S MECHANICAL A ENGINEER Sept 2015
Publication of the South African Institution of Mechanical Engineering, incorporating News of Associate Organisations
IN-FIELD DIAGNOSTIC SERVICE YOUNG ENGINEERS BROUGHT UP TO SPEED
Opportunities identified and challenges dealt with, keeping a long term focus on sustainable business.
ENERGY
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LEVEL 4
Chris Reay
Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)
Your Institution over the last three years has developed and beta tested the PDP and is at a stage where it is ready to move into a productive phase by involving all the necessary players
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Type 30 Reciprocating Air Compressors • 34 models • 6.9 – 345 bar • 1.5 – 30 kW
S MECHANICAL A ENGINEER
The monthly circulation is 3 947
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Forthcoming Workshops : October – November 2015 Programmes and Registration Forms obtainable from Carey Evans, Tel. 031 764 7136 or Email: carey@saimeche.org.za
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Event Code
Event Title
Start Date
End Date
Region
Booking Closure Date
C6915
Lubricants & Oil Monitoring
01 Oct 15
01 Oct 15
Cape Town
21 Sep 15
C4615
Value Engineering; Value Management
21 Oct 15
21 Oct 15
Cape Town
9 Oct 15
A2915
Lubrication & Lubricants
28 Oct 15
28 Oct 15
Durban
16 Oct 15
A6915
Lubricants & Oil Monitoring
29 Oct 15
29 Oct 15
Durban
16 Oct 15
A6515
Fans and Air Handling
25 Nov 15
26 Nov 15
Durban
13 Nov 15
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Dr Steve Lennon
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Vaughan Rimbault
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UD filter Oil-free compressor
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Left to right: Pieter van Wyk, Wayne Jacobs and Charl Ackerman
Nitrogen generator range
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Academic
Career Path
Kudzai Nyangoni
find out if you qualify to #joinourtable at pps.co.za PPS is an authorized Financial Services Provider.
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Achievements
Commentary
Projects
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Thomas Surmon, SAIT President, and Daan Burger of Wearcheck Africa
Belinda Harker of Sasol Technology, with SAIT Executive Committee Member, Shawn Pharo
Professor Bojan Podgornick, Institute of Metals and Technology, Slovenia, with Adrian Velaers of Sasol and Robert Pittroff of Osborn Engineered Products
Gerrie Claassen of University of Pretoria with Lionel de Jager and MariĂŠ Julsing, both of Spectro Analytical Instruments
Speakers and Delegates
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Filter Focus COO, Craig FitzGerald
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Mark Burn, Managing Director of Air & Vacuum Technologies
Air & Vacuum Technologies are extending their product range with the introduction of Hydrovane products
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Adding Hydrovane compressors to their ranges makes sense for Air & Vacuum Technologies
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Vane compressors will complement the existing range of products at Air & Vacuum Technologies
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September 2015
POWER
GENERATION
T O D A Y
PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: samecheng@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial Contributors: Liesl Venter and Patricia Holburn Advertising: Colleen Cleary Circulation: Catherine Macdiva DTP: Lindy Fobian/ Jacquelene Nene Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.
Copyright
Xianming Ye
Prof Xiaohua Xia
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.
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Energy Efficiency Activities Primary energy
Improve imported coal quality and install online coal analyser Replacement of creep damaged pipework Conduct air heater leakage tests and raise defects for repair of air ingress
Boiler
Optimise air/fuel ratio in the mills Turbine cycle
Maintain turbine condenser backpressure to the designed value Re-tube boiler feed pump and turbine condensers Implement energy efficient lighting project
Electrical
Condensate extraction pump variable speed driver retrofit Switch off conveyor belts that are not coaling
Table 1. Proposed Energy efficiency activities Descriptions
Reporting Period
YTD
ITD
Weekday evening peak average demand impact (MW)
11.581
0.935
11.581
Energy consumption impact (MWh)
5107.033
5107.033
5107.033
Coal consumption impact (kton)
4.113
4.113
4.113
Table 2. Summary of the energy consumption and average demand impact Weekday (MW) Morning Off-peak
Morning Standard
Morning Peak
Midday Standard
Evening Peak
Evening Off-peak
Baseline
366.038
443.426
490.572
502.997
507.399
506.051
471.217
Actual
374.621
456.313
485.589
492.151
495.818
488.853
433.550
Impact
-8.582
-12.887
4.983
10.847
11.581
17.198
Saturday (MW) Morning Off-peak
Morning Standard
Midday Off-peak
37.667 Sunday (MW)
Evening Standard
Evening Off-peak
Evening Off-peak
Baseline
377.094
496.344
502.329
507.399
488.634
462.695
Actual
386.291
488.998
491.497
495.818
461.201
455.602
Impact
-9.197
7.346
10.832
11.581
27.433
7.093
Table 3. Weekday and weekend demand savings
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Evening Standard
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Figure 1. The average sent-out demand profiles (MW)
Figure 2. The average coal profiles (ton/hour) Descriptions
Reporting Period
YTD
ITD
Weekday evening peak average demand impact (MW)
5.067
0.409
5.067
Energy consumption impact (MWh)
2237.216
2237.216
2237.216
Coal consumption impact (kton)
1.487
1.487
1.487
Table 4. Summary of the energy consumption and average demand impact
Figure 3. The average internal demand profiles (MW)
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Figure 4. The average coal profiles (ton/hour) Weekday (MW) Morning Off-peak Baseline
22.854
Morning Standard 27.838
Morning Peak 29.624
Midday Standard 30.024
Evening Peak 30.248
Evening Standard 29.823
Evening Off-peak 26.449
Actual
23.370
24.330
25.173
25.218
25.181
25.280
24.881
Impact
-0.516
3.508
4.451
4.807
5.067
4.543
1.568
Saturday (MW) Morning Off-peak
Morning Standard
Sunday (MW)
Midday Off-peak
Evening Standard
Evening Off-peak
Evening Off-peak
Baseline
23.566
29.832
29.985
30.248
28.136
27.795
Actual
23.507
25.254
25.165
25.181
25.080
24.687
Impact
0.059
4.578
4.819
5.067
3.056
3.107
Table 5. Weekday and weekend demand savings
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Anton Allner, industrial lubricants strategy executive for Engen
Manny Faria, divisional manager power generation at LH Marthinusen
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Jeremy Kirsch, executive director of Clyde Bergemann Africa
September 2015
Robert Melaia and Richard Botton of Marthinusen + Coutts
Bhushan Deshmukh and Rashid Shaikh of Steam Equipment
Leon Baidjurak, Kudzai Nyangoni and Geoffrey Chingwaru of Howden
Steven Lumley and Daan Burger of Wearcheck at Powergen Africa
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MAN ITEMS Y BE OFF CAN ER FROM ED STOCK
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MULTI_ALLOYS_MECHANICAL_ENG_130x1 1
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September 2015
Hydrogen fuel cell technology initiative partners with the Minister of Science and Technology, L-R: Andrew Hinkly, Executive Head Marketing of Anglo American Platinum; Mike Hellyar, Managing Director, Air Products South Africa and Minister of Science and Technology, Naledi Pandor.
Johnny Canada, technical service manager, Vert Energy, is rewinding an exciter stator, below deck on a vessel in situ, while the vessel is fully operational
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Voith Turbo's Vice President of the Power, Oil & Gas Division Derain Pillay
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Unkown
942
Other
43
Cutting And Welding
215
Electric
644
Friction
80
Spontaneous Combustion
18
Smoking
78
Explosives
301
Suspected Arson
211
Vehicles/Diesel
53
Flammables Gas
50
Table 1. Principal causes of fires
Table 2. Annual fire incidents
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Figure 1. Conveyor fire at Duva Power Station
Figure 2. Damage to conveyor belt structure after Duva Power Station fire
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Table 3. Example of a conveyor belt risk assessment tool
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Figure 3. Reversal of ventilation method
Figure 4. Air locks should have two doors opening in the normal direction and at least one opening in the opposite direction
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Requirement
Class1
Class 2
Class 3
Low Risk
Med risk
High risk
< 12
13-20
21-25
12.1
2 x 9 kg DCP fire extinguishers placed between 5 and 15 m Yes from all pulley clusters
Yes
Yes
12.2
25 mm x 30 m hose reels to be positioned every 30 m along HR the full length of the belt. The minimum dedicated pipe diameter feeding the reels is to be 50 mm and minimum nozzle pressure to be 300 kPa.
HR
HR
12.3
65 mm fire hydrants within 85 m from all points of the con- Yes veyor structure. Hose boxes with 2 x 65 mm x 30 m hoses plus one 45 mm x 30 m hose with nozzles to be placed at each hydrant.
Yes
Yes
12.4
Anti-slip detection to stop the belt if the speed reduces by 20% HR
Yes
Yes
12.5
Automatic suppression system compliant to the requirements No or NFPA 16. The suppression system is to cover the drive pulley; the head and tail pulley; the take-up tension pulley and the last low tension bend pulley; the top and bottom belt surfaces around these pulleys to minimum of NFPA 15 – 7.2.3 + 1m outside these areas. Any machine or tank containing hydrocarbons in the vicinity of the belt must be installed to trip the belt in the event of any suppression head activating.
HR
Yes
12.6
Direct contact temperature probes must be fitted to all pulley No bearings. If a temperature of 68 degrees is detected, an alarm shall sound and belt must be stopped
HR
Yes
12.7
Heat detection on all pulley clusters. It must sound an alarm No at 68 degrees and must stop the belt. If a temperature of 90 degrees Celcius is detected it must activate the suppression system.
HR
Yes
12.8
Optical IR3 flame detection on the main drive pulley clusters No
HR
Yes
Yes = Mandatory required
No = Not required
HR = Highly recommended
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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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Skills on Site September 2015
Septmeber 2012
1
Figure 5. By-pass water connection to test fire suppression sprays
Table 5. Airborne pollutant limits
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Figure 6. Typical ventilation layout for a mechanised mine
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Figure 7. This sensor is used to monitor the bearing temperature
Figure 8. Schematic of fire hydrant placement
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HVAC
Green is a Business Decision Green has moved on from feel good and do good, to smart business. Taking care of the environment was always a good thing to do but did it bring business benefits or was it just an expensive investment? According to Scott Meikle, managing director South Africa at AHI-Carrier, “Sustainability may once have been a buzzword, but now it’s a business imperative.” He chats to “SA Mechanical Engineer” about some of the latest trends and happenings in the HVAC space, and AHI-Carrier’s appointment as official Toshiba distributor. “We have seen major developments on the sustainability front,” says Scott. “This is evidenced by, if nothing else, the introduction of the Green Building Council (GBC), and the rapid increase in the number of buildings green star rated. And it’s not just about office blocks. “In the Sistine Chapel, the HVAC system was recently replaced by a major intelligent building project which doubled the efficiency and tripled the cooling capacity.”
The ability to integrate video systems that are able to count the number of people entering the Sistine Chapel allows for a more effective set air quality, temperature and humidity which not only saves the environment, but helps preserve classic artwork for future generations He notes that the ability to integrate video systems that are able to count the number of people entering the Sistine Chapel allows for a more effective set air quality, temperature and humidity which not
only saves the environment, but helps preserve classic artwork for future generations. Owner’s rental income is also preserved. Recent research carried out by the GBC, shows that green buildings bring higher rentals and make for better investments. “A high green star rating on a premises allows a developer to charge a premium rental rate which is a tangible benefit. Despite the higher initial price-tag, the payback periods are quicker for chiller systems,” Scott asserts.
Big consumers
Globally, buildings consume around 40% of the world’s energy, about 40% of which is taken up by HVAC systems. Enter an efficient chiller which can make all the difference. Carrier is an industry leader in the field of energy efficiency and their 23XRV is one of the world’s most efficient chillers. Between 2006 and 2011, Carrier reduced greenhouse gas emissions by 35%, they have three US Green Building Council certified factories under the
Scott Meikle
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HVAC
LEED rating system; and since 1994, they have led the industry in the phase-out of ozone-depleting refrigerants while introducing energy efficient heating, air-conditioning and refrigeration systems. Heat pumps too are energy friendly as the waste heat generated by the chillers is used to provide hot water into buildings, removing the need for hot water geysers, which typically use a lot of electricity.
It’s water too
Buildings and cooling systems are not just big users of electricity, they also use a lot of water. “Water shortages have been predicted, says Scott, which means air-cooled chillers are becoming much more relevant in South Africa. Water-cooled chillers do lead to a certain amount of water loss to the atmosphere, which air-cooled chillers avoid. In fact, in the five years between 2006 – 2011, on an absolute basis, Carrier’s water usage decreased by 27%,” Scott is proud to add.
need to be brought up to speed right now and into the future despite the acknowledged skills shortage in the country. While we remain focused on the here and now, businesses of the future must be forward thinkers. “Change is guaranteed and to move forward we must take a stance now and consciously act on it,” Scott concludes. AHI-Carrier Tel: (011) 878-6000 www.ahi-carriersa.co.za
Innovation in the industry is significant. The Carrier
Which means air-cooled chillers are becoming much more relevant in South Africa AquaForce 30XWchiller, for example, is up to 20% more efficient than its predecessors, and uses a non-ozone depleting refrigerant.
New market
As of August 2015, AHI-Carrier is the official Toshiba distributor in South Africa. Toshiba has leading products in the VRF (Variable Refrigerant Flow) category. For Carrier, traditionally a player in larger industries and buildings, this will open up the smaller and medium sized markets, as well as the residential sector. Early in 2016, Carrier will launch these new products. “The Toshiba range is a very exciting introduction and means that we can now provide for all air-conditioning needs in South Africa and neighbouring countries.” This new refrigeration technology is different from the technology used in old systems. Scott likens it to comparing between a car with an old engine and one with a modern, green-friendly engine. They are totally different systems which means technicians THE SOUTH AFRICAN MECHANICAL ENGINEER
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MARKET FORUM
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MARKET FORUM
Darryl Campbell
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Tap into DRC’s $24 trillion mineral reserves This is your chance to network with government and key decision-makers in DRC’s profitable mining industry. BOOK YOUR SPACE NOW!
15 - 16 October 2015
DRC MINING & INFRASTRUCTURE INDABA
15 October: DRC Mining Industry Awards
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KINSHASA - DRC
Don’t miss out on the latest technologies and innovations on DRC’s copperbelt. BOOK YOUR SPACE NOW!
20 - 21 October 2015
KATANGA MINING WEEK
Power Focus Day: 19 October 2015 Golf Day & Sites visits: 22 October 2015
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SAMHYDRAULIK, which is one of the leaders in the field of hydraulic transmission, has been operating for over 25 years in the international market, offering a complete range of orbital hydraulic motors and power steering units, axial pumps and motors for medium and high pressure ranges, all characterised by excellent performances. SAMHYDRAULIK employs 120 people who operate inside a very modern and efficient plant that spans over 6 000 square metres to assure a high standard and flexible production capacity. The latest computer technology is used for both design and production, combined with strict quality control procedures during all production phases, which translates into innovative, reliable and functional products that meet the various needs of the market. Its ISO 9001 certification, held since 1994, is the result of a qualityorientated philosophy on which SAMHYDRAULIK has always based its operation.
A H 14
AXIOM HYDRAULICS (PTY) LTD Tel: (011) 334-3068 / 334-3086 Fax: (011) 334-4543 E-mail: axiomjhb@mweb.co.za
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