaimer ELECTRICAL ENGINEERS PROMECH Publishing and The South African Institution of Mechanical Engineering  SOUTH AFRICAN ASSOCIATION OF CONSULTING ENGINEERS as well as any other body do not take responsibility for the opinions expressed  THE SOUTHERN AFRICAN ASSOCIATION FOR ENERGY by individuals. EFFICIENCY (SAEE) Printed by: Typo Colour Printing, Tel: (011) 402-3468/9  THE SA CAPITAL EQUIPMENT EXPORT COUNCIL FSC (Forestry Stewardship Accreditation)

THE SOUTH AFRICAN MECHANICAL ENGINEER

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SA INSTITUTION OF MECHANICAL ENGINEERING

Council 2014 - 2016

Company Affiliates

Office Bearers President .................................... KK Nyangoni (Kudzai) Vice President ........................................ E Zawilska (Ewa) National Treasurer ..................,................. A Roos (Andre)

Branch Chairpersons Central .......................................... S Murefu (Stephen) Eastern Cape ............................................ W Rall (William) KwaZulu/Natal .................................... R Walker (Raymond) Mpumalanga Highveld.......................... L Odendaal (Louis) Vaal......................................................C Mphephu (Cillia) Western Cape .................................... S Pietrangeli (Sven)

Ainsworth Engineering

Mod-U-Flow

Alstom Power Service SA

Osborn Engineered

Babcock Ntuthuko Engineering

PPS Insurance Co Limited Rotek Engineering

Bosch Projects

S.A.M.E Water

DCD Rolling Stock A division of DCD

Sasol Technologies

ELCIME Engineering

SEW Eurodrive

Festo (Pty) Ltd Group

Siemens Ltd

Fluor SA

Portfolios: Communications/Strategic Planning/ Specialist Group.....................................CD Reay (Chris) Company Affiliates......................................R Mills (Bob) To be confirmed....................Prof JL van Niekerk (Wikus) Professional Development Programme............................ M Black (Malcolm) Technology Programme .................. SZ Hrabar (Steve)

Chief Executive Officer: Vaughan Rimbault

Spicer Axle SA

GEA Air-cooled Systems Hansen Transmissions SA Hatch Goba

Tenova Takraf Africa

Howden Power

Thyssenkrupp Engineering

Howden Projects

Ultra-Flow Engineering Services

Industrial Water Cooling

National Office Manager: Anisa Nanabhay PO Box 511, Bruma, 2026 Tel: (011) 615-5660 Fax: (011) 388-5356 Email: info@saimeche.org.za Website: www.saimeche.org.za Membership Email: membership@saimeche.org.za

Tenova Mining and Minerals SA

Vital Engineering

MBE Minerals (SA) (previously

Wedag SA (Pty)

KHD Humboldt Wedag SA)

Weir Minerals Africa

Megchem

Winder Controls

Forthcoming SAIMechE Training Workshops Programmes and Registration Forms obtainable from Carey Evans, Tel. 031 764 7136 or Email: carey@saimeche.org.za In-house bookings and enquiries for our many available workshops: Linda Robinson, Tel. 031 764 7136 or Email: linda@saimeche.org.za Event Code

Event Title

D6015

Start Date

End Date

Region

Booking Closure Date

Finding Inventive Solutions to Engineering & 05-May-15 Technical Challenging Problems

06-May-15

Vaal

24-Apr-15

F7715

Value Engineering in Projects

12-May-15

14-May-15

Mpumalanga

30-Apr-15

A9015

Pump Design, Operation, Maintenance & Trou12-May-15 bleshooting

14-May-15

Durban

30-Apr-15

D2815

Running Effective Meetings

13-May-15

13-May-15

Vaal

01-May-15

C6015

Finding Inventive Solutions to Engineering & 19-May-15 Technical Challenging Problems

20-May-15

Cape Town

08-May-15

B9314

Coaching Skills for Managers in Engineering

20-May-15

20-May-15

Port Elizabeth

08-May-15

B7715

Value Engineering in Projects

26-May-15

28-May-15

Port Elizabeth

15-May-15

A9315

Coaching Skills for Managers in Engineering

27-May-15

27-May-15

Durban

15-May-14

F6015

Finding Inventive Solutions to Engineering & 2 Jun 15 Technical Challenging Problems

3 Jun 15

Mpumalanga

22-May-15

D7715

Value Engineering In Projects

2 Jun 15

4 Jun 15

Vaal

22-May-15

C9315

Coaching Skills for Managers in Engineering

3 Jun 15

3 Jun 15

Cape Town

22-May-15

D2915

Lubrication & Lubricants

17 Jun 15

17 Jun 15

Vaal

5-Jun-15

D6915

Lubricants and Oil Monitoring

18 Jun 15

18 Jun 15

Vaal

5-Jun-15

H0815

How Technology Evolution Enables Inventive 23 Jun 15 Engineering Designs

24 Jun 15

Rivonia

12-Jun-15

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April 2015


SA INSTITUTION OF MECHANICAL ENGINEERING

From SAIMechE: Joyce Naude, Carel Kruger, Graeme Lloyd, Lynne Smedley-Williams, Anisa Nanabhay, Stephen Murefu, Brian Mtwa and Eli Levy

Central Branch Technical Presentation & Dinner

Michael Young of Emerson addressed the SAIMechE Central Branch Technical Dinner on the company’s SmartAisle datacentre efficiency management platform. The dinner was hosted at the offices of the Engineering Council of South Africa (ECSA) in Johannesburg on 25 February 2015. The efficiency management platform is based on the principle of separating cold and warm zones in datacentres, and incorporates special cooling capacity and airflow management, raised-floor sealing, cable entry sealing and cabinet sealing with blanking panels. Carel Kruger (Central Branch), Michael Young (Emerson) and Stephen Murefu (Central Branch)

IT PAYS TO KEEP THE RIGHT COMPANY Find out if you qualify to #JOINOURTABLE at www.pps.co.za

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COVER STORY

New Products for a New Year With prolonged strikes across several industries taking its toll on equipment suppliers in 2014, this year is looking a lot better. “SA Mechanical Engineer” speaks to Hilton Fortmann, sales and marketing director for Regal Beloit South Africa. market – for the first time. The Regal Marathon electrical motors comply with International Electrotechnical Commission (IEC) standards.”

Hilton Fortmann, Sales and Marketing Director for Regal Beloit South Africa

S

tarting 2015 with a bang, this electrical and mechanical motion-control and powergeneration products manufacturer is introducing a new range of products into the South African market.

With electrical motors responsible for over 65% of the country’s power consumption, the case for energy efficient product is a no-brainer “The renowned PPA motor has been enhanced to meet and exceed IE3 efficiency standards,” says Hilton. This Regal Marathon IE3 range is still the highest specification motor available as standard off-the-shelf and we are very excited to introduce these motors into the South African – and African

In the European Union, as per the Erp Directive 2009/125/EC, IE 3 motors (power outputs 7.5kW - 375kW) became mandatory for installation on direct-on-line applications from January 2015. This will, however, not be the case locally. “In Europe and America, IE 4 and 5 technology is already in development,” adds Hilton. The motor is equipped with vacuum pressure impregnation, windings and regreasable bearings. It’s suitable for variable-voltage variable frequency drives while it also functions with reduced noise levels. Suitable across several sectors including engineering, mining and the general industrial environment as well as various areas of manufacturing, the new products will add significant benefit to end-users over and above the obvious cost savings. With electrical motors responsible for over 65% of the country’s power consumption, the case for energy efficient product is a no-brainer. “Power availability and cost is a concern and therefore we believe this range of products is going to be a game-changer for many users,” Hilton asserts.

Understanding benefit

“Nobody has to be told about the cost of electricity or the significant consumption of electrical motors, so the first question from a customer is about reducing power usage which has a very real affect on the customer’s bottom-line.”

While the motors will require an increased capital outlay equal to or slightly higher than the current IE2 PPA range, the long-term power savings are substantial. Regal’s new IE3 Marathon motors are designed to ensure improved efficiency all round, resulting in lower operating costs. Hilton adds, “They are also of the highest electrical specification quality available with a proven design and will therefore suit the harsh conditions of Africa superbly.”

A vast range of electric motors are available from Regal Beloit facilities country wide

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COVER STORY

The company holds a vast amount of stock to ensure downtime of clients is kept to a minimum

Regal Beloit, one of the largest manufacturing facilities in the world, headquartered in Beloit, Wisconsin, USA, with 27 000 employees worldwide and over 69 manufacturing facilities globally, is expanding its footprint on the African continent. “Our current stock value at cost is over R70 million at any given time to ensure we are able to service customers at a moment’s notice.” And with names such as Sasol, Exxaro and Xstrata on their books, ensuring downtime is kept to a minimum is a key priority.

Repair of premium products

“Our aim is not just to give the local market a product that is energy efficient and green, but one that will benefit them where it matters. It will save costs over time.”

They are also of the highest electrical specification quality available and will therefore suit the harsh conditions of Africa superbly

Bold steps forward

Integrity

Despite the first two quarters of 2014 impacting severely on equipment suppliers thanks to the mining and then metal industry strikes, Hilton asserts that the corner was being turned already in the third quarter of 2014 as sales began to pick up. “And it’s not just about supplying a motor, it’s about implementing a solution. These products have been tested for durability and are manufactured from high quality materials. The integrity of the product has to stand the test of time.” Training is vital too. “We have introductory and advanced electric motor maintenance courses as well as installation courses on offer locally, and can offer on-site training in South Africa or elsewhere on the continent. This aspect plays an important role as it is necessary to move away from systems where motors are installed without much thought.”

How a premium efficiency motor is repaired and maintained, is an integral aspect of maintaining the high levels of efficiency and reducing MTBF (Mean Time Between Failures). Regal have invested in upgrading its Middelburg repair facility to cater for the total solutions selling philosophy and total cost of saving initiatives, backed by approved high-end repairs to maintain the integrity of their premium products.

“The integrity of a product is intricately linked to where it is installed, what and how it is being used, maintained, how it is repaired. It’s crucial to ensure the right motors are being used for the right applications.” Hilton tells us that their efforts are being met with increased market enthusiasm. “There is a big move afoot towards running plants as efficiently and cost-effectively as possible and with that comes a demand for more efficient motors. In Africa especially, there is a distinct need for more than just a product. It has to have integrity, there has to be back up, it has to be efficient and save on costs – our new Regal Marathon IE3 range delivers on all fronts,” Hilton concludes. Regal Beloit South Africa, Hilton Fortmann Tel: (011) 453-1930, www.regalbeloit.co.za Email: hilton.fortmann@regalbeloit.com

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LETTER TO THE EDITOR

Responsibilities Dear Madam

17 March 2015

I

received a few days ago my copy of the September 2014 issue of the "SA Mechanical Engineer." This late delivery can be attributed to the latest Post Office strike, nevertheless, I enjoy reading this publication even if it is “old news”. I agree with Chris Reay’s article on “Stop Producing Engineers…….” but, we who are active in our profession are not entirely innocent in the dilemma of involving the wrong/unqualified persons in engineering activities. There are very valid reasons why we have different gradings and responsibilities for Pr. Eng, Pr. Eng Tech, Pr. Tech, GCC, etc. We all too conveniently abuse these responsibilities with the result that the Pr. Eng Tech is assigned tasks which a Pr. Eng should take responsibility for and Pr. Tech’s conduct Pr. Eng Tech’s work, and so forth. Not to mention the GCC’s responsibilities which are abused and neglected by many organisations.

THEGRASSOV-SERIESCOMPRESSORS Reduced Total Cost of Ownership •

Reduced power consumption due to improved COP

Increased service intervals

Minimum maintenance costs due to onboard Grasso Maintenance Monitor

Extremely low oil carry over

Improved cost per kW ratio

Simple installation of packages, no water cooling required

Maximum Reliability & Ease of Maintenance •

Proven composite material valves for increased maximum operating hours

O-ring seals, no scraping or polishing required

50% less fixing bolts all over compressor housing

Supplied standard with heavy duty thrust bearing

Continuous monitoring of discharge temperature per cylinder via Thermo Master option

How often do we hear that an artisan is an engineer and I am not degrading the important work these people must do. We also hear of engineers being produced by colleges and universities of technology. I am of the opinion we are degrading the potential engineers being produced by universities (UP, Stellenbosch, Wits, UCT, etc) You may now ask what is my real issue? You placed an article of a Prominent Professional, Maxwell Nemutshili, Manager Mechanical Engineering, Exxaro. I believe Maxwell is an excellent manager and that he is doing a good job under the circumstances. I admittedly do not have all the information of his appointment to this position but a Mechanical Engineering Manager must be a Mechanical Engineer, and preferably professionally registered which according to the ECSA website, he is not. I assume that there are professional engineers, aspiring professional engineers, professional engineering technologists, engineers/technologists/ technicians-in-training, technicians and artisans in this Mechanical Engineering division of Exxaro all reporting to Maxwell. I can imagine the mammoth task Maxwell must have trying to lead this division/ department without the required formal academic and practical training as a Mechanical Engineer. I am not directing this matter at Maxwell because he was placed in this situation by a higher authority. My issue is the guidance and leadership young engineers, technologists and technicians require to become well qualified and experienced professionals who can register with ECSA. This is what our profession requires, well trained technical persons at all levels who we can be proud of and take our profession forward as aptly mentioned by Chris.

GEA Refrigeration Africa (Pty) Ltd

19 Chain Avenue, Montague Gardens, 7441, RSA P.O.Box 36815, Chempet, 7442, RSA Phone: +27 21 555 9000, Fax: +27 21 551 4036 industrial@gea.com, www.gearefrigeration.co.za

GEA Refrigeration Technologies

This is my personal opinion and view and not that of my employer.

engineering for a better world

Alf Hare (Pr.Eng), Email: Alf.Hare@aecom.com

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CAREERS

Professional Profile Thys Horn Managing Director of METQ Mineral Process Equipment

Projects Most challenging

Designing, manufacturing, constructing, erecting and commissioning a chrome washing plant in record time to produce concentrate on grade.

Academic

Most rewarding

School:

Shorter spirals were developed to achieve the same and better results compared with traditional long spirals. In some applications, it is the only spiral that gives separation. Another advantage of short spirals is capital cost saving, firstly when purchasing the spirals and secondly, as a much lower structure is required.

Standerton High School

Graduate Studies: University of Thys Horn Pretoria: BSc. Mechanical Engineering University of South Africa: Masters in Business Leadership (MBL)

Commentary

Career Path First Employer:

Graduate training for 2 years with the former Iscor (on bursary), and then assistant Resident Engineer as Planning Engineer.

Growth path

Joined Armscor and involved in several projects.

Being a mechanical engineer and then moving into the metallurgical field, definitely has some advantages. By understanding the process better, one can solve problems better. If there were no problems and things happened by itself, there would be no need for engineers.

Message to young engineers:

Keep learning, expand your knowledge and experience, to become a better problem solver.

Resident Engineer at Lyttleton Dolomite Mine. Was responsible for production, maintenance, projects, labour, budgets and general administration. Also acting as Mine Manager. Started own company, Metquip as supplier of general mining and process equipment. Later specializing in spiral gravity separators and hydro cyclones.

Achievements A design

To manufacture the spirals, the wear surface needed to be coated with polyurethane. A two component polyurethane spray machine was developed and built in-house for this purpose, with an accurate ratio and dynamic mixing of the components An alumina ceramic pump impellor to pump slurry was designed and built with the purpose of achieving a long life and a piece of equipment which is friendly to handle.

IT PAYS TO KEEP THE RIGHT COMPANY Find out if you qualify to #JOINOURTABLE at www.pps.co.za

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UKZN’s Solar Car The 16th installment of the KwaZulu-Natal Industrial Technology Exhibition (KITE) promises a host of stateof-the-art inventions and this year visitors will be treated to viewings of the University of KwaZulu-Natal’s (UKZN) revolutionary solar car, Apalis.

T

he UKZN Solar Car Project, which started in 2001, was a six-year project, the end result of which was a car named Wildebeest. Unfortunately, through a lack of funding, the car was never able to compete and was benched in 2007. In 2012, a new group of UKZN staff members, Kirsty Veale and Clinton Bemont, built on the lessons learned during the production of Wildebeest, and developed a new solar car named Apalis. The sleekly-designed Apalis, which still holds all the South African records for the Challenger Class, was named after a small bird found in KwaZulu-Natal. Visitors to KITE 2015 will get the opportunity to view this impressive vehicle. UKZN has since developed another solar car,

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the Hulamin-iKlwa, which took part in the 2014 Sasol Solar Challenge, winning the South African competition and setting distance records for the Olimpia Class. The team’s largest industrial sponsor, Hulamin, has pledged funds to allow the team to take part in the 2015 World Solar Challenge. This will be the first year that an African team has ever taken part. The Hulamin-iKlwa will be en route to the World Solar Challenge in Australia in June and the KITE organisers wish the South African team the best of luck with the race. Running from 9 to 12 June at the Durban Exhibition Centre, the KITE bi-annual event is one of the highlights on the technological calendar and is not to be missed. www.kznindustrial.co.za

April 2015


MATERIALS

Cutting Edge Services The Vaal University of Technology (VUT) has formed a Technology Station for material processing technologies at its Advanced Manufacturing Precinct in Sebokeng, Southern Gauteng.

T

he Technology Station will make a significant contribution to the development of scarce skills, research, innovation and technology transfer in the manufacturing industry as well as assist Small and Medium Enterprise (SMME) manufacturers of metal-based products and composite-based not only to improve their products but also their product knowledge, processes, process knowledge and skills.

Addictive manufacturing

The Addictive Manufacturing (AM) facility offers a range of prototyping and manufacturing technologies, including 3D printing (3DP) in PMMA and casting sand for metal casting, fused deposition modelling (FDM) in ABS M30, polycarbonate, polycarbonate ISO and Ultem 9085 and laser sintering (LS) in PA2200 polyamide (nylon) and Alumide (aluminiumfilled-nylon). The facility has the ability to create useable prototypes and final components quickly and accurately, in a range of materials.

Tooling and machining

The tool room for mould and die manufacturing

offers a one-stop design, research and development service with access to 3-axis CNC milling and general machining capabilities. Using this technology, the facility is able to offer services to local industry, mainly machining of working parts and prototypes for research projects.

GRP casting and composites

Components are manufactured using high-tech composite technologies including carbon-fibre. Moulding materials include: epoxy resins, polyester resins, silicone rubber and urethane rubber. Casting materials include: polyurethane, fast cast polyurethane. Fibreglass moulds are also manufactured for the concrete and urethane industries.

CNC robotic milling

Engineers at the Technology Station have mastered the art of converting the scalier (organic) into electronic data (geometry). They can upscale or downscale data to generate copies of sculptures or other artistic work. The station has access to two robots; one 8-axis robot and 15000mm x 1500mm x 500mm on the axis robot.

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MATERIALS

The product development team is made up of industrial design, engineering, additive manufacturing (AM) and tooling specialists. A typical design project will start with 2D concepts, culminating in 3D components. Industrial designers assist in the aesthetics or visual appearance of the product. Other design elements include ergonomics, man-machine interface (MMI), costs and manufacturing methods and appropriate materials.

Non-contact digitising

3D scanners (non-contact 3D digitisers) use either an LED or laser to pick up and convert data to digital media. Users include reverse engineering, the ability to check for deviation and to generate copies of artistic work. The scanners can scan data up to 15 microns and objects of any size can be scanned and precisely replicated.

Contact digitising

The facility uses a portable contact digitiser to determine precise point-by-point digital measurements. It is used to capture the physical properties of three-dimensional objects and accurately translate them into 3D models. This digitiser has a workspace clearance of 1.27m and is accurate to 0.2286 mm. The Vaal University of Technology, Tel: (016) 950-9000 www.vut.ac.za 72703_HFT_SA Mech Engineer.indd 1

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BUSINESS Consulting engineering and project implementation firm Hatch Goba has transformed its regional office in Madagascar from an entirely expat-based workforce - to one that is 95 percent local within the space of just four years.

The team ensures that they are able to effectively manage capex projects from pre feasibility study

Sustainable Employment in Madagascar

H

atch Goba Site and Capex manager, Yanick Laliberté notes that the office was originally established in 2010 in Fort Dauphin to provide project management services directly to QMM – an ilmenite and zircon mining operation, jointly owned by Rio TintoQIT Madagascar Minerals and the Malagasy state.

The aim is to establish a formal mentorship programme within the company where experts in the various fields can act as mentors to the younger and less-experienced staff members “The branch was originally comprised entirely of expats from South Africa and Canada. As it began to establish a more permanent position in the country, emphasis was placed on localising the staff base. The Fort Dauphin team currently consists of 15 professionals in various disciplines,” he states. Six engineering staff are responsible for project management and design, and three construction specialists are responsible for construction, health, safety, environmental and quality (HSEQ) management. Six project services employees manage administration, document control, procurement, logistics, business development and human resources.

Up to speed

Despite the success of the Fort Dauphin office transformation programme to date, Hatch Goba Industrial Minerals director and project manager, Giulio Capuzzimati admits that a number of challenges have been encountered. “When the need for a local office in Madagascar was recognised, there was concern that local staff could be isolated from the rest of the organisation.” As a result, training and development of the Malagasy staff has been a priority for Hatch Goba. “Shortly after starting at the company, all of the employees are brought to the Johannesburg office for internal training, which was developed to ensure that they are successfully integrated into the global company.” In addition, Hatch offers Malagasy staff external training. For individuals focusing on a specific field, such as project management or engineering, the company has put in place a training programme that enables them to study through institutes and training organisations in South Africa.

Mentorship

To ensure that the Malagasy staff have access to all the experience and knowledge that they may require, Hatch Goba is also currently in the process of

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Another challenge has been the language barrier, as French and Malagasy are the dominant languages in Madagascar

establishing a global mentorship programme. This programme will give employees the opportunity to spend an extended period of time at Hatch Goba offices in Johannesburg, or in Montreal. The aim is to establish a formal mentorship programme within the company where experts in the various fields can act as mentors to the younger and less-experienced staff members. “It’s not only focused on technical mentoring, but also on career development choices and decisions,” says Giulio. Another challenge has been the language barrier, as French and Malagasy are the dominant languages in Madagascar. To improve communication between the Malagasy staff and the English-speaking South African mentors, English lessons are being offered to the local team.

Contract awarded

The transformation programme has proven to be highly effective, as Hatch Goba was recently awarded another three-year contract by QMM for all onsite and offsite EPCM services for Capex projects. “This sign of continued trust and satisfaction is proof that we are committed to transformation without compromising on efficiency.” Looking to the future, Giulio believes there is potential for growth across Madagascar. “Our proven success with QMM has opened up the opportunity for us to expand our service offering to other clients across the region. If local development continues at this rate, I am confident that the potential for growth in Madagascar will be unlimited,” he concludes. Hatch Goba, Tel: (011) 239-5300, www.hatchgoba.co.za

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EXHIBITION

Platform for Frank Debate The inaugural Southern African Metals and Engineering Indaba (MEIndaba) will present a platform to debate and tackle issues that have plagued the sector in the last decade. Shaky labour relations, transformation, the National Development Plan and the flood of cheaper imports are some of the issues that will take centre stage during both the plenary and break-away sessions.

Irvin Jim, and ArcelorMittal CEO Paul O'Flaherty will present papers and take questions from the floor as panellists.

Disappointing performance

“The indaba will afford speakers and delegates an opportunity not only to participate and engage robustly with one another in a conference which will change the face of the sector in the region, but also to network and exchange ideas with industry peers and policymakers,” says Seifsa CEO, Kaizer Nyatsumba. The conference will be held against the backdrop of a disappointing sector performance in 2014. It was expected that growth would resume after the 2% contraction during 2013, but hope of continued domestic and international recovery faded during 2014.

Survival of the sector

Kaizer Nyatsumba

H

osted by the Steel and Engineering Industries Federation of Southern Africa (SEIFSA), the Indaba aims to stimulate growth in this vital sector of the economy that has under-performed considerably in the past few years.

“For companies operating in the metals and engineering sector to survive in such turbulent economic times, it is vitally important that robust discussions are held and strategies aimed at ensuring the survival of the sector are devised,” Kaizer observes. Seifsa, Tel: (011) 298 - 9400, www.seifsa.co.za

S MECHANICAL A ENGINEER

is proud to be a media partner of

Leading industry leaders and experts such as Minister Rob Davies, Numsa General Secretary

The sector was also dealt a blow by the five-month platinum miners’ strike organised by the Association of Mineworkers and Construction Union, a rival of the National Union of Mineworkers. Widespread incidences of intimidation, vandalism and violence were reported during the strike, which further dampened investor confidence and resulted in low levels of activity across the sector.

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AFRICA’S ONLY DEDICATED HEATING, VENTILATION, AIR CONDITIONING, REFRIGERATION & ENERGY EVENT

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Special Protection Against Slurries Over and above large quantities of abrasive solids found in mining slurry, there is usually an abundance of various corrosive chemicals in the sludge, making the choice of wear liners for valves and pumps a speciality best left up to the experts who deal with this phenomenon daily.

SA Mechanical Engineer” visits industrial valve manufacturer, Ragon Industries in Pretoria. “The company originated with the initial aim of primarily marketing ball valves for high abrasion at above normal temperatures, but this soon paved the way to also specialise in the manufacture of other valves, specifically for slurry and other highly abrasive and corrosive substances,” says Dirk Coetzee, a director of Ragon.

Unique series

The result is the Ragmax and Ragate range of valves which is locally designed, developed and patented worldwide. Well-known in the mining and processing industries locally and abroad, Ragmax, a control valve series and Ragate, a shut off valve range are today exported to countries such as South America, Australia and Europe.

To provide the necessary quality control in terms of cost-effective wear linings for both abrasion and corrosion resistance according to each specific application’s requirements, we recently invested in a specialised spraying system Although the basic body component of the valves is imported, the unique refinements, finishing and final wear resistant coating is all undertaken locally to suit specific applications. “To provide the necessary quality control in terms of cost-effective wear linings for both abrasion and corrosion resistance according to each specific application’s requirements, we

Dirk Coetzee of Ragon Industries

Knife gate valves

Twice the lifespan of any other valve, yet it only weighs 10% of that of other valves for similar applications

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recently invested in a specialised spraying system,” Dirk explains. “The process involves HVOF technology and is applied by a six axis robotic machine which reaches all possible corners and crevices as found in pumps and valves.”

How it works

HVOF or high velocity oxygen fuel spraying is a thermal process in which, in a high velocity oxy-fuel action, a mixture of gas or liquid fuel and oxygen is fed into a combustion chamber where the mix is ignited and combusted continuously. The resulting hot gas, at a pressure close to 1 MPa, emanates through a converging diverging nozzle to flow through a straight barrel section where it exits at a velocity which exceeds the speed of sound. Specifically for slurry and other highly abrasive and corrosive substances

The HVOF spray brings about 100% repeatability with its consistent, near perfect layers on all the products we treat to ensure an unvarying quality Here a powder feed stock is injected into the gas stream, which accelerates the powder up to 800 m/s. This stream of hot gas and powder is directed, typically by a robotic arm, to the surface to be coated. The powder partially melts in the stream before it deposits on the substrate in layers to build up the required thickness of the protective layer. The resulting coating has very low porosity yet high bond strength. HVOF coatings can be as thick as 12 mm. They are typically used to deposit wear and corrosion resistant coatings on materials in the form of ceramic and metallic layers. Common powders include WCCo, chromium carbide, MCrAlY, and alumina. The process has been most successful for depositing cermet materials and other corrosion resistant alloys such as stainless steels, nickel-based alloys, aluminium and hydroxyapatite for medical implants.

Advantages The HVOF spray brings about 100% repeatability with its consistent, near perfect layers on all products

“Not only has the HVOF process brought our products to a new quality level in terms of wear resistance, but we now have the flexibility to customise the wear surface for specific abrasion or corrosion challenges,” Dirk adds. “By using different powders and mixture combinations, we can often save the customer the high cost of summarily coating wear surfaces with the most expensive wear resistant material when they don’t really need it. For certain applications and wear conditions, a lower cost base material is much more cost effective for a given application and just as suitable.” The HVOF spraying service is aimed at the valves that Ragon makes, but is also offered as a service to apply protective linings on pumps parts such as impellers, shaft sleeves and casings. “The HVOF spray brings about 100% repeatability with its consistent, near perfect layers on all the products we treat to ensure an unvarying quality,” Dirk as-

Butterfly valves with a special coating

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serts. “What’s more, all the surfaces on any shape can be reached by the arm and no shape is too difficult to treat.”

Slurry valves

In addition to its Ragmax range of slurry valves, positioners, ball valves, limit switches and samplers are also on offer. “The Ragmax valve, in sizes ranging to fit pipe diameters from 25mm to 1 200mm, is specifically designed to last longer than any ordinary butterfly, pinch, diaphragm or knife gate valve,” Dirk says. “This design has not only proved to deliver the stable flow plant design and flow engineers want, but it has been shown to have twice the lifespan of any other valve, but at only 10% of the weight of other valves for similar applications.”

Remote monitoring

It is difficult and costly to wire in a monitoring system for valves and therefore about 280 million valves produced worldwide per year, are manually operated without any monitoring capabilities. “Based on hi-tech wireless and sensor technology, we now have a wireless Valve Controlling & Monitoring System which is an excellent solution for controlling and monitoring valves reliably at low costs,” Dirk says.

“The Wiles Valve Network control system can monitor and switch valves on or off remotely thorugh a wireless network. The system has a GUI interface to the operator and engineer in the control room by PC/IPC for controlling, monitoring and diagnosing valve status in real-time wirelessly. It can also communicate with PLC/DCS/SCADA via a protocol adaptor, with servers via the Internet.”

We can often save the customer the high cost of summarily coating wear surfaces with the most expensive wear resistant material when they don’t really need it The company supplies and fits valves and value-added products as its main line of business but the best fun and the most fulfilling is sharing experiences. Dirk says in conclusion, “Over the years we have built up a huge reservoir of knowledge about the in’s and out’s of our industry which we are happy to pass onto clients when they purchase from us or when they make use of the service we recently introduced to refurbish any make or type of valve, backed by a risk-free guarantee.” Dirk Coetzee, Ragon Industries, Tel: (012) 548-0834, Email: dirk@ragon.co.za

DISCOVER YOUR TRUE POTENTIAL. CHANGE THE COURSE OF YOUR FUTURE.

The Southern Africa Stainless Steel Development Association (Sassda) is committed to the development of the industry and its people. The Fundamentals of Stainless Steel is one of the six interactive courses Sassda has to offer.

FUNDAMENTALS OF STAINLESS STEEL This is an intermediate course aimed at people who have acquired a basic understanding of stainless steel through workplace experience and/or from completing the Introduction to Stainless Steel e-learning course. The targeted audience would include newcomers to the industry, as well as persons requiring a more in depth knowledge of stainless steel, such as salespersons, supervisors, managers, specifiers and end users.

Carries 1 CPD point from SAIMechE and SAIIE This course covers:

• Who Sassda is and the role they play in the industry • Understanding what makes stainless steel unique • The basic advantages and classifications of stainless steel • Identifying the main classifications of stainless steel as well as the basic grades,composition, properties and uses of each • The principles explained in the “Spider” • Identifying the top 20 alloys • Corrosion: how to avoid it, differentiate between the different types of corrosion and how each affects stainless steel • The physical and mechanical properties of stainless steel • The difference between the type, form and finish of stainless steel • Familiarising with the SA primary producer manufacturing process • The difference between flat, long products, castings and tube & pipe • Identifying the different types of stainless steel contamination • Being familiar with the process of the restoration of the passive layer • Understanding how to clean, store and maintain stainless steel

DWFCOLL 518452

Terms & Conditions apply for all course bookings and cancellations.

®

For more information visit: www.sassda.co.za Tel +27 11 883 0119 | Fax +27 86 639 4277

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Commercial Heat Pumps: A Retrospective M&V Case Study This article examines various aspects of the Measurement & Verification (M&V) of a commercial energy efficiency project. Aspects considered include the optimal use of available data; specification of targets; potential for distortions in reported impacts and possible effects of subsidy structure on M&V credibility. The importance of M&V involvement in the project from as early on as possible is highlighted.

A

large hotel chain in South Africa undertook a commercial energy efficiency project with the installation of heat pumps for water heating, keeping the conventional electric elements in place as a backup only. The project plan was to install 85 heat pumps across 35 different hotels and made use of a subsidy offered by the supply utility. For M&V purposes, it was agreed that metering of water heating energy at each site would be supplied by the existing energy monitoring system. This article is a result of some of the M&V experi-

Guest occupancy is often taken as a primary driver of energy used for the building hot water requirements

ence acquired during the project. In some cases actual data is used and in others, principles are described with hypothetical data.

Energy drivers

One of the challenges of M&V is to balance costs against reporting accuracy. Overall accuracy, in turn, is based partly on the extent to which appropriate baseline adjustments can be made. Multi-variable modelling can yield a greater accuracy but the time taken to build such models could elevate costs beyond what could be justified by the project impacts. Thus the energy driving variables need to be chosen properly. The SANS 50010:2011 national standard and the IPMVP (International Performance M&V Protocol) allow for building occupancy to be considered as a primary energy driver in a commercial building and in a hotel, guest occupancy is often taken as a primary driver of energy used for the building hot water requirements. However the manner in which this single independent variable is used can be optimised to improve baseline model accuracy.

Correlation

Let’s suppose that accurate data are available for nightly beds sold and also for half-hourly energy used for electrical water heating. A first attempt to find the correlation between these two variables may be to simply regress the daily energy usage as a function of occupancy. Although a reasonable correlation may be found, this is not necessarily the best use of the available data. In a hotel, guests who stay overnight are very likely to use hot water on the night of the stay and also the following morning. It is only fair to associate the hot water usage on any given morning with the occupancy the previous night and not the occupancy on the day of use. Figure 1 shows two possible periods of energy usage, which could be modelled as a function of occupancy. Figure 2 & Figure 3 show the improvement in co-efficient of determination (R2).

Distortion of reported impacts

It happened that after the heat pump retrofit, some hotels introduced load management programmes to shift water heating outside of peak periods. Conversely, some hotels already had load management programmes in place which ceased after the heat pumps were introduced.

Figure 1: Association of occupancy with energy usage over the period of occupancy rather than on the date of occupancy

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Figure 4 shows an example of how evening peak impact of the heat pump can be exaggerated even though the load shifting is energy neutral. Although this can be accounted for with a baseline adjustApril 2015


PIPES, PUMPS & VALVES

ment, there are still cases where such adjustments could be overlooked. Firstly, cost-effective M&V for a project of this size requires some degree of automation in reporting which may do away with visual inspection of demand profiles. Secondly, the client may not inform the M&V body of the load management project and the M&V of the related impacts may well be assigned to different M&V bodies which may be in competition with the first.

Evening peak impact of the heat pump can be exaggerated even though the load shifting is energy neutral This emphasises that during the scoping phase of such projects, M&V bodies need commitment from ESCO’s and clients to inform them of the need for ad-hoc baseline adjustments and also of any past or planned projects which affect the same electrical load.

Figure 2: Regression of hot water energy use vs occupancy for the energy used from 00:00 – 23:30

Adjustments

In order to determine the impact of the heat pumps only, the baseline needs a routine energy adjustment for occupancy and also an energy neutral ad-hoc adjustment such that it matches the profile of the post implementation demand. The latter is to avoid distortions in the reported time-of-use impacts. These adjustments are described by Equation 1 and shown in Figure 5. This method of baseline adjustment also deals with the alternative scenario encountered where load shifting only occurred during the baseline period but not after the heat pumps had been installed. Equation 1

Figure 3: Regression of hot water energy use vs occupancy for the energy used from 12:00 – 11:30 the next day

where

i = 30min time-of-use period DABL = Adjusted baseline demand DPI = Post implementation demand DBL = Baseline demand (unadjusted) m, c = Regression co-efficient, constant OBL = Av. baseline monthly occupancy OPI = Av. post implementation monthly occupancy

Specification of target impacts

For the hotel chain in question, the ESCO developed 24 hour baselines for each hotel from which target demand and energy impacts were estimated. The demand targets however were neither stated as 24-hour average impacts nor as evening peak impacts but were merely quoted as peak demand impacts with no indication of when they may occur. Furthermore these peak impact targets were then added together for the 35 hotels. Once the project had been approved by the utility for subsidy purposes, this total target was submitted to the M&V body as the overall project target demand impact. As it cannot be known at what time of day the peak

Figure 4: Exaggeration of heat pump impacts due to load shifting

impact at each hotel would occur, it is not possible to summate the target impacts for the entire project as electrical demand is a rate measurement. However, during project evaluation and appraisal by the utility,

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which reflected gross underperformance. The heat pumps were saving energy as planned, but were collectively being compared to an unrealistic target. This emphasises the importance of the M&V body becoming involved as early as possible and strictly scrutinising the method by which the predicted impacts have been arrived at.

Subsidy structure

The heat pump retrofit project was partially funded by a utility rebate which was structured as follows. A set price is determined for demand impacts (Rands/MW) and once the project is implemented, a three-month period begins during which an M&V body assesses the impacts.

Figure 5: Baseline adjustments to objectively reflect heat pump energy savings per time-of-use period

In order to meet DSM targets, utility subsidies need to be structured not only to attract short term market uptake, but also be lucrative for ESCO and client to remain committed to sustained savings a miscalculation of this type may easily be unintentionally overlooked. The inevitable result was project-level M&V reporting

During this period, the ESCO is responsible for project performance and after the period, onus is transferred to the client to ensure savings are sustained for a five-year period. Provided the project performs, lump sum subsidies are paid shortly after the assessment period with a minimum portion of 5% retained. In the case of the hotels, metering was already in place to measure hot water demand. The intention was that the same meters, which measured the electric elements in the baseline phase, would reflect the heat pumps post implementation. However site visits revealed that substantial new electric backup elements had been added which were not in the original project scope. Moreover some of the new electric elements were not being metered. The M&V body requested an audit to ensure that all hot water loads were being measured.

Commitment MAN ITEMS Y BE OFF CAN ER FROM ED STOCK

The structure of this subsidy has a knock on effect for M&V. In order to continue credible reporting over the five-year period, the client needs to not only continue supplying reliable electrical and occupancy data, but also needs to remain committed to notifying the M&V body of changes for which non-routine baseline adjustments may be required. Apart from the threat of being charged penalties, there is little incentive for the client to maintain this vital commitment to the M&V process. In order to meet DSM targets, utility subsidies need to be structured not only to attract short term market uptake, but also be lucrative for ESCO and client to remain committed to sustained savings. If only small retainers are utilised, there is little to stop the client deviating from the agreed project scope. Should the client fail to comply with M&V requests for accurate metering of all relevant loads and updates regarding scope deviations, the confidence level associated with M&V reporting could suffer. There is little recourse from an M&V perspective unless non-compliance has an implication for the client. Presented at the Southern African Energy Efficiency Convention (SAEEC) 2013. 14 - 15 November, Emperors Palace, Gauteng. www.saee.org.za. The paper was presented by Richard Larmour, Energy Research Centre, University of Cape Town, South Africa

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POWER

POWER GENERATION

GENERATION PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: samecheng@promech.co.za

T O D A Y

Pitch Control on Turbines

Website: www.promech.co.za Managing Editor: Susan Custers Editorial Contributors: Liesl Venter and Andrea Müller Advertising: Colleen Cleary Circulation: Catherine Macdiva DTP: Zinobia Docrat/ Jacquelene Nene Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.

Copyright

All rights reserved. No editorial matter published in “Power Generation 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.

Wind energy turbines are not only exposed to strongly fluctuating winds but have to use these forces as efficiently as possible. Therefore dynamic pitch control is essential to boost the efficiency of this renewable energy technology by adjusting the rotor blade to the required angle. Encoders are ideal for dynamic pitch control on wind energy turbines in order to boost efficiency

A

t low wind speeds, the rotor blades are directed towards the wind and turned away again as the wind forces increase, so as to ensure that the wind turbine continues to operate safely even at high wind speeds. Just as for many applications involving rotational movements, there are different approaches enabling the use of encoders – starting from simple solutions with only one incremental encoder right through to a combination of two redundant absolute encoders.

Both in the single turn and multiturn variant, this encoder type needs only one single magnet Reliable values

The gear motor positions the rotor blade while an additional brake ensures that the required position is maintained safely

even in the event of a power failure. Since the encoder is mounted directly onto the drive, it has to return reliable positioning values within the temperature range from minus 40 to plus 100°C. The optical gear based multi-turn Acuro AC58 encoders from Hengstler, have proven to be the best and most suitable solution in this regard. The position is determined by means of an optical rear illumination method. The mechanical multi-turn gear is also scanned optically so that it is not necessary to test the magnetic effects which may be caused by the drive brakes in particular. Such scanning is not susceptible to magnetic interference and therefore suitable for direct mounting on all motors that are provided with brakes. In addition, the encoder offers high resolution values and is able to indicate both absolute and incremental signals which can be used as reference values and/or for speed

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adjustments. As a result, no additional resolvers or tachometers are necessary.

Encoder shaft

Another alternative is to mount the encoder directly on the slewing ring of the rotor blade. In this case, it is coupled by means of a cog wheel mounted on the encoder shaft. Since the mechanical stresses on the sensor are significantly higher than in the case of motor installation, this application places totally different demands on the encoder.

It not only surpasses most of the common load module types, but also offer ten times the load capacity of commercially-available encoders To reduce the encoder bearing load, bearing modules have often been used in the past. This installation variant calls for a specifically robust encoder such as Acuro AR62. Featuring a compact design and extremely sturdy ball bearings, it is suitable for very high axial and radial loads. With a maximum admissible load of 300 N (both axial and radial), it not only surpasses most of the common load module types, but also offer ten times the load capacity of commercially-available encoders. Similar to AR58, AR62 is an electronic multi-turn

7767 - KITE 2015 VISPROM ENG&VECT 180x130 AD Paths.indd 1

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encoder that also exhibits wear-free pulse wire technology. Magnetic single turn and multi-turn scanning ensure high shock and vibration resistance. It is also resistant to environmental influences such as humidity and wide temperature ranges. Offering protection class IP69K this encoder type is suitable for complete outdoor installation.

Mechanised design

Finally the encoder can also be mounted onto a limit switch box. On-site installation is facilitated by a complete, pre-adjusted component assembly. In this approach the mechanical requirements are not as high compared with direct installation on the rotor blade. Both in the single turn and multi-turn variant, this encoder type needs only one single magnet. The multi-turn encoder uses pulse wire technology, which means that it operates completely wear-free without battery and gear. The energy required for position detection is produced from the rotational movement alone, a significant advantage of this technology. Countapulse Controls, Gerry Bryant, Tel : (011) 615-7556 Email: bryant@countapulse.co.za www.countapulse.co.za

April 2015

2015/03/23 1:31 PM


POWER GENERATION

Climate Change Reporting Tool

Putting Waste Gas to Work

Engen Petroleum is wowing front runners with its comprehensive range of lubricating oils for engines running on waste gases. According to Engen Lubricants business manager, John Kennedy, numerous waste gases are found in nature and as by-products of industrial processes, including natural gas, biogas (landfill and sewage gases), coal seam gas (coal mine and coal bed gases), and furnace gases (from steel, ferrochrome, ferromanganese and calcium carbide production plants).

Robbie Louw, director of carbon advisory firm Promethium Carbon

Kumba Iron Ore has submitted the first climate change report to London-based Carbon Disclosure Project (CDP) using a digital reporting language that provides improved data analysis and helps companies to make better investor capital allocation decisions. The Climate Disclosure Standards Board (CDSB), a consortium of business and environmental organisations, including CDP, have worked with software development company Arkk Solutions and the carbon and climate change advisory firm Promethium Carbon, to test this method of financial and non-financial reporting to the CDP, using Kumba as the first submission. The software is based on eXtensible Business Reporting Language (XBRL). The intention is to improve the quality and accessibility of environmental data by enabling companies to tag their data using XBRL. This will help to automate the sharing of business information. “However, it is important that we apply human experience to our development of digital environmental reporting. That is what this project provides,” says Robbie Louw, director of carbon advisory firm Promethium Carbon. “With the first XBRL submission to the CDP, Kumba supports the development of environmental reporting. This is coupled with other environmental initiatives

implemented by us including an ongoing diesel energy efficiency management project on our transportation fleet, energy efficiency programmes such as installing solar geysers on change houses, mine houses and hostels as well as the installation of LED lights throughout workshops and offices,” says Rodgers Mundembe, environmental manager, Kumba. Various water management programmes have been implemented by Kumba such as controlling spray water on the coarse and fine lines through a gravity feed as well as reducing the power requirement for water pumping. “We continue to implement energyefficient technologies wherever possible, such as compressed air leak detection and optimised conveyor belt control,” Rodgers concludes. Kumba has an internal energy, greenhouse gas emissions and water tracking and forecasting web-based database. These databases are used to track the progress of the energy-efficiency initiatives and water-efficiency projects, in order to reach company targets. Promethium Carbon Robbie Louw Tel: (011) 706-8185 Email: robbie@promethium.co.za www.promethium.co.za

“Instead of being an environmental burden, these gases can run gas engines of various designs for specialist tasks including gas transmission, power generation, conversion into less harmful substances and many other applications,” says John. So, for example, methane produced by waste sites can be burnt in gas engines to generate power, while simultaneously being changed into carbon dioxide that is far less harmful for the environment. Other applications include converting sewage to methane for running engines; converting carbon monoxide produced by steel works to carbon dioxide; and recovering gas from farm waste such as vegetation and refinery waste water. John says after all these wastes have been passed through a ‘digestion’ process to produce the gas used in gas engines, the other by-products are completely safe fertiliser and water that can be used for irrigation. The Engen range of premium quality gas engine oils (GEOs) has been formulated with the latest technology to meet the complex demands of gas engines and the fuels with which they operate. “Gas engines require lubricants formulated specifically for them, to meet the high demands of gas engine designs, operating conditions and environmental factors,” John concludes. Engen, Gavin Smith, Tel: (021) 403-4312 Email: Gavin.Smith@engenoil.com

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POWER GENERATION

Soot Blower Control Valve

Recently, a local power station requested Mitech to supply a soot blower control valve to operate with the following requirements: 3 kg/s maximum flow rate; 1 kg/s minimum flow rate; inlet pressure-norm 172 bar (a); inlet pressure-max 190 bar (a); normal pressure drop160 bar (a); maximum pressure drop 174 bar (a); temperature 540°C; and fail action (open under spring tension with no air). In response, Mitech designed and manufactured a soot blower control valve with the following specifications. The body is a 50 mm Globe Control Valve manufactured in chrome molly with a butt weld

28

flange rated to ANSI 2500#. The trim is a stainless steel energy dissipating disk stack with a 20 mm seat diameter and ANSI V leakage rate, operating in an under-flow direction. The chrome molly bonnet has stainless steel/ grafoil gaskets and guides, and operates with live loading. The actuator is a pneumatic piston type operating in an open-spring fail position, while the positioner is a pneumatic/pneumatic type. Previously, the power station had used another manufacturer’s cage guided globe control valve for the application and had experienced problems. The

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body cracked due to the wrong material (stainless steel) being used, and the trim lasted a short time due to only having a single pressure drop. With the new soot blower control valve, the power station has reduced emissions with more efficient heat transfer/steam generation due to minimised fouling of the boiler, decreased coal usage and reduced wear and tear. Mitech, Pieter Badenhorst Tel: (011) 927-4850 Email: enquiries@mitech.co.za www.mitech.co.za


OILS & LUBRICATION

The Right Stuff The dynamics of the lubrication field have seen some significant changes in recent years. While the primary function of lubrication might still well be to ensure surfaces are slippery, one of the most important things an operator can do for his or her machinery is ensure the right product and system is being used. “SA Mechanical Engineer” speaks to Hilgard Steenkamp, general manager of Orapi Africa.

Engine or equipment failure is expensive, timeconsuming and impacts on customer relations. “Ongoing research and development into lubrication has seen the development of a sophisticated range of products that, when applied correctly to the proper function, can have a major impact on the operations of an organisation and ultimately the bottom line.”

Top of the agenda

With some 350 line items available in South Africa alone, the extensive Orapi range can be daunting. “Educating the market is obviously key,” adds Hilgard. “Not only do customers have to ensure the right lubrication is being applied correctly but also in the correct amounts. In fact, in many cases we find ourselves having to persuade customers to use less lubrication to gain a longer lifespan out of their equipment.”

Hilgard Steenkamp, general manager of Orapi Africa

With its headquarters in France, Orapi manufactures a range of lubricants and other products in Europe and Canada that are distributed across the world. “Research and development is at the top of the agenda for the group,” Hilgard continues. “And our application systems have been thoroughly researched, developed and inspected by our technicians.”

Gone are the days of applying just any lubricant to a piece of machinery,” says Hilgard. “Just as too much or too little lubrication can cause equipment failure, so can using the wrong lubrication result in catastrophic consequences.”

His team is loathe to just summarily deliver technologically-advanced products to a plant or factory

World standard products are imported into South Africa

International standards

The standards coming in from Europe are much higher than what the local environment requires but Hilgard highlights that once customers are exposed to these products, they are more inclined to continue implementing them into their factories, even if at a slightly higher cost, as the long-term saving warrants the outlay. Using the right lubricant has major advantages

With skills shortages an ongoing challenge in the South African manufacturing sector, using lubrica-

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► EIA Process

► Environmental Risk Assessments

► Geographical Information Systems

► Agricultural Assessment and Advise

► Project Managment

► Wetland and Riparian Services

► Natural Resource Services

► Visual Impact Assessments

► Ecological/Biodiversity Services

► Public Participation Process

► Application Assistance

► Game Ranch Management

► Developement Research, Monitoring and Evaluation

N2 Mnini ECO Duties

Plant rescue

Durban Coal Terminal Site Inspection

Ohlanga Pump station ECO Duties

Freightpak Warehouse Site Audit

Public participation Makhabeleni

Ballito Interchange Botanical survey

Site assessment Sundumbili pipeline

l Tel: (031) 303-2835 l Fax: 086 692 2547 l l Email: info@afzelia.co.za l www.afzelia.co.za l

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Septmeber 2012

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OILS & LUBRICATION

Using the right product for the correct application saves costs in the long run

and cleaing products are crucial, but ensuring the specific equipment is maintained and kept strong and reliable, is also non-negotiable.” When we ask about new trends in the market, Hilgard talks environmentally friendly. “The race to go green has impacted significantly on our business and we have worked hard towards developing ranges of products that are energy efficient and environmentally friendly. tion that decreases maintenance and increases the lifespan of equipment is fast gaining traction. Increased automation plays a role too. “There is also great emphasis on ensuring the safety of the labour force. Thanks to the technological advances being made, modern lubricants are far safer than ever before and also have very little environmental impact.” According to Hilgard, however, his team is loathe to just summarily deliver technologically-advanced products to a plant or factory. “We believe in providing a solution rather than just a product and so we build a very close relationship with the customer to understand his or her needs and requirements in order to deliver a solution that speaks to the heart of the particular business,” he explains. “In the past there was nothing wrong with using the same lubricant across a range of equipment or washing parts with paraffin to clean them. “But as new solvents and products have been developed, there are now very specific applications that can be combined in different ways to bring about a more efficient operation. Users must know when to use a grease and when to use an oil and why.”

Non-negotiable

Hilgard tells us it’s about anticipating the complete needs of a plant. “The two main causes of equipment and machinery failure can be attributed to improper lubrication and contamination. Naturally the relevant lubrication product and specific protection

In the past there was nothing wrong with using the same lubricant across a range of equipment or washing parts with paraffin to clean them “Also we are slowly but surely seeing the emphasis being less on cost and performance and more on a broader range of capabilities and lubrication deliverables,” Hilgard advises. “Aspects such as quality, service, support and contamination control are becoming far more critical.”

Making a difference

In addition, the opportunity to transform plant equipment through using the right lubrication is great. “It starts with education and then with the benchmarking of products with best practice. By using the right lubrication, you are moving ahead of the pack and will ultimately gain a competitive advantage.” For Hilgard the proof is in the pudding. “We have been working closely with a large petrochemical organisation locally where you didn’t dare enter the factory without using earplugs. A recent visit, however, saw us walk through clean premises with minimum noise.” The reason? The correct lubrication is being applied to the right equipment. “Not only have we reduced the noise level for the factory, but we have also helped to establish a far cleaner and more pleasant operation for all concerned.” Hilgard Steenkamp, Orapi, Tel: (011) 454-5138, Email: info@orapiafrica.co.za; www.orapi.co.za

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Responsible Management of Used Oil What happens to the oil in your workshop? Just one litre of oil that ends up in our waterways has the potential to pollute one-million litres of water which can contaminate the drinking water of about 100 000 households or destroy waterborne environments kilometres downstream from where the pollution takes place.

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hankfully, since the establishment of the Rose Foundation in 1994, awareness of these issues has been raised. As a result, there has been widespread reform in how companies deal with waste oil and no fewer than one-billion litres of oil has been prevented from entering our environment over the last twenty years. Rose Foundation’s CEO, Raj Lochan, tells “SA Mechanical Engineer” that the foundation is a national non-profit organisation established to promote and encourage the environmentally-responsible collection and recycling of used oils and related waste in South Africa. It was established by the manufacturers of lubricating oil directly as a response to growing concern around the consumption and recycling of oil and petroleum products.

We have seen an investment by the industry of over R100 million in building used oil storage infrastructure in four cities Creating employment

The Rose (Recycling Oil Saves the Environment) Foundation is also funded by major stakeholders in the lubricants industry enabling them to meet environmental responsibilities while creating widespread employment opportunities through sustainable recycling. These efforts have not gone unnoticed and have been praised by Government as an extremely successful and sustainable waste management model, which has been recognised globally as best practice. In fact, the foundation was recognised by the Green Supply Chain Awards (presented by “SA Mechanical Engineer’s” sister publication “Supply Chain Today”) as an industry leader in green logistics. “We have seen an investment by the industry of over R100 million in building used oil storage infrastructure in four cities, supplying oil storage tanks, while facilitating the collection and disposal of used lubricating oil totalling more than 1 billion litres. This has been done proactively without being enforced and has rather been embraced by producers as part of their extended producer responsibility (EPR),” Raj explains.

Changing with the times

“We have worked hard to stay abreast of current

Raj Lochan of the Rose Foundation

legislation governing the classification, management and disposal of waste and we ensure that our members remain compliant ahead of changing regulations. We also continue to play a leading role in the establishment of partnerships aimed at effectively dealing with used oil and other potential contaminants such as containers and other products associated with oil such as rags etc,” Raj adds. He continues that in 2005, the foundation facilitated the formation of an independent body that represents the interests of the collectors and processors of used oil. The National Oil Recycling Association of South Africa (NORA-SA) ensures that the collection, transportation, storage, refining, recycling, disposal and utilisation of used oil is managed in a sustainable, ethical, environmentally-compliant and responsible manner. In just ten years, this association has grown from strength-to-strength and has become truly representative of responsible oil-recyclers. With 66 members who are collectors, seven members who are processors and one associate member, NORS-SA plays a key role in developing the industry.

Growing reach

Other initiatives by the foundation include a leading role in the formation of the South African Industrial Containers Reconditioners Association (SAICRA). This body was formed in direct response to growing requirements of the manufacturers and the

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OILS & LUBRICATION

The sumpy is being actively promoted to encourage the private DIY disposal of car engine oil in a responsible manner. These are easily available at franchised spares shops and supermarkets. The sumpy comes in two sizes, 18 litres and 9 litres.

Rose Foundation recycling station

reconditioners of drums to become responsible and compliant. In the three years since its establishment, SAICRA already has 31 members and has become entrenched within the industry with a memorandum of agreement with the Chemical Allied Industry Association (CAIA) – so SAICRA now represents approximately 80% of the reconditioners of drums in South Africa. “We have made it a priority to partner with key players in every step of the oil industry. A good example is the agreement we entered into with Collect-A-Can in 2004, which collects all the empty oil cans from service station forecourts. Another green initiative is with the municipal waste sites where people are able to drop off their used oil and other related wastes,” Raj says.

Oil can be recycled many times over, without losing its efficacy. Rose champions the petroleum industry’s ‘cradle to grave’ philosophy Shared responsibility

He concludes that oil can be recycled many times over, without losing its efficacy. Rose champions the petroleum industry’s ‘cradle to grave’ philosophy. With full collection services and drop-off points situated in 12 centres nationwide, the foundation provides businesses with a convenient and responsible way of disposing of used and unwanted oil, one less thing to worry about!. Rose Foundation, Raj Lochan, Tel: (021) 448 7492, Fax: 0866527384, Email: usedoil@iafrica.com, www.rosefoundation.org.za

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Characteristics of Lubricants This article is the second of a 4-part series designed to remind Tribologists of the basics of Tribology.

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n boundary lubrication, asperities of metal on the moving surface protrude through the oil film, coming in contact with similar asperities on the fixed surface, causing metal-to-metal contact resulting in high sliding friction leading to an increase in temperature.

Unfortunately, there are many cases where bearing loads are too high, speeds too low, bearing designs unsuitable or methods of application of the lubricant unsatisfactory, for the fluid film to be established or maintained. Under such conditions the journal, slider or gear is said to operate under boundary lubrication.

In some cases, temperatures are high enough to melt the metal, and with two hard metals in contact, will cause local seizures. In a combination of a steel journal and a soft metal bearing, the softer metal asperities melt and flow into the adjacent hollows and valleys. The local melting of surface asperities must not be confused with surface welding of areas which can result in seizure of a bearing. In the latter

For extreme cases of boundary lubrication, it has been found that even efficient oiliness agents cannot prevent metal-to-metal contact and result in seizure, so that other forms of boundary lubricants termed “extreme-pressure” (EP) lubricants have had to be evolved. These extreme-pressure lubricants form boundary layers under high temperature, high pressure conditions, by chemically combining with the metal surfaces to form thin, solid non-polar layers.

case, a much greater area is involved and parts of the surface of one body are torn out by the other.

Good example

Worm gears provide a good example of machinery operating under boundary lubrication conditions, as the greater part of the motion between worm and worm-wheel is sliding; in addition, loads are frequently high and speeds low. Another example is a guide shoe working on a slideway in a slow speed reciprocating motion. At the end of the stroke, the shoe comes to rest and then reverses direction, so that it is impossible to establish a fluid film. The same principle applies to reciprocating motion of a piston in the cylinder of an internal combustion engine. This is particularly true when the piston reaches the top end of the cylinder where the high surface temperatures greatly reduce the viscosity of the oil.

Fatty oils

Under the conditions of boundary lubrication, the addition of special additives must be employed to provide a film with a greater strength than the oil alone. Lubricants used under boundary conditions should possess the property of adhering strongly to metal surfaces, frequently referred to as “oiliness”. Animal and vegetable fatty oils possess this property to a higher degree than mineral oils, and when small quantities of these materials are blended with mineral oils, they significantly reduce friction and wear. These fatty acids which impart an “oily” property to the lubricant are polar materials, and have an exceptionally high affinity for metal surfaces forming a chemical bound with the metal. The polar molecule orientate themselves rather like the pile on a carpet, with the back cloth representing the metal surface, with one end secured and the other end unattached. An orientated adsorbed film of this type offers appreciable resistance to compression but with little resistance to motion, as the pile structure is very flexible and the molecules bend over without breaking easily. Sliding friction between metal surfaces is thus greatly reduced.

Compression

It would appear from this that fatty materials would be ideal boundary lubricants. Unfortunately they oxidise and decompose fairly rapidly at high temperatures associated with high loads and speeds; they form sludge and deposits and at the same time they also reduce the load carrying capability. Boundary Lubrication (Extreme pressure condition)

If all machinery could be designed to operate under hydrodynamic lubrication, wear would be confined

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SAIT

only to stopping and starting periods and bearings would last indefinitely.

The solid chemical Extreme-Pressure boundary film tends to shear as surface asperities pass over each other, and before the layer can be re-established, a further chemical reaction must take place. Gear oils are a typical application for E.P. type boundary lubricants.

Such films offer little resistance to shear but a high resistance to compression. As they have considerably higher melting points than polar compounds, they are more suitable for high temperature, high load, slow-speed conditions.

To be continued in the next edition, when Types of Lubrication will be discussed. Thomas Surmon, SAIT President, Tel: (011) 804-3710, Fax: 086 719-2261 Emails: secretary@sait.org.za and admin@sait.org.za www.sait.org.za

Temperature

Extreme-pressure (EP) agents are chemically inert except at high temperatures, thus they require high localised temperatures generated by friction to react with the metal surface.

Power Generation: Top of Mind Power-Gen Africa, taking place 15-17 July 2015 in Cape Town, will present the latest technologies and developments across the entire power-generation sector: conventional power, nuclear, gas and renewables. Hot topics to be presented include: Financing the Power sector; gas turbine technologies; integration of renewables; concentrated solar power; universal access to power; and plant modernisation and life extensions.

Showcase of latest technologies

Over 100 leading regional and international exhibitors will also be showcasing their latest equipment and technological designs Power-Gen Africa, Tel: (021) 930-9515, Email: andrewe@pennwell.com www.powergenafrica.com

IT PAYS TO KEEP THE RIGHT COMPANY Find out if you qualify to #JOINOURTABLE at www.pps.co.za

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FOOD & BEVERAGE

Competition Challenge SEW-Eurodrive and Pneumax, co-sponsors of the PneuDrive Challenge Engineering Design Competition, have announced that students will need to design a “Game Changer� for the food and beverage industry in 2015.

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TI statistics for commodities associated with the food and beverage industry report that the industry was valued at more than R132 billion in 2013. It is also an industry that the South African government has identified as one of the top three priority areas for creating jobs, with a plan to see the creation of 145 000 jobs in the agro-processing sector by 2020.

2015 the competition organisers will be on the lookout for talented young engineers brave enough to think out of the box Game changers needed

Food and beverage companies are under pressure worldwide. Small, medium and large businesses in this competitive industry face a myriad of essentially unpredictable challenges. Adverse weather conditions, legislation changes, rising commodity prices, higher transportation costs and consumers becoming increasingly conscious of what they purchase, come to mind.

lenge has proven itself as a successful model that can accelerate the introduction of young engineers into industry. In 2015 the competition organisers will be on the lookout for talented young engineers brave enough to think out of the box, and with the potential to design applications that could make a big impact on the food and beverage industry. The winners of the competition will receive a tenday all-expenses paid trip to Germany and Italy where they will have an opportunity to present their designs to the head offices of the sponsor companies. SEW-Eurodrive and Pneumax also offer more than R300 000 worth of equipment to competing universities to ensure that future students are afforded the opportunity to experiment with the latest in drive engineering and pneumatic technology. Sew-Eurodrive, Rene Rose, Tel: (011) 248-7000, Email: pneudrive@sew.co.za, www.sew.co.za

Large companies have more resources and better access to capital to address challenges. However, it is the small-to-medium size processors and manufacturers that have to proactively find solutions to these pressures if they want to maintain or grow market share.

Innovative engineering

The importance of offering students access to the latest in drive and pneumatic technology, and how these can be used practically in business, cannot be stressed enough. With the rollout of the competition to universities around the country at the beginning of each year, the co-sponsors typically find that students have very limited, if no knowledge at all, about the latest drive and pneumatic technology that is available. This suggests not only a lack of technology awareness that universities obviously cannot keep pace with, but a serious gap in student understanding of how the technology can be used to improve business and manufacturing processes.

Out the box

Started in 2008, the PneuDrive Chal- 2 Billion can ends being produced annually by Nampak DivFood alone THE SOUTH AFRICAN MECHANICAL ENGINEER

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EMERGING OPPORTUNITIES IN THE WORLD’S FASTEST GROWING CONTINENT

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Conference & Exhibition 15–17 July 2015 Cape Town International Convention Centre, Cape Town, Republic of South Africa www.powergenafrica.com | www.distributechafrica.com

For booth bookings and sponsorship enquiries, please contact:

Invitation to Participate POWER-GEN Africa and DistribuTECH Africa, will once again provide comprehensive coverage of the power needs, resources, and issues facing the electricity generation and transmission & distribution industries across sub-Saharan Africa.

Leon Stone Exhibition Sales International T: +44 (0) 1992 656 671 E: leons@pennwell.com

The events will feature multi-track conference sessions covering strategic, technical and renewable topics with practical solutions and benchmark case studies and concurrent exhibition floor featuring prime movers showcasing the very latest equipment and technologies. POWER-GEN Africa and DistribuTECH Africa have quickly established themselves as sub-Saharan Africa’s leading events that cover the full power spectrum from supply to delivery, focusing on the current and future trends, as well as the needs and resources within this region of the world.

Andrew Evans Exhibition Sales Africa T: +27 (0) 21 930 9515 E: andrewe@pennwell.com

Nowhere else provides you with the opportunity to reach and meet over 3,000 high-level industry professionals in one place, allowing networking, business and sales opportunities with key industry buyers and influencers from around the continent.

To register and obtain further information, visit www.powergenafrica.com or www.distribtuechafrica.com Owned & Produced by:

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THE SOUTH AFRICAN MECHANICAL ENGINEER

Supporting Association:

20/11/2014 09:59

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AWARDS

Young Welder of the Year 2015 Jacobus van Deventer has won the Young Welder of the Year 2015 competition and will go on to represent South Africa at the WorldSkills competition to be held in Sao Paulo, Brazil, from 11-16 August 2015.

Morris Maroga SAIW President and Jaco van Deventer Young Welder of the Year 2015

Jaco is only 20, but the quality of his work is beyond his years,” says SAIW’s (SA Institute of Welding) Etienne Nell, the Young Welder of the Year convenor. “He also has an excellent work ethic and is willing to learn. We are hoping for a competitive showing by him in Sao Paolo,” says Etienne. Jaco, who is apprenticed at Steinmüller, faced tough competition this year, and only beat overall runner-up Romario Arendse from West Coast College by 1.25 points. The win boiled down to the stainless steel section of the competition, which required the young welders to weld a

7744 - COPPERBELT 2015 HALF PAGE AD SA MECHANICAL ENGINEER.indd 1

Romario Arendse (left) - overall runner up with Morris Maroga, SAIW President

box without rotating or moving it in any way. Jaco scored an impressive 9.3/10 for this project, pushing him to the front of the competition. Etienne remarks, “The competition has generated a great deal of interest from all over the country. With 20 finalists, we had a record number of participants this year and as this has become the foremost skills test for young welders in South Africa, we expect participation to continue growing.” Southern African Institute of Welding, Jim Guild, Tel: (011) 298-2100, Email:guildj@saiw.co.za www.saiw.co.za

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MARKET FORUM

Key Topics South Africa’s Department of Energy is throwing its full weight behind efforts by the utility industry to find urgent and sustainable solutions to current energy challenges, says African Utility Week event director, Evan Schiff. The conference and exhibition takes place from 12-14 May in Cape Town. Every year African Utility Week gathers the industry to learn, share knowledge and debate the key topics that will secure the future development of Africa’s power and water industries. Topics will range from regional collaboration in the power sector to the untapped potential of renewable energy and investment challenges. African Utility Week and Clean Power Africa, www.african-utility-week.com

Basic Prediction Data With the latest update to AMS Suite: Machinery Health Manager, the CSI 6500 protection system communicates additional prediction data to allow users to make real-time decisions on operating their critical assets. Emerson Process Management has expanded the protection of critical assets to include basic prediction capabilities with only minimal time and wiring investments. These basic prediction capabilities for the CSI 6500 protection system are available in the recently released version 5.61 of AMS

Suite: Machinery Health Manager. Using a simple Ethernet connection from the CSI 6500, users receive periodic parameter trends and spectrum/waveform data delivered at specific intervals. This data is particularly useful for determining the health of sleeve bearings on turbo machinery. This automated process for acquiring prediction data eliminates the need to connect to buffered outputs on the protection system and reduces the risk of inadvertently causing a machine trip. In addition, waveform data from the CSI

Making SA’s Food Safe The South African food industry is taking matters into its own hands. Food manufacturers and retailers are now working together to become self-regulated in terms of food safety and compliance so that not only domestic consumers but also entire industries, such as tourism and the international investment sector, may be confident about the food that is produced and consumed in South Africa. For self-regulation to take place, the food industry needs to check every stage of its supply chain and be rigorous about its certification, auditing, label verification and overall operational standards. Amanda Rogaly, MD of FoodSure says some of the big food companies in South Africa are already well on their

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6500 is now incorporated onto the circular polar plots available in AMS Machinery Manager v5.61, facilitating diagnosis of developing valve faults in reciprocating compressors. Emerson’s AMS Machinery Manager integrates data from route-based, online, and wireless vibration solutions as well as third-party oil and infrared analysis data to provide a complete picture of machinery health. Emerson Process Management Michael Eksteen, Tel: (011) 451-3700 Email: Michael.Eksteen@Emerson.com

had with one of their manufacturers in India late last year.”

The food industry is the way to total compliance and second largest employer label verification but this in South Africa employis a lengthy process. “The ing around 1.5 million real challenge is making it people, turning over more clear to other and smaller, than R20 billion per anindependent companies what num. "With more and they need to do.” Amanda Rogaly more food companies in Amanda adds, “If the food South Africa seeing the light and instigatsource and manufacturing process cannot ing independent checks so that they are meet international standards, the attrac- able to reassure themselves, their retail tiveness of setting up a manufacturing customers and, ultimately, the consumers plant to service the SADC region or the that consume their products, the more continent in general would be hampered. we can expect this industry to grow and, International organisations cannot afford importantly, contribute to stimulating our the liability and reputational risk associ- economy," Amanda concludes. ated with food scares that often occur in third world countries. An example of FoodSure, Amanda Rogaly, this is the experience that Tiger Brands Tel: (021) 464-1144, www.foodsure.net

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MARKET FORUM

Offering Complete

Fluid and engineering couplings supported by a technical advisory and solutions service for specific applications, including existing installations

BMG has been appointed distributors in Southern Africa for the Vulkan Drive Tech products range, which includes couplings and braking systems. “With the introduction of Vulkan’s fluid and engineered flexible couplings, BMG’s coupling offering is now complete,” says Carlo Beukes, BMG’s power transmission product manager. “BMG, which now carries a vast stockholding of standard Vulkan couplings, also has access to the complete range of Vulkan braking systems. “With Vulkan’s compact fluid coupling design, it is possible to replace existing applications, without the need for any modifications to the existing layout, therefore ensuring ease of replacement and reduced project costs.” Important components for BMG in the Vulkan range are Flexomax GBN

maintenancefree couplings, with a maximum torque of 1 288 kNM and shaft diameters up to 600 mm. These torsional flexible couplings are equipped with speciallydesigned elastic elements which work in compression, allowing for maximum

torque transfer, heat dissipation and product longevity. BMG’s Power Transmission Division Carlo Beukes, Tel: (031) 576-6200 Email: carlob@bmgworld.net, www.bmgworld.net

To-do-Lists

There is a well-known adage, that says: ‘if you want to get something done, give it to someone who is already busy’. Busy people find smarter ways to do things, quicker and often more effectively. But not everyone can multi-task or remember everything that needs to be done. An example of the need to manage multiple requests, track and then followup on queries, is the customer service department where smart technology can be a lifesaver. Task Express, developed by Cape-based Khanyisa Real Systems (KRS), has been effective in streamlining multiple tasks, routing them to the correct person and as a result, increasing the response time, helping organisations create satisfied and happy customers in the process.

to a customer, without the need for that customer to go through several referrals before getting to the right person, organisations using Task Express, have noted improved customer confidence and an overall boost in company reputation.

“With more and more companies automating the contact page on their websites, we felt there was a need to construct a simple but sophisticated programme that could manage query flow and route these immediately to specific mailboxes” comments Brent Blake, project director at KRS. In being able to respond quickly

The list builder and task scheduler are easy to use and eminently scalable – from the individual ‘coffice’ worker (coffee shop office) to large companies (with multiple branches) handling large volumes of management tasks. Far more than a task tick box listing programme, Task Express allows users

to collaborate online (via the website), allowing managers to see in realtime, what employees are doing and literally ‘be on the same page’. Assumption and work overload are reduced. The system can also be accessed from anywhere, making it an indispensable tool for office workers and those on the go, for managing workflow, sharing information and more importantly sending reminders. Khanyisa Real Systems, Tel: (021) 681-2900, www.krs.co.za

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MARKET FORUM

Zimbabwe Distributor Appointed Hytec Services Africa (HSA) has officially appointed Zimbabwe-based Hilmax Private Limited as a distributor in that country, effective 4 February 2015. The appointment came into effect after three months of discussion, incorporating reciprocal visits between senior members of each organisation. With effect from the date of appointment, the family-owned Hilmax, which has hydraulic hoses and fittings as its core business, distributes the entire range of the Hytec Group products. Petrus Viljoen, sales supervisor, HSA, who facilitated visits between the two companies’ senior directors, will attend to the Hilmax business on a monthly basis. “Hilmax’s core business, the fact that they have strategically placed operations to service the mining industry, as well as its primary focus on servicing this industry’s hose and fitting requirements, are only a few of the reasons Hytec believes them well-suited to represent the

Pictured at the official appointment of the Hytec Group’s Zimbabwean distributor, Hilmax, are (top): Patrick Musavaya, Hilmax Operations Director and Gary Shaw, Africa Development Manager, Hytec Services Africa. Bottom: Pascal Musavaya, Hilmax CEO and Petrus Viljoen, Sales Supervisor, Hytec Services Africa

Hytec Group in Zimbabwe,” says Petrus. “Hilmax’s client base comprises practically the entire hydraulic industry in Zimbabwe,” he points out. “The company will be able to increase its growth opportunities by supplying the

Hytec Group’s full range of hydraulic, pneumatic and automation products.” Hytec Services Africa Petrus Viljoen Tel: (011) 573-5460 www.hytecgroup.co.za

Pontoon assembly adjacent to the tailings dam at Sungun Mine

Middle East Contracts APE Pumps has completed two orders placed by Iran’s Sungun copper mine, one for a train of eight pumps to operate as a very large multistage machine transferring slurry to the tailings dam, the second for four pontoon-mounted axial flow pumps to recycle dam water. The two orders are together worth some AED 23-million (USD 6,4-million) to Wadeville-based APE Pumps.

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John Montgomery, the engineer behind the design of the twelve machines covered by the two orders, says when commenting on the order that South African engineering companies are stepping in to fill part of the void left by European firms reluctant to enter into contracts with Iran. “We have this year received an order for a large mixer pump related to the

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Iranian oil industry, and we are tendering on several other contracts in that country,” he adds. APE Pumps Peter Robinson Tel: (011) 824-4810 Email: apepumps@mweb.co.za


MARKET FORUM

Maintaining Africa’s Pumps Advanced after sales systems enables KSB Pumps and Valves to maintain a massive fleet of pumps in tip top working condition, wherever they have been sold and installed throughout Africa. No matter the age, make or model of the pump, as long as it bears the KSB name, the company undertakes to ensure spares and services are available on short notice throughout the continent for the duration of the pump’s life. Having sold hundreds of thousands of KSB pumps over the past six decades, the important task of supplying after sales services is undeniably one of the most important services offered by the company and is prioritised throughout each division as a result. According to KSB Pumps and Valves aftermarket sales manager, Andreas Gremels, as a first-choice supplier of pumps for important applications such as bulk and municipal water authorities, power stations, petroleum refineries, mines, irrigation schemes and industry, the company has also introduced advanced condition monitoring equipment to assist customers with preventative maintenance

KSB Pumps and Valves aftermarket sales manager, Andreas Gremels in one of the company’s spares and parts warehouses in Germiston

and optimisation of pump systems. KSB’s advanced SES Efficiency System is able to do a complete energy efficiency analysis, detect variations in flow rates, vibrations and other clues that it interprets and analyses in real time to optimise pumping systems and assist with the scheduling of appropriate preventative maintenance to ensure the least disruption on liquid transfer systems. Simultaneously, field staff and service

personnel are able to assist customers with the operation and maintenance of pumps anywhere on African soil. Depending on the size and scope of the pumping operation, KSB Pumps is able to make available framework agreements with regard to service, repairs and spares. KSB Pumps and Valves, Annett Kriel Tel: (011) 876 5600 Email: Annett.Kriel@ksb.com www.ksbpumps.co.za

Great Compressor Solutions Rand-Air has completed a number of successful hires for DCD Marine Cape Town, a provider of turnkey ship repair solutions to the marine and oil and gas sectors and part of the DCD Marine Cluster. Rand-Air provided critical compressed air so that two of the company’s major repair projects, for international clients, were kept ‘up and running’ recently. The projects were based at the Port of Cape Town’s A-Berth and at Saldanha Bay. Generators were used to power the various pieces of equipment on board the rigs and compressors were used in the pumping, blasting and painting operations on both sites. Rand-Air has been involved in intensive research of the upstream oil and gas industry to ensure that it supplies the appropriate product to point of need.

In keeping with its dedicated safety ethos, the company has ensured that it is compliant with the stringent regulations for off-shore repair services and that it supplies only rig-safe machines to its customers. Rand-Air Cindy Ross Tel: (011) 792-1754 www.randair.co.za

Louwrens Erasmus, general manager of Rand-Air

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MARKET FORUM

Remote Areas

“Our customised screens are often the preferred equipment due to their robust design and proven performance. Understanding the difference in design and duty for process plant screens, particularly sizing feed preparation in washing and Dense Media Separation (DMS) applications, is a key feature of our ongoing success in many sectors of the mineral processing industry,” says Derrick Alston, CEO of Joest. “We have supplied six vibrating screens to a gold mine in Liberia, eight vibrating screens to a gold mine in Mali and 15 vibrating screens to a gold mine in Burkina Faso,” he adds. “We have also supplied screens to Tanzania and have had vibratory feeders installed in a large coal mine in Mozambique. We are optimistic that our growth in Africa will go from strength to strength. This is largely due to the excel-

A double deck vibrating screen (up to 4.3 m) in a coal application

lent reputation that our brand has gained over the years. A particular advantage of Joest equipment is the increased lifespan, structural integrity and ease of maintenance of the equipment, which is

particularly important in remote areas in Africa,” Derrick concludes. Joest , Kim Schoepflin, Tel: (011) 923-9000 www.joest.co.za

South African Expertise Following approval of the prefeasibility study (PFS) prepared for the greenfield Golpu Project in Papua New Guinea, WorleyParsons has now embarked on the feasibility study stage. Adopting an innovative approach, the PFS split the project into two stages, the first targeting the upper higher value portion of the orebody, which is expected to have a 27 year life, followed by a second stage encompassing the remaining ore reserve. The Golpu Project feasibility is working up technical, procurement and operational plans to create a long-life,

world class mine in Papua New Guinea’s Morobe Province. The project comprises an underground mine and process plant with significant associated infrastructure to exploit this prime deposit. WorleyParsons’ Johannesburg Mining Centre of Excellence began work on the PFS in January 2014 and by the end of last year had confirmed a compelling business case for the life of the mine using this two-stage approach. WorleyParsons’ scope for 2015 now comprises a feasibility study for Stage 1, a PFS for Stage 2 and Early Works Engineering for Stage 1. “We’re delighted that the business case

Index to Advertisers Aesseal

Inside Back Cover

African Utility Week Inside Front Cover Afzelia 30 Copperbelt Trade Expo

41

Engen 12 Engineer Placements

16

Frigair 18 GEA Regrigeration

10

Hytec 14 ILS 4 KZN Industrial Technology

46

26

MEIndaba

Outside Back Cover

Multi Alloys

24

Nkosi’s Haven

34

PowerGen Africa

40

PPS Regal-Beloit Sassda 21

WorleyParsons, Rob McGill Tel: (011) 218-7000 Email: rob.mcgill@worleyparsons.com www.worleyparsons.com

On the Move!

7, 11, 38 Outside Front Cover

Universal Storage

36

Value Logistics

32

Verder 28

THE SOUTH AFRICAN MECHANICAL ENGINEER

has been given the green light,” says WorleyParsons’ Rob McGill, divisional manager, Mining Studies. “This is the biggest international project study undertaken by WorleyParsons’ Mining Centre of Excellence here in Johannesburg, and it has effectively demonstrated our ability to leverage the underground mining and processing capability that resides in our South African hub to add value to customers globally.”

VOL 65

April 2015

Chris Whitehead has been appointed national sales manager for DISA Equipment (Pty) Limited, trading as Doosan, part of Invicta Holdings Limited.


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April 2015

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Southern African

28th & 29th May 2015

Metals and Engineering INDABA Engage

EMPERORS PALACE Innovate

Contribute

Sustain

The inaugural Southern African Metals and Engineering Indaba is set to become a milestone in the history of the metal and engineering sector in particular and the manufacturing sector in general. Several high-profile experts and thought leaders such as Trade and Industry Minister Rob Davies, NUMSA General Secretary Irvin Jim and ArcelorMittal CEO Paul O’Flaherty will present insightful papers during the main plenary session. Topical issues including the participation of women in the sector, the future of manufacturing in Southern Africa, striking a balance between international competition and dumping, labour stability, transformation and Southern Africa’s infrastructure deficiencies will be under the spotlight during the proceedings. The conference will provide an opportunity for more intense, sector-specific discussions during the afternoon break-away sessions. Delegates and exhibitors will also use the opportunity to foster business networks and discover new technological innovations during the exhibition that will run on the side lines of the Indaba.

Meet some of our keynote speakers:

Trade and Industry Minister

NUMSA General Secretary

ArcelorMittal CEO

Rob Davies

Irvin Jim

Paul O’Flaherty

For ticket bookings, and more information visit www.meindaba.co.za

OFFICIAL MEDIA PARTNERS

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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 65

April 2015

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