Page 1

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

1


DMU 50 ECOLINE

New look, even better performance

Excellent 5-sided machining and more affordable than ever

The ECOLINE from DMG / MORI SEIKI is being seen in a new light and is taking the tried and true ECOLINE Series into a new dimension. The new DMU 50 ECOLINE boasts the usual high-quality standards with an even greater performance and a simpler and more reliable design at an unbeatable price.

Standard Features

>> Efficient 5-sided machining of easy and complex work pieces in one setup >> Highest precision - NC swivel rotary table with digital drives >> Powerful milling spindle: Standard 8000 rpm / 83 Nm [40 % DC] / 13 kW (option 10 000 rpm) >> Tool changer with 16 (30) pockets in the pick-up magazine >> Direct path measuring system X / Y / Z (optional) and a centrally lubricated roller guide for consistent precision >> Control: DMG SLIMline® with SIEMENS 840D solutionline with ShopMill

Productivity, reliability and quality Contact Franz, Anthony or Michael at:

Tel: 011 976-8600 • Fax: 011 394-2471

Retecon (Pty) Ltd

2

Cape Town: 021 MECHANICAL 555-2270/1ENGINEER • Port Elizabeth THE SOUTH AFRICAN VOL 62 041 April453-2720 2012

• Durban: 031 701-8149


AN ENGINEER’S VIEW

Feedback on Candidate Phase Training Chris Reay

Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)

As most members will have read about in recent communications, SAIMechE is represented on the ECSA Strategy Committee working group (WG1) that is formulating the curriculum structure for the revised process of undertaking the candidate phase training period for purposes of registration as Professional Engineer. The new structure will first be developed for the Pr Eng level and then followed by those for Professional Technologist, Professional Technician and Professional Certificated Engineer.

T

he WG1 is comprised of representatives from ECSA and all the ECSA approved Voluntary Engineering Associations (VAs). The spirit of cooperation between the parties is very positive, and it is encouraging to witness this collective focus which perhaps illustrates the concern that all the VAs have over the serious shortage of skilled and experienced engineering resources in the South African economy. The most recent deliberations conclude that the country has one fifth of the engineering capacity that is required to meet the intended projects and operational requirements to start to move us into acquiring developed country status.

Do the best with the graduates from the tertiary institutions as quickly as possible now This snapshot, of course, does not reflect all the issues along the whole supply chain in meeting the desired outcome of professional status of our engineering resources. This starts with the concern on the dismal performance of the schooling system in maths and science subjects where our education authorities’ pre-disposition to the lowest common denominator standards acknowledges pass rates of 30% as acceptable. So what are the quick wins in this challenge? We need to do the best with the graduates from the tertiary institutions as quickly as possible now, while measures to beef up the capacity of the supply chain elsewhere are undertaken by “others”. The focus is then on providing the Candidate Engineer with the best training and development methods and facilities during the first period after graduating. ECSA has developed the new exit level outcomes-based competency standards which can be viewed on their website. These then form the first requirements in constructing the full training programme, and will be

followed by specific guidelines for each discipline and aligning the generic structure of these with the requirements of the QCTO. The aim of the latter is to enable ECSA to have the resulting curricula registered as qualifications with SAQA so that the employers of the graduates undertaking the candidate phase programme will be able to claim the relevant funds from their SETAs to assist with the costs of the programme development, the cost of remunerated Mentors and a contribution to the trainee’s stipend.

Your participation

The VAs will be authorised by ECSA to oversee and mentor the programmes such that the trainee undertakes the planned activities and records the outcomes in a portfolio of evidence that forms the submission for registration. The purpose behind this article is to invite members to log in to the SAIMechE website Candidate Phase Training Group to make suggestions and give feedback on their current and past experiences during their candidate phase training so that these can be reviewed and incorporated into the new programme. Such issues as mentoring, the type and frequency, the facilities that were needed but not available at the employer, the standards of supervision, the opportunities to be exposed to essential activities, the role observation and participation play in the process are all relevant to this venture. Please assist us in this exercise. The identification of engineering work legislation we expect to be promulgated by the start of next year. Hope runs eternal.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

3


WALTER & SPECTRA – PARTNERS IN PROVIDING CUTTING EDGE TOOLING TECHNOLOGY.

We’re driven to find out what our customers want and committed to make it happen. We concentrate on the applications and what they need to do. We help engineer the engineering. Spectra Carbide Tooling Technology (PTY) Ltd. 24 Desmond Street, Korsten, Port Elizabeth PO Box 2631, North End, 6056 Tel: 0860 23 23 23 Fax: 0860 33 22 33 spectra@spectra-sa.co.za www.spectra-sa.co.za

4

THE SOUTH AFRICAN MECHANICAL ENGINEER

To us, perfection is practical. It’s the most productive and efficient way to achieve results, and the only way to turn vision into reality.

www.walter-tools.com VOL 62

April 2012


April 2012  VOLUME 62  NUMBER 4

Contents

On the cover: A project of IMechE and SAIMechE www.imeche.org www.saimeche.org.za

Memorabilia

CESA

8 To the Rescue

33 Unquestionably Ethical

Monthly Column

HVAC

9 Prominent Professionals

34 Specialised Engineering 37 Fast-track Project

Pipes, Pumps & Valves 11 Curious and Exciting Experiences 15 Joint Initiative 17 Soapbox 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.

36 Nonsensical

Regulars

Opinion Copyright

Letter to the Editor

Materials & Machine Tools

3 An Engineer’s View 6 Institution News 38 Market Forum

18 Serving Market Needs

POWER GENERATION TODAY 21 Your Own Personal Power Plant 25 Power Generation News

Computers in Engineering 29 Going Global? Check Your ERP System First 31 Closing the Gap

The monthly circulation is 4 242

Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123, Republic of South Africa Tel: (011) 781-1401, Fax: (011) 781-1403 Email: samecheng@promech.co.za, www.promech.co.za Managing Editor Susan Custers Editor Kowie Hamman Circulation Catherine Macdiva Advertising Mark Bennett DTP Zinobia Docrat/Donovan Vadivalu Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R405,00 (incl postage and VAT) per year; R1 020,00 per year for Africa/ Overseas. Disclaimer

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

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

Official Publication of THE SA INSTITUTION OF MECHANICAL ENGINEERING and endorsed by:

 CORROSION INSTITUTE OF SA  SA PUMP MANUFACTURERS ASSOCIATION  SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION  THE SA INSTITUTE OF TRIBOLOGY  NUCLEAR INSTITUTE  SA INSTITUTE FOR NON-DESTRUCTIVE TESTING  NATIONAL SOCIETY OF BLACK ENGINEERS  INSTITUTE FOR CERTIFICATED MECHANICAL AND ELECTRICAL ENGINEERS  SOUTH AFRICAN ASSOCIATION OF CONSULTING ENGINEERS  ASSOCIATION OF SOCIETIES FOR OCCUPATIONAL SAFETY AND HEALTH

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

5


THE SA INSTITUTION OF MECHANICAL ENGINEERING

Council 2011/2012 Office Bearers

President .................................................. G Barbic (George) Vice President .............................................. D Findeis (Dirk) National Treasurer ............................... KK Nyangoni (Kudzai)

Branch Chairpersons

Central ...................................................... M Cramer (Mike) Eastern Cape ................................................ W Rall (William) KwaZulu/Natal ................................................. J Moto (John) Mpumalanga Highveld.............................. L Odendaal (Louis) Western Cape ........................................... Dr D Blaine (Debbie)

Portfolios:

Communications/Strategic Planning/ Specialist Group..................................................CD Reay (Chris) Young Engineers Forum................Prof B Collier-Reed (Brandon) Education: Universities of Technology............... E Zawilska (Ewa) Membership .................................................... E Zawilska (Ewa) Professional Development Programme..........M Black (Malcolm) Technology Programme ................................. SZ Hrabar (Steve) To be confirmed....................................................A Roos (Andre) To be confirmed.........................................G Bartholomew (Bart)

Annual Dinner The SAIMechE Western Cape Regional Branch Dinner was held on 15 March 2012. The 80 attendees were treated to some fine food and wine, but the highlight of the evening was the presentation by the guest speaker, Richard Palmer from WSP – Green by Design. During his talk on sustainable cities, from the perspective of planetary boundaries, resilient city infrastructure and resource efficient buildings, he highlighted the importance of incorporating natural resources in modern day design to ensure a sustainable future.

Chief Executive Officer: Vaughan Rimbault 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: Central, Eastern Cape, Mpumalanga & KZN: membership@saimeche.org.za Membership: Western Cape: saimeche.wc@vodamail.co.za

Company Affiliates

Osborn Engineered Products SA

Alstom Power Service SA

Rotek Engineering

Babcock Africa Limited

RSD a division of DCD-Dorbyl

Bateman Engineered Technologies

S.A.M.E Water

Bosch Projects

Sasol Technologies

Fluor SA

SEW Eurodrive

GEA Air-cooled Systems

Siemens

Hansen Transmissions SA

SNC-Lavalin SA

Hatch Africa

Spicer Axle SA

Howden Power

Spirax Sarco SA

Howden Projects

Thyssenkrupp Engineering

Industrial Water Cooling

Transvaal Pressed Nuts & Bolts

THE SOUTH AFRICAN MECHANICAL ENGINEER

Richard emphasised that Africa has the potential to become a world leader in Green Design since urbanisation in Africa is in its infancy, thereby giving engineers the freedom to design and build infrastructure that has a minimal effect on our natural resources.

“SAIMechE's Exhibitor Soapbox at Electra Mining

MBE Minerals (SA) (Pty) Ltd Ultra-Flow Engineering Services (previously KHD Humboldt Vital Engineering Wedag SA) Weir Minerals Africa Megchem Eng & Drafting Services Winder Controls

6

Richard Palmer presenting his talk on Green Design in the context of sustainable cities

VOL 62

This year SAIMechE will host an Exhibitor Soapbox in parallel with the Electra Mining 2012 exhibition. As the name implies, the Exhibitor Soapbox will give the exhibitors a 30-minute opportunity to present their products and services to a captive audience in a separate presentation room, with absolutely no restriction on either the format or the content of the presentation. Just like at Speaker's Corner in London, the audience will be free to come and go as they like (unlike at Speaker's Corner we will not allow heckling!). Freed from any constraints, we April 2012


THE SA INSTITUTION OF MECHANICAL ENGINEERING

hope to see exhibitors bringing their top marketing games to the presentations. SAIMechE will chair each session to ensure strict time-keeping, and a programme of the presentations will be made available well before the exhibition. Visitors will be able to plan their visit to Electra Mining to coincide with presentations they would most like to attend. Attendance at the Exhibitor Soapbox will be free to all Electra Mining visitors. So make sure to visit the show and join us for the Exhibitor Soapbox. More details will be made available soon.

About Electra Mining: Ranked as the second largest mining show in the world and with global recognition for its broad reach across mining, construction, industrial and power generation industry sectors, Electra Mining Africa once again proves its status as a world-class event attracting high numbers of quality exhibitors and visitors, both benefiting from the platform created to showcase the latest in products, services, technologies and trends. Visit www.electramining.co.za for more info.

Electra Mining 10-14 September 2012, Expo Centre, Nasrec, Johannesburg

Triumphant delegates demonstrating their collaborative skills at a recent interactive workshop on “Leadership & Management Principles and Practice�. Such workshops are particularly suited to In-House environments where colleagues are able to learn and work together as a cohesive unit

Forthcoming SAIMechE Training Events Event fee : R2,920.00 per person per day (excl.VAT). SAIMechE Members in good standing may claim a 20% discount on their event fee. An early payment discount of 5% of invoice value may be claimed for event payments received no less than 7 calendar days before the event start date. A registration form and full terms and conditions may b e obtained from Carey Evans on E-mail carey@saimeche.org.za or Tel. 031-764-7136. Also, detailed individual event programmes are available from Carey. For information on In-House events, as well as event planning, kindly contact Linda Robinson on linda@saimeche.org.za or Tel: 031 764 7136. Code

Abbreviated Title

Date - Start

Date - End

Region

C2212

Lean Manufacturing Workshop

1 May 12

3 May 12

Cape Town

F6112

Leadership and Management Principles & Practice Workshop

2 May 12

3 May 12

Secunda

A2412

Predictive & Preventive Maintenance Best Practice Workshop

8 May 12

8 May 12

Durban

F2412

Predictive & Preventive Maintenance Best Practice Workshop

15 May 12

15 May 12

Secunda

C6112

Leadership and Management Principles & Practice Workshop

23 May 12

24 May 12

Cape Town

B2212

Lean Manufacturing Workshop

29 May 12

31 May 12

Port Elizabeth

C2412

Predictive & Preventive Maintenance Best Practice Workshop

5 Jun 12

5 Jun 12

Cape Town

B2412

Predictive & Preventive Maintenance Best Practice Workshop

12 Jun 12

12 Jun 12

Port Elizabeth

E2512

Effective Management Roles Workshop

13 Jun 12

12 Jun 12

East Rand

K2412

Predictive & Preventive Maintenance Best Practice Workshop

19 Jun 12

19 Jun 12

Bloemfontein

E2412

Predictive & Preventive Maintenance Best Practice Workshop

21 Jun 12

21 Jun 12

East Rand

A2512

Effective Management Roles Workshop

4 Jul 12

4 Jul 12

Durban

B2512

Effective Management Roles Workshop

1 Aug 2012

1 Aug 2012

Port Elizabeth

F2512

Effective Management Roles Workshop

15 Aug 2012

15 Aug 2012 Secunda

C2512

Effective Management Roles Workshop

12 Sep 2012 12 Sep 2012

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

Cape Town

April 2012

7


MEMORABILIA

To the Rescue When the retired Defence Force members of the GEM Village in Irene, Tshwane, were donated a 25-pounder field gun to display on their premises, they had it restored and then built a “platform of honour” for the commemorative piece of warfare equipment. But moving the 6.5-ton, G2-gun from its temporary stand to its permanent home proved an almost impossible challenge.

T

hat is until retired Captain D r i e s Rabie (74), a resident of GEM Village, called in Retired Defence Force Captain Dries Rabie congratulates the help of MerFrancois Pieterse (left) and Ferdi de Beer (right) on a cedes-Benz Comjob well done mercial Vehicles Centurion. Always ready to face up to a challenge, Unimog sales executive Francois Pieterse enlisted the help of Ferdi de Beer, Technical Specialist at Mercedes-Benz South Africa, and the Unimog was called into play. The operation of moving the solid piece of steel to

8

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

its final resting place got off to a shaky start when the team realised that the Unimog’s tow pin was mounted way higher on the vehicle than the gun’s coupling could reach and some heavy-duty jacks had to be found, as it was an impossible task to lift by hand. Displaying some major driving skill, Ferdi reversed the Unimog within millimetres of the coupling and the gun was hooked! Driving at snail’s pace in order to manoeuvre the Unimog and its valuable cargo around some tight corners, Ferdi’s real challenge was to position the gun on a metre-high raised platform in an extremely confined space. Shirle Greig, Tel: (012) 677-1904, Email: shirle.greig@daimler.com

April 2012


MONTHLY COLUMN

Prominent Professionals rand Aquarius project which we completed on time with an immaculate safety record. The second one was the Matotolo project which, in terms of the timeline, was a gruelling project which we completed on time, within the budget and had no safety issues whatsoever.

Projects Most challenging

Phildy Scholtz, Projects Director, DRA Mineral Projects

Academic

Any project is a challenge, but it is important not to give up. You have to remain positive throughout a project in order to make it a success. Sometimes you have to cope with external factors such as volatile labour issues. On other projects you have to cope with weather conditions such as unexpected torrential rain causing flooding which hampers construction and holds work up for days on end.

Most rewarding

School

To face challenges like this and still deliver on time within your budget can only be achieved through team work. Fortunately we have engineering teams who work like this which makes it a very rewarding exercise when you pull through to make it a success.

Swartkops High School in Centurion

Graduate studies University of Pretoria, Mechanical Engineering

Post-Graduate Honours degree in Mechanical Engineering; Project Management studies

Professional Bodies ECSA registered as professional engineer; registered project engineer with the Project Management Institute.

Career Path - First employer Iscor mining at Mooiplaas dolomite mine

Growth path Worked here through various departments; mechanical engineering then plant design and finally to the project management department. Then joined DRA as project engineer to eventually become project manager and then senior project manager

Present employer & position DRA – as project director responsible for the execution of projects in Africa

Achievements

Commentary Are there shortcomings in the Mechanical Engineering Industry in South Africa?

Engineering creates value and growth in an economy. Growth is only possible through capacity and we should address the scarcity of good engineers through training and awareness campaigns to attract young leaners to the industry.

How would you mend this? It is very important that the foundations of our educational system remain on a par with international standards. This is an area which South Africa has to develop much further by creating opportunities for everyone.

Message to young engineers My message is plain and simple. Byt Vas… don’t give up! Engineering isn’t easy and the going isn’t always smooth or without pain, but don’t give up, the dividends are well worth it.

Future

A project Of the various projects I’ve done so far, two stand out as specific achievements. The one was the multimillion

I’d like to see Africa develop to its full potential, like the East has done. We simply need to educate and develop our people so that they can benefit from these developments.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

9


Pumps ƒ Valves ƒ Systems

Knockout Unexpected Outages MDX pumps are designed to match the life cycle of your mills. At a major copper mine in Chile, GIW’s patented hydraulic design and advanced materials have almost tripled parts life. The result was a reduction in costs and increased production at the mine site. Got a hard rock slurry problem? GIW offers expert slurry pumping solutions around the globe. Minerals are everywhere. So is GIW. KSB Pumps and Valves (Pty) Ltd www.ksbpumps.co.za

A KSB Company

MDX 750 Pump

10

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012


PIPES, PUMPS & VALVES

Curious and Exciting Experiences “SA Mechanical Engineer” received this press release from Germany detailing some harrowing experiences of valve installation engineers — we wonder whether our readers have similar tales to tell? and dealers – and the valves themselves become unknown stars. Schroeder Valves can spin a tale or two. This manufacturer of pump protection valves, automatic recirculation valves, control valves and throttles has sales offices around the globe. “The products are nearly entirely special designs, which sometimes are as large as a room and weigh as much as an elephant,” explains Axel Mücher, CEO of Schroeder Valves. Not only are the valves special, but so are the different environments where they are installed. Schroeder Valves, for example, equips snow cannons in many skiing regions with its fittings. It can often happen that an employee has to work at over 3 000 metres altitude.

Two abominable snowmen

“There is one job we’ll certainly never forget,” Axel remembers. He travelled to the Austrian town of Tauplitz with a colleague to repair a defect bypass in a valve. The weather made certain the job would be unforgettable. They set off in a car fitted with snow chains, yet after driving halfway, the car couldn’t go any further. The customer arranged for a snow cat to bring them up to an altitude of 2 800 metres. Both thought that would be a spiffing idea - until they noticed the snow cat’s cab was already occupied by two other men. “We had no other choice than to sit on the bonnet,” says Axel.

V

Perching outside at minus 10°C, the snow cat drove them one and a half kilometres through a near snow storm to their assignment. On arrival, Axel and his colleague resembled abnominable snowmen. “And that’s exactly how we felt ourselves.” All is well that ends well – the bypass was repaired! alves control lots of things, whether in industrial plants and machines or in a private household. They fulfil their duties – for most of us – nearly invisibly. How-

The VAG mechanic stood there well prepared, but with his heart pounding while waiting for the helicopter ever, stories about valves do not have to be boring. Installing valves can often be extremely demanding for the technicians sent forth by manufacturers

Installing in the wild

But, things can get even more spectacular, as Frank Löffler tells it. A mechanic working for VAGArmaturen GmbH had to travel 18 000 kilometres to the wild outback of Tasmania. Far away from civilization, Frank had to struggle along a mountain, across rocky terrain and through bothersome vegetation to install a shut-off valve for a historical wooden water conduit at a dam. The conduit is a real historical beauty. Back in 1914, the Lyell Mining and Railway Company built a dam for a power station, right at the

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

11


PIPES, PUMPS & VALVES

foot of Lake Margret, near Queenstown and its 2 000 inhabitants. A three kilometre long water conduit was built to supply a mine with electricity and water. Nearly nine decades later the entire construction was shut down temporarily so the wooden conduit could be renovated, because its wood had become porous.

And thus the ball valves became news in Malaysia, amidst a flurry of flashbulbs Neither power nor crane

Frank Löffler wasn’t the only one who had to cope with the rocky path leading to the dam. VAG also had to come up with a way to transport the valve. Since there was no road, a truck was out of the question. A helicopter was the only solution. VAG disassembled the valve into its individual parts, because the 3.5 ton valve would have been too heavy for a helicopter. Body, valve disk and lift cylinder were to be transported to the dam in three flights. To add insult to injury, neither electricity nor a crane would be available, so exactly what tools,

12

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

hoisting and alignment gear would be needed for this job had to be determined in advance. The VAG mechanic stood there well prepared, but with his heart pounding while waiting for the helicopter. Due to bad weather, the flights were delayed several times. Finally, the shut-off valve was delivered. Frank now had to work quickly: the body had to be put into position on top of the new plateau anchored in the rock, the extremely heavy valve had to be aligned and the axle bearings installed. Finally, Frank was able to install the hydraulic lift cylinder. It was precision work under the most difficult of circumstances, yet the experienced VAG-employee managed it all without skipping a beat. “That was an assignment with an adventure as a bonus,” said the mechanic enthusiastically. “I felt just like Indiana Jones!”

A flurry of flashbulbs

Sometimes there is enough excitement for a valve to hit the news. This was the case for large-diameter ball valves made by Schuck Armaturen. After receiv-

April 2012


PIPES, PUMPS & VALVES

ing an express order, the company had to deliver ball valves weighing several tons by plane for the first time to Malaysia. A subsidiary of Petronas, the Malaysian oil and gas giant, had ordered ball valves with a diameter of up to 36” for the world’s largest liquid natural gas terminal. The valves had to be able to withstand 118 bars of pressure. Because the delivery period was rather short, a plane had to pick up the bodies in India where they were cast. Despite their weight of 19.5 tons, the valves were flown as air freight from Frankfurt to Malaysia after they had been assembled. Then it was time for the big show – for the first time ever, a Boeing 747 landed at the small airport of Bintulu in the state of Sarawak, a town with a population of 50 000. Reporters and television crews flocked to the event and thus the ball valves became news in Malaysia, amidst a flurry of flashbulbs …

The world is not enough

In different cases however, the world is not enough for some fittings. Space can be a nice place, too. Stöhr rocketed 56 specially-made valves with nominal diameters ranging from DN 15 to DN 200 into space when they were built into South Korean carrier rocket Naro 1. The valves ensure the rocket is fuelled with liquid gases before lift-off and are an utterly vital part of the 30 metre tall and 141 ton heavy rocket with a diameter of 3.90 metres. The parts have to function absolutely precisely, as they ensure the highly complex fuelling process works without any problem whatsoever. Liquid gases, such as liquid oxygen with a temperature of -196°C, have to flow into their tanks in a matter of seconds. Due to security reasons, fuelling on the Naro Space Centre’s launch pad can only take place as part of the take-off process. Thanks to Stöhr, everything went smoothly. In the end, the space mission was not entirely a success, as the satellite was destroyed. An independent commission declared it was due to the nose cone – parts of it were not released as planned. The rocket didn’t make it into orbit.

Insurgents attack

Valves aren’t the only ones living dangerous lives, mechanics can also be exposed to serious dangers. Two employees working for Schroeder Valves found themselves ambushed in India while travelling by train from Calcutta to a steel plant in Raigarh, where they were supposed to give technical support. The journey was originally expected to last 16 hours. After around halfway, the train passed through the Bhalulata station in the state of Orissa. “We were suddenly wakened by a detonation and deafening noise,” one of the two Schroeder employees remembers. Chaos suddenly broke out. “People ran confused, panicking and shouting. We saw smoke rise.” 50 Maoist rebels had blown up the tracks - as well as parts of the train station – and taken

railroad staff as hostages. “Luckily, things went well for us,” says one of the men from Schroeder. Nonetheless, it was far from a pleasant experience. Due to the attack, the train and both Germans were stuck fast in the middle of the jungle for an entire day. For the first few hours, the mechanics were able to jump out of the train onto the ground to pass the time. Three hours later however, the army, surrounded the train and ordered the passengers to stay indoors for their safety. Food and water was also a big problem – what was served looked and smelled inedible, the mechanics didn’t touch any of it. …

Jump out of the train onto the ground to pass the time In the end, the train travelled backwards to the closest station, where the engineers had to return to Calcutta. The customer had to be helped by email and spare parts delivery. So don’t say installation work is a boring affair … Petra Hartmann-Bresgen, Kathrin Kleophas Tel: 0049 211 4560 541/-544 Hartmannp@messe-duesseldorf.de

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

13


Competence in Heat Transfer Suppliers of a wide range of heat exchangers GEA Ecoflex

Cut the cost of corrosion!

Need high resistance to pitting and crevice corrosion – but not the expense of titanium? SWEP's Mosteel line may be the answer. Also excellent resistance to chloride stress corrosion cracking. And our state-of-the-art brazing technology eliminates the risk of intergranular corrosion. Mo-steel heat exchangers cut worries and costs in pulp and paper industries using corrosive, chloride-rich fluids. The pit resistance of SWEP's Mo-steel CBEs can be a significant economic factor in oil coolers in various industries (sugar, plastics etc). Even a corrosive, polluted water supply can be used in our Mo-steel exchangers.

GEA Refrigeration Technologies

GEA Grasso (Africa) (Pty) Ltd

19 Chain Avenue, Montague Gardens, 7441, PO Box 36815, Chempet, 7442, South Africa Tel. + 27 21 551 4034, Fax + 27 21 551 4035

14

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

www.grasso.co.za


PIPES, PUMPS & VALVES

Joint Initiative A groundbreaking internal restraint joint for PVC piping, manufactured in the USA, differs from traditional splinelocked internal restraint systems, as it comes fitted with a steel support ring, as well as serrated grip-ring and a rubber seal integrally formed into the pipe socket – in order to maintain the economic effectiveness of socket and spigot-type joints. The product, which is fitted to 110 mm, 160 mm and 200 mm PVC pressure pipes, conforms to internationally-recognised American Society for Testing and Materials (ASTM) F1674 specifications that incorporates a 1-million pressure-cycle test, and also carries the SABS approval when used in pipe systems carrying the SANS 966 and SANS 791 marks of approval. We speak to product manager Renier Snyman. “The Durolok internal restraint joint is ideally-suited to the local horizontal directional and trenchless drilling market, where it can serve as a cost-effective replacement for the industry-standard range of buttwelded High Density Polyethylene (HDPE) piping.

No time will be lost waiting for the butt welds to cool down, as is the case for HDPE pipe No time lost

Renier Snyman, DPI Plastics

T

he Durolok has been introduced to the South African market by DPI Plastics, manufacturers of water reticulation, drainage and pipefitting systems.

“PVC pipe fitted with the Durolok restraint joint has many advantages over HDPE pipe in trenchless applications. In terms of flow characteristics, the thinner walls of PVC pipe allow greater delivery of water for a similar size of HDPE pipe,” he explains. “Durolok’s state-of-the-art cartridge installation means that PVC pipes do not have to be strung out and pre-jointed into continuous strings for installation. Each length may be jointed in a short access pit, as required during the ‘pull’, with no need for specialised jointing tools. What’s more, no time will be lost waiting for the butt welds to cool down, as is the case for HDPE pipe.” When compared with external restraint joints, Renier points out that Durolok technology keeps corrosion to a minimum, owing to the fact that the restraint components are fully resin-coated and fitted internally in the pipe socket and; therefore, do not come into contact with the fluids being transported in the pipe or the surrounding soil.

Changing mindsets

He adds, “The easy installation process means that contractors save both time and labour, as no additional tools are required to fit and tighten the restraint device. The internal restraint system eliminates the need for trained operators to fit the restraint device, and cuts out the inherent risk of human error, which include over-tightening of clamps and tie bars. THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

15


PIPES, PUMPS & VALVES

confident that with all the pipe rehabilitation work currently being undertaken in South Africa, it will be seen as a viable and cost-effective solution for the civil industry”. Another innovative product being introduced to the South African market by DPI Plastics is the patented Ultralok PVC-M coupling for the jointing of plainended pipes, developed in-house. The first-of-itskind product, which is designed for applications of up to 16 bar pressure, is being aimed at both the civil and mining industries.

It will be a challenge changing the mindset of local contractors and engineers Bright future

But he admits that it will be a challenge changing the mindset of local contractors and engineers; however, he is confident that Durolok will make a successful entry into the South African market. “The product has enjoyed global success, and I am

“The Ultralok PVC-M coupling and components are fully-protected against corrosion. What’s more, the design mechanism of Ultralok is different from any other product on the market in terms of its robustness and gripping nature. The clamping mechanism is unique because it is manufactured from high-impact PVC, and comes with a unique pressure-enhancing rubber seal,” explains Renier. “As the pressure increases, the design of the seal facilitates a distributed type of load on the seal; thereby, alleviating the load on the body of the coupling.” He notes that the company currently has a 105 mm prototype - specifically-designed for the mining industry. The product meets numerous high-pressure requirements, and has successfully met the following test criteria for SANS 1283 Specification: - one hour test at 54,50 bar - the ten-hour test at 50,60 bar - the one hundred hour test at 45,50 bar - the one thousand hour test at 16 bar x

600C water temp

- the pipe/joint deflection test “We are confident that Ultralok will have a bright future in South Africa and we are looking at expanding into the polyethylene market too,” explains Behrendt. “The design concept of this coupling will facilitate itself for additional markets that will include civil, industrial and agricultural applications,” he adds. DPI Plastics (Pty) Ltd, Tel: (011) 345-5600, Fax: (011) 345-5780, www.dpiplastics.co.za

Engineer Placements Professional opportunities

Our job board continues to display a wide variety of excellent job positions that you can review and apply for on- line. Keep your credentials on our secure and confidential database, update them at any time. We keep in touch with you. www.engineerplacements.com

16

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012


OPINION

Soapbox On his rounds, Kowie Hamman, our Editor, is conducting an informal survey on the lighter side of engineering. We follow up from last month with two pertinent questions.

Describe your first day at work? Brian Volk of PHC Projects - Interesting, because the company that I had joined as a Student Engineer was an abattoir and everybody was keen to see how I would handle lunch which was steak, egg and chips.

Phildy Schlotz of DRA - I arrived at a mine as trainee engineer mmm uhhh it was a very novel experience and I was very excited.., but it wasn’t all new to me because I had worked on a mine during the holidays – the fact that it was a very small mine and that I was the only trainee engineer made it better – all in all it was a very good year for me…

Tom Esterhuizen of Tom Esterhuizen & Associates - it was at the department of water affairs and not a very inspiring day because I had to do mundane clerical work.

What do you think of computers and the digital world? Brian Volk of PHC Projects - Being BC(before computers) I find that computers have many uses and advantages, however they have also brought many additional complexities and problems. I find it difficult to cope with the constant change and new features, particularly as I probably never fully understood some of the technology or features in the first place. Although it is a fact that we would find it very difficult to operate without them these days, they are having several negative effects on the ways we do things. Nobody can think without a calculator or computer these days, nobody does mental arithmetic. Computers and the digital world are creating huge waste because of printing every document and information overload.

Phildy Schlotz of DRA - … it plays a major role in our daily work…

Tom Esterhuizen of Tom Esterhuizen & Associates - they are indispensable… Thalefang Mtombeni of Schaeffler - My first job was here with Schaeffler where I now work. It was a very exciting day when I started working here straight after training. I had heard that the job entails a lot of travelling and that’s what attracted me to this company in the first place.

Thalefang Mtombeni of Schaeffler - It is huge in our business, indispensible. I can communicate with collegues anywhere in the world to sort out problems or get advice… ten years ago this was impossible. The secret is to keep up with the latest technology constantly.

Izak van Niekerk of Bell Equipment - Lost, but excited! Izak van Niekerk of Bell Equipment - Can’t live without it – speed and efficiency means business! Konnie de Boom of Megchem – My first day was at the Technical Corp of the SADF in Pretoria. Konnie de Boom of Megchem – no comment. THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

17


MATERIALS & MACHINE TOOLS

Serving Market Needs What started as a lending institution serving the financial needs of the country’s machining shops has evolved to become on of the top machine tool suppliers in the country.

L

ibcor has long since stopped financing machine tool purchases preferring instead to pursue the “more noble” profession of importing and reselling machine tools to the exacting specifications of its customers.

In all instances the machines are sourced to offer the best quality at a reasonable price At the helm of the company is general manager, John Silburn, who is the second generation involved in the company and has a wealth of experience. He portrays a quite confidence of a man who intimately knows the ability of his team to meet the requirements of customers and potential customers. After all, the business has a track record in machine tool

18

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

and plastic moulding machinery that spans back more than a quarter of a century.

Big choice

Libcor derives its longevity from its ability to source and sell a diverse offering of machines to the metalworking and plastics industries. In all instances the machines are sourced to offer the best quality at a reasonable price. “We fulfil the requirements of the middle-end of the market who require solid high quality machines at a reasonable price. Our range does not include machines at the pinnacle of technology, but rather tried and tested products that are proven to be able to do the job right. “That doesn’t mean that we can’t or won’t source

April 2012


MATERIALS & MACHINE TOOLS

those machines from our suppliers should one of clients need one, but rather that we prefer to serve the mainstream market as best we can,” says John.

Full range

The company has long standing relationships with its suppliers including a 27-year relationship with its first supplier, Nan-Rong injection moulding machines. Other agencies include Romi CNC turning and milling machines, TMT CNC machines, Boschert punching & forming machines, Full Shine blow moulding machines and Chum-Power PET machines. The company also has a full range of standard machine tools, drills, mills, lathes and bandsaws from suppliers like Eumega & HDCNC Contour milling machines, ERLO Drilling machines, Mello grinding machines, Rong Fu bandsaws, Mascut, Baoji & Contour CY & CD lathes, as well as measuring equipment and digital readouts from Jenix.

Service centred

John explains that the company was built on the premise of service to the manufacturing industry and that the tradition continues to this day. “Our service begins with sourcing the right machine for the job and spans the supply, set-up and ensuring the correct operation of the machine. We also make sure that we carry all commonly-used spares, parts and accessories for our machines so customers can be assured of the least possible downtime in the event of a failure. “Most importantly our technicians are trained overseas at our suppliers training facility and are properly qualified to do the job. Our customers buy

Made the company a first stop for customers looking to buy good quality machines at a reasonable price more than a machine from us, they buy peace of mind knowing that they are getting the right machine at the best price, with service and back-up to match,” concludes John. Libcor, John Silburn, Tel: (011) 022-1811, Email: jsilburn@libcor.co.za, www.libcor.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

19


E

,

y, energy man c n e i ffc 01, tax incen age e tive me y 50 0 g r O s‌ n e t n IS

Do you just want to start saving energy anD money? Contact Energy Cybernetics OUR SERVICES Energy consulting Energy auditing Energy management tools Energy policies and strategies Energy training

OUR WORKFORCE 26 Engineers 8 CEMs 11 CMVPs 8 Technicians and technologists 4 Software developers

OUR CLIENTS Eskom, Anglo American, Sasol, Exxaro, CSIR, Vodacom, Avis, BMW, MTN, Netcare, SAB, Samancor, De Beers, PPC, Barloworld, World Bank, Old Mutual Properties, etc

(018) 297 5908 - (012) 369 9880 - info@energycybernetics.com - www.energycybernetics.com

20

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012


POWER GENERATION

PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: editorial@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial: Kowie Hamman, Eleanor Seggie Advertising: Mark Bennett Circulation: Catherine Macdiva DTP: Zinobia Docrat/ DonovanVadivalu Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.

Copyright

TICKER TAPE

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.

Your Own Personal Power Plant

Martin Viljoen, managing director of hudu

The world, and Africa in particular, has an abundance of sunlight, now all we have to do is harness it widely and effectively through improved and reliable technology. One of these technologies is photovoltaic (PV), a method of generating electrical power by converting solar radiation into direct current electricity using semiconductors that exhibit the photovoltaic effect.

P

hotovoltaic power generation employs solar panels composed of a number of cells containing a photovoltaic material. Driven by advances in technology and increases in manufacturing scale and sophistication, the cost of PV has declined steadily since the first solar cells were manufactured. Net metering and financial incentives, such as preferential feed-in tariffs for solar generated electricity, have supported solar PV installations in many countries. In South Africa, PV technology is here and is steadily being adopted as a cost effective means to supplement energy in domestic, commercial and industrial applications. A

Eskom started implementing a demand response aggregation pilot programme (DRAPP) in February, with the intention of securing 500 MW of buy-back contracts from as many as 1 000 industrial and commercial customers by the start of winter 2012.

Taking the first step in making a global imprint, Tata Power on Monday formed a joint venture with a South African mining company, Exxaro. The 50:50 joint venture will be called Cennergi (Pty) and will

hudu’s electrical engineer, Elmond Khoza

The walls are filled with actual working solar power controllers, inverters and battery banks

local company specialising in engineered solar power solutions is hudu, operating from headquarters in Paulshof just north of Rivonia. “SA Mechanical Engineer” speaks to managing director, Martin Viljoen, about local developments in this field.

look for electricity generating opportunities across South Africa, Botswana and Namibia.

South Africa plans to invest R2-billion to build an ethanol plant implemented by Sugar Beet RSA in collaboration with the government. The plant could start operating in 2014 and would initially produce about 90-million litres of fuel a year.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

21


POWER GENERATION

PV farm which will have over 2 000 solar panels installed to complement the energy supply of an entire retirement village in Pretoria.” The company specialises in the supply, design, installation and maintenance of custom-built, hybrid, on- and off-grid solar power plants for domestic, commercial, and industrial applications. Martin explains, “hudu was founded in 2005 through a passion for eco design. Our expertise in developing renewable energy solutions has allowed us to offer a clean and green energy lifestyle for many customers. We have a strong technical background with an engineering and design team as part of our group, ensuring a complete turnkey solution from design to implementation.”

Concept showroom

A small PV unit for housing where there is no electrcity at all being tested at

PV for Pretoria

“Our products are accredited by all the relevant industry bodies and designed to be incorporated into either existing or new architectural projects. Right now we’re in the process of finalising one of the biggest PV projects in South Africa, a solar

“The future of renewable energy lies in looking at the building as whole,” he warns

TICKER TAPE

“We deliberately decided to go with the concept showroom theme so that people who visit us can get the ‘look & feel’ of the products; they walk in and can actually see the products working,” Martin says. “I think ours is the first of its kind in South Africa and we intend putting one up in Cape Town and Durban in due course. “We had to get special permission from the owners of the building to install the system, but we’re not interfering with their power supply, we’re simply reducing our consumption from the grid significantly,” explains Martin. “Our intention with the South African commercial, industrial and high-end

hudu’s showroom in Rivonia

22

As we enter the premises, situated in a shopping centre, it immediately strikes us that hudu is serious about hudu’s facility getting people to understand solar energy systems. Their showroom has a modern arty feel about it, yet the walls are filled with actual working solar power controllers, inverters and battery banks supplying this working environment with all its energy requirements from PV panels installed on the roof of the building.

The construction of what is to become Africa’s biggest wind farm will start by June in an arid region of northern Kenya.

business, labour and government is constricting the development of an adequate exit strategy for SA’s dependence on coal-fired power

French utility EDF plans to bid for a contract to build nuclear reactors in South Africa in a possible Franco-Chinese partnership.

The Econometrix Karoo Shale Gas Report estimates that the commercial exploitation of shale gas resources will add hundreds of billions of rands in value to the economy and create hundreds of thousands of new jobs

World Wildlife Fund (WWF) South Africa states that the near-term interests of coal stakeholders within

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012


POWER GENERATION

domestic markets is mainly to feed solar-generated power into the building’s grid in order to reduce consumption from the main electricity supply and not to replace it altogether.

Supplementary

“The solar PV installation we did at the AECI building in Johannesburg is a typical example,” adds Martin. “The feed we put into the building’s grid is not independent of the main supply, it purely assists to reduce the electricity bill. This is called a hybrid system, typically also suitable for domestic installations, where we make use of solar power, but also draw on the grid when necessary. We can also make use of extra alternative energy sources such as wind power combined into one packaged solution, depending on how far the client wants to go.” Usually companies either supply solar heating, PV, or wind generators, but here it’s all available under one roof. Martin also has a well-thought through philosophy in terms of renewable energy solutions. “The future of renewable energy lies in looking at the building as whole,” he warns. “Firstly all our buildings need to be properly

A PV installation in Kirstenbosch near Cape Town

insulated to reduce energy losses which result in higher consumption. The second aspect is to reduce the electrical load which starts with simple things like changing light bulbs and using alternative heating sources. Only then should you decide on what type of renewable energy source you’re going to install.

This means the power generated can be shared among those units where the demand is highest Long term investment

“Although the cost of these systems is coming down significantly, it remains an expensive exercise right now. However, predictions show that by 2015 the local grid price of electricity will be on a par with the price of PV energy,” adds Martin. “This means that the demand for alternative energy sources will rise dramatically which is even more reason to start looking at installing such systems now. At the moment pay-back time for a PV system is 7 to 9 years, but we expect this to drop to well below five years in the near future.

TICKER TAPE

The PV panel still lets light through

hudu is the sole distributor for Suntech Solar Photo Voltaic (PV) panels. “They develop, manufacture and deliver reliable and cost-effective solar energy solutions and are the world’s largest crystalline and Monocrystalline silicon module manufacturer, with

The US non-governmental organisation Water Defence has joined forces with the Treasure Karoo Action Group against hydraulic fracturing.

Public hearings on a new wind farm planned for Port Elizabeth are underway in the city. The hearings are to test opinion on the building of a wind farm at Blue Horizon Bay, west of Port Elizabeth.

The energy department is busy drawing up a technical report on the integrated energy plan as preparation for the development of the plan. The report would be completed by the end of the 2012/13 financial year.

Poland's top utility PGE is in talks with French nuclear reactor builder Areva on cooperation in renewable energy projects, mainly offshore windfarms, reports Reuters.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

23


POWER GENERATION

while ensuring consistency in supply even if one or two inverters are not fully functional. Power not consumed charges a battery pack, but this pack is otherwise charged from the main supply when all the solar energy is being consumed through the system.”

System options

System options include Off Grid application, On Grid application, Grid Interactive application and a UPS Backup application. “The Off Grid application enables the user to harvest energy from the sun through the battery bank as a primary source of power while a wind turbine and an AC collector can be connected to support the system,” explains Elmond. “With the On Grid Application, the grid is the primary source of energy while energy generated by the PV panels is pushed into the local grid.

hudu also did a PV installation at AECI

more than 1.3GW of solar modules already installed worldwide,” says hudu’s electrical engineer, Elmond Khoza. “All products are designed according to the iec/ui standard and manufactured in IS09001 and IS014001 certified product lines. All the Suntech off-grid modules come with a 25-year power output warranty and a 5-year materials and workmanship warranty.”

Divide and conquer

“This is the product we used at the retirement village, Oostvallei, in Pretoria,” Elmond adds. “The village has 122 flat roofed cottages on which we’re installing a total of 2 400 panels delivering 480 KW. With this installation we followed the proven old adage: divide and conquer. The system has 122 inverters, one for each dwelling instead of all the power going through just one large inverter. “This means the power generated can be shared among those units where the demand is highest

The PV panels tucked away out of site on the roofs of the units at the retirement village in Pretoria

24

THE SOUTH AFRICAN MECHANICAL ENGINEER

“In the Grid Interactive application, the grid-power is mostly used when the PV array produces excess solar energy after loading the back-up batteries. If the PV load exceeds consumption, the excess will be fed back into the main grid for credit [depending on ‘Rebid’ developments],” elaborates Elmond. “Finally, in the case of a UPS, the converter connects together with batteries, grid charger, PV panels and charger controller, to a separate DB board. In the event of a power failure, the UPS will feed the designated sections on the DB board with power.”

Warning

Many people have in the past burnt their fingers with inferior solar energy products, but as technology matures more people are gaining confidence to try out alternative sources of energy. “I’d suggest that anyone who wants to invest in a PV system make sure that the guarantee on the system, especially the panels, is ceded from the manufacturer through to the client,” Martin suggests in conclusion. “A guarantee of 25 years, like ours for example, should be in place from the manufacturer and obviously users should deal with a reputable company able to carry such a guarantee.” Who do you call… hudu. Martin Viljoen, hudu, Tel: (011) 234-6116, Email: martin@hudu.co.za

The PV installation in Pretoria

VOL 62

April 2012


POWER GENERATION NEWS

A project for the Department of Correctional Services that involved the replacement of the existing boiler at the Nelspruit Prison, has recently been completed. “A new John Thompson 1,8 ton horizontal boiler, which uses steam as an efficient source of heat generation, has been installed at the prison to improve the hot water system at the establishment,” says Arnold Retief, a director of Ai-Tec. “This modern boiler system, the first of its type to be installed in the Mpumalanga area, provides steam to the kitchen, laundry and hot water systems at the prison. The benefit of this boiler is improved steam output for more efficient heat generation.” Ai-Tec’s boiler systems are designed for use in establishments that use steam as a source of heat generation, including hospitals, mine hostels, correctional services and boarding schools.

Replacement of the existing boiler at the Nelspruit Prison

In addition to supplying new boilers, the company provides a repair and maintenance service for hot water, steam and smokeless boilers. Services for the upgrade of boiler plants include rebuild-

ing, re-tubing, relocating and installation of the new system. The company also undertakes conversions – for example, boiler automisation and automated soot blowing systems. Other services include electrical work, as well as the prepara-

tion of boilers for government inspection and attendant training. Arnold Retief, Advanced Industrial Technology (Ai-Tec), Tel: 0861 248-320, Email: ArnoldR@ ai-tec.co.za, www.ai-tec.co.za

Smart Grid Market in Europe In order to ensure the optimum utilisation of renewable resources, it is important to interlink regional grids. The potential for generation of electricity from renewable resources for most countries is not significant. For instance, the excess wind energy produced in the UK during periods of low demand could be trans-

ferred to Norway and be used to pump water into the country’s hydro electric power stations. The construction of a super smart grid (SSG) in Europe would help in optimising the utilisation of the enormous potential for solar and wind power from North Africa, thereby satisfying the electric-

ity needs of the Mediterranean and the rest of Europe. By developing a unified European power market equipped with smart technologies, the problem related to the high cost of power supply can be easily solved. www.globaldata.com

Gas Turbines for BRIC nations According to estimates, the BRIC countries alone account for more than 50% of total infrastructure investments in the world. At present, 15% of the total global gas turbine market revenue comes from the BRIC nations. The main reason is their increasing demand for electricity due to their huge populations- China and India are the

most populous countries in the world. The availability of natural reserves and resources and rising electricity demand in all the BRIC countries will drive their gas turbine markets in the future. The BRIC gas turbine market is expected to experience a considerable growth from $1,432 million in 2005 to $2,623 million in 2015. The major contributing

factor for the growth will be growing environmental concerns. At present, BRIC nations are heavily dependent on coal for fulfilling their power needs but gradually BRIC’s focus is shifting towards gas based power generation due to its clean nature. www.globaldata.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

25


Passion Through Our People

RELIABILITY THAT CAN BE TRUSTED

CAPE

As the oldest and largest generator set manufacturer in Cape Town, IMS Cape provides reliable standby power options guaranteed to ensure optimum uptime of any operation. Standard off-the-shelf generator sets as well as custom built units for specific applications are available. Capacities range from 20 kVA up to 2000 kVA and can be increased upwards with multiple synchronised sets. Options include both stationary and portable configurations; all manufactured to stringent quality standards.

+27 21 507 7200

26

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

|

www.zest.co.za


POWER GENERATION NEWS

Savings ThermoWise, in conjunction with Eskom, will save an old age home in Durban over R1,6million in electricity costs over the next five years. “Eskom was commissioned by an old age home in April 2010 to log and monitor the monthly electrical consumption for the establishment’s hot water system,” says Bronwynn Fine, sales director, ThermoWise, specialists in energy solutions. “After thorough investigation and analysis, Eskom and ThermoWise recommended the installation of three air to water heat pumps to optimise electricity savings at the old age home. “These environmentally friendly heat pumps significantly increase the energy savings that already result from the existing solar system installed on the roof of the building. “All ThermoWise heat pumps have a guaranteed savings of 50% on electricity usage to heat water, however, in this installation and in many others, savings of 64% have been achieved.” Bronwynn Fine, ThermoWise, Tel: (031) 569-4453, Toll: 0860 heat h20 / 0860 43284 20, Email: bronwynn@thermowise.co.za, www.thermowise.co.za

With the installation of three air to water heat pumps at an old age home in Durban, ThermoWise, in conjunction with Eskom, will save the establishment over R1,6-million in electricity costs over a five-year period

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

27


28

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012


COMPUTERS IN ENGINEERING

Going Global? Check Your ERP System First Globalisation is changing the way businesses compete. Jeremy Waterman, managing director of Softline Accpac believes that in order to succeed, companies should create new ideas that help them tap into global markets, from extending supply chains to include foreign suppliers to reaching new customers across the world via web commerce.

I

f your business is considering testing international waters, you are not alone. An increasing number of small to mid-sized manufacturers and distributors are already tapping into the global marketplace. These companies are reducing costs on the supply side by working with lower-cost vendors in countries such as China, Mexico and Japan and are increasing revenues by making high-demand goods and services available to new and previously unattainable markets.

Jeremy Waterman

Although you might have expanded your domestic business at some point by establishing remote sales offices, production facilities or warehouses, thanks to technological advances in web-based processing and security, you can enter the global marketplace without opening a

physical location in a foreign country.

Time to check you application

You have to ask yourself if your current business application is supporting your business operations and transactions beyond South African borders. If you’re still using the same application you bought when you started your business, chances are it was designed to operate in a single entity, domestic environment only.

Is your current business application supporting your business operations beyond South Africa? Dealing in different currencies

One of the best ways to tell is to review the key functional issues that your software will need to have in order to conduct business in other countries. Currency, for example, is of utmost importance. If you’ve never dealt with currency other than the South African Rand, you will need to contend with other currencies. With the volatility of the various exchange rates involved, it’s imperative to be able to take your customer’s native currency into account at each stage of the order processing cycle. To facilitate this fundamental need, the software should allow you to quickly perform across-the-board changes to exchange rates from one currency to another. It should also be able to store, and promptly update price lists in the customer’s currency so the pre-defined price is automatically used when the customer places an order.

Sounds like Greek to me

Effective communications is paramount for successful international commerce. A software system that doesn’t take different languages into account can be a significant barrier. Your enterprise THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

29


COMPUTERS IN ENGINEERING

for transit in their own language helps ensure accurate picking and avoidance of unnecessary returns. Customers who receive invoices and packing lists in their native language will spend fewer time double-checking for accuracy and will ensure less enquiries being sent to the customer service department.

Seamless information flow

A software system that doesn’t take different languages into account can be a significant barrier system should be able to associate any user’s ID with their native language, so screens automatically display in their language at login, regardless of their physical location or job function.

A modern enterprise system needs to do more than function within the four walls of a business. Information needs to flow seamlessly to and from all parties in an extended global supply chain, regardless of whether it’s between your own business units or with a foreign business partner. For example, by linking your ERP system with a foreign manufacturing facility owned and operated by a third party, your business partner becomes an extension of your company, one that can access, share and update key information such as production schedules, promised delivery dates and advanced shipment notifications as if they were part of your own business. Effectively collaborating with suppliers is critical for gaining the cost and efficiency benefits of working with foreign suppliers.

Instructing warehouse pickers to secure goods

In closing

Does your current application accommodate these multi-national functional requirements? If not, it might be time to purchase a new ERP system that has these capabilities built-in. Business entities such as currency, language and taxation rules need to be so well integrated into the fabric of the business application that program modifications to your current system would be too extensive and costly to attempt. The old mantra about thinking global while acting local rings true with how you prepare your enterprise software system for meeting global challenges. When selecting a new ERP system, ensure it not only meets these functional requirements, but that it’s developed by a vendor with the experience and culture for keeping pace with the ever-changing laws and regulations. With careful planning and implementation, you’ll have a truly multi-national enterprise system that runs smoothly, adapts readily to change and allows you to have a more cost-effective and profitable business. Softline Accpac, Jeremy Waterman, Tel: (011) 304-2000, Fax: (011) 304-2030, www.accpac.co.za

30

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012


COMPUTERS IN ENGINEERING

Closing the Gap The gap between client and designer has always been one of communicating visual concepts in a way that is understandable by all parties. A lot has been done with CAD and 3D walk-throughs, which have made it easier to translate concepts.

The Connex 500 – remarkably compact for a printer packed with punch

H

owever, one of the most effective methods of conveying design ideas is through the use of physical models. The trouble is that these are considered costly and timeconsuming to produce. “SA Mechanical Engineer” recently encountered a three-dimensional printing solution, designed for the engineering field. The different 3D printers from Objet are unique in their ability to produce robust models for engineering and other design applications. Available in a number of platforms aimed at various budgets, from high-end multi-materials systems down to affordable desktop units, each utilises inkjet-type technology to create models based on computer generated 3D designs.

Each utilises inkjet-type technology to create models based on computer generated 3D designs Helping architects

Jacques Kleynhans, DemaPlastech

“We help engineers by developing systems and materials for rapid prototyping and simulation of the final product in three aspects,” says Zehavit Reisin, head of business, consumables at Objet. “Firstly, we look at form: does it resemble the look of the end product in shape, color, surface smoothness, etc.? Secondly, does it fit together using all the materials and parts specified by the designer? And finally we look at function, asking whether the prototype fulfills the functional purposes it was designed for, and can it be used in the actual working environment the end-product is designated to function in. THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

31


COMPUTERS IN ENGINEERING

Architectural steps from design to model to final site

“For example, one thing that is crucial is having models that keep their dimensional stability under different environmental conditions. They need to be able to withstand temperature fluctuations, as well as the pressure often applied by transportation, storage, and other usages performed by the engineer.”

It used to cost about R3 million for a printer; now you’re looking at 10% of that

“I believe that this is set to change in the next two or three years, for a number of reasons. Price was previously an obstacle but this drops every year. It used to cost about R3 million for a printer; now you’re looking at 10% of that.

Zehavit goes on to explain that the company recognises the importance of materials that best represent the intended end product. “Our materials cover the range from simulating standard plastics, and recently we also launched materials that simulate ABS plastics, which is an engineering plastics material. Having a variety of materials with different physical properties and in different colors, such as transparent materials, bio-compatible materials, high temperature-resistant materials and more, enables Objet to meet various prototyping needs.”

“Designers are also learning that 3D printing streamlines the design process to eliminate errors from the outset, which saves costs down the line. The further along the process you go the more expensive mistakes become,” Jacques continues, describing the procedure step by step. “Typically, the engineer does a 2D design and shows the client. The next step is to do a 3D render because it gives the client a better idea of the visual. But you’re still looking at a flat thing. Where 3D printing comes in is that it fills the gap between the model and the engineer.

Matchless multi-material capabilities

“The modeler takes the two-dimensional design and converts it to a three-dimensional solid. We then print it to scale and the engineer can show the client a replica which is an exact model of the final article.”

While the entire range is designed to produce models efficiently, the Objet Connex series can jet two materials simultaneously to create a composite material for a variety of thermal and mechanical properties. “The digital material is a combination of two base materials that are jetted together from different print-heads in a pre-defined composition,” Zehavit elaborates. Materials can be rigid, flexible, soft, or all of the above in the same model. Moreover, different colors and shades such as greyscale tones, blue tones, or pure white and black elements can be combined within the same print job. Objet is the only company to offer a 3D printer with this capability, and currently provides its Connex customers with sixtyfive different materials for various end-user needs.

Baby steps

“South Africa is a new territory for us, but we see a very big market here for this range,” she emphasises. Jacques Kleynhans, whose company DemaPlastech

32

markets the range in South Africa, shares this opinion. “In spite of being in the country for about 13 years, 3D printing is still in its infancy locally. Many people haven’t heard of it – even engineers and designers and people who are clued up on new technology don’t know much about it.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

Office-friendly system

While you might imagine the system would require a room of its own, Jacques explains that the equipment is very office-friendly. “Picture a normal inkjet printer on your desktop with three cartridges to produce colours,” he explains. “3D printing is a similar concept. The printer uses Objet inkjet technology to jet multiple layers of polymer onto a surface. Imagine slicing an apple into fifty slices – you’d have a small disk on the bottom and another disk on that – it takes millions of layers to create a final article.” Jacques Kleynhans, DemaPlastech, Tel. 011 462 2990, Fax. 011 462 8229, Email. jacques@demaplastech.co.za Website. www.demaplastech.co.za

April 2012


CESA

Unquestionably Ethical Consulting Engineers South Africa’s (CESA) new President Naren Bhojaram, presented his presidential message and theme for the year at a function held in Johannesburg. With a theme of ‘CESA Engineers – Unquestionably Ethical’, Naren addressed the global issues impacting the industry; the state of the Consulting Sector; the Procurement Environment; and delivery models to enhance job creation with a strong emphasis on Business Integrity and the eradication of corruption. He also addressed the ‘one thing we can all do to grow our economy’.

N

aren urges the Minister of Economic Development, Ebrahim Patel to urgently consider the Consulting Engineering Sector as a designated sector for local preference ensuring a better platform for job creation, attracting young people to join the sector thus accelerating training and development. In order to encourage the private sector to invest in the development of infrastructure projects Naren believes that we need to be entrepreneurial about project delivery mechanisms. The easing of Public Private Partnership regulations will facilitate this. CESA is willing to actively participate in order to accelerate service delivery and job creation.

Political undermining of the opinion and value add of these professionals will continue to be a deterrent in attracting these skills back into the public sector Engineering is becoming unattractive

CESA is very concerned about the inconsistencies between the newly-promulgated Preferential Procurement Framework Act Regulations and the Construction Sector Codes of Good Practice promulgated in terms of the BBBEE Act. It is calling upon National Treasury and the Department of Trade and Industry to urgently address these inconsistencies. Naren states, “We would like to see a return to sanity – Private Sector is compelled to abide

by these Regulations, but State Owned Entities do not have to satisfy their own or Government’s Regulations with respect to transformation.” The issue lies with National Treasury for allowing this exemption. It is important that parastatals comply with the legislation not because their own systems are no good but there is a need for uniformity in procurement in our industry which will result in a win win for all.” He strongly believes that the element of ‘Quality’ must be included in the Procurement of Professional Services regulations as a single process and not just as a pre-qualifier. Technical evaluation of tenders must include input from technical professionals in the bid evaluation committees. He maintains that political undermining of the opinion and value add of these professionals will continue to be a deterrent in attracting these skills back into the public sector. He strongly contends that engineering has become an unattractive industry on account of the profession being reduced to a mere commodity with appointments being made on the basis of the cheapest price, with expertise and experience not considered adequately.

Individual honesty

In answering the question of “Where does the power really sit with the procurement of professional services” Naren states that our country’s current lack of institutional strength within Government is a breeding ground for corruption. He believes that the one thing that we can all do to grow our economy is to address the issue of Business Integrity not only at a corporate level but on an individual level. CESA member firms are being asked to focus their attention on every single employee. He believes that Business Integrity is not only about companies, government or institutions, but about individual human beings – honesty is the only way! All CESA member firms are constitutionally required to have a Business Integrity Management System (BIMS) in place. “We will continue to bring top of the mind awareness to our members and individuals in our industry to continuously explore their personal ethical balance so that we remain “CESA Engineers – Unquestionably Ethical” concludes Naren .

Pictured left to right: Abe Thela - Deputy President CESA, Naren Bhojaram – President CESA, and Graham Pirie – CEO CESA

Graham Pirie, CESA, Tel: (011) 463-2022, Email: gspirie@ cesa.co.za, www.cesa.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

33


HVAC

Specialised Engineering The design of heating, ventilation and cooling (HVAC) systems should not only be undertaken by a mechanical engineer, but one with specific experience in HVAC. But there is a serious shortage of such experienced HVAC specialists even while the industry continues to grow.

ing is starting courses for young engineers across various disciplines this year, but HVAC specifically is not covered as yet. So, the only way a young engineer can gain the necessary experience is by working for contractors, suppliers or consultants in the industry. “When we conduct interviews with prospective candidates for these courses, I soon find that not a single one of them knows much about HVAC system design other than being very comfortable with the computer” George elaborates. “There’s nothing wrong with this, but you can’t rely purely on computer design to arrive at the most efficient system cost effectively. First hand knowledge of real-live problems is invaluable right from the start of the design process otherwise it’s bound to cost more to fix afterwards.”

Analyse design

As with the engineer currently under George’s wing learning the design ropes, George reckons it takes a qualified young engineer another five to six years of learning from an experienced engineer before he or she is ready to ‘fly solo’. “My apprentice knows by now not to come to me and say, but the computer gave me that,” chuckles George. “Granted, the programmes of today are fantastic, but there’s no substitute for experience when it comes to analysing a design and assessing whether it will work or not in practice.

George Barbic of George Barbic & Associates

S

A Mechanical Engineer” speaks to veteran mechanical engineer, George Barbic, who specialises in the design of HVAC systems. “The handful of bigger suppliers in South Africa of HVAC systems employ one or two engineers with experience, but most of these guys are reaching retirement age now and there are far too few young engineers following in their footsteps,” he says. “Unfortunately, many of the bigger players do not actively support the proper training of HVAC engineers.”

The only way a young engineer can gain the necessary experience is by working for contractors, suppliers or consultants in the industry Experience needed

As most design work today is undertaken by consulting engineers like George, young engineers have limited opportunities to gain experience from specialists in this field. “Although an HVAC system can only be designed by a mechanical engineer, very little is formally covered at university,” he adds. “The South African Institution of Mechanical Engineer-

34

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

“Many young engineers today don’t want to put on the overall and get their hands dirty by doing actual work in the field. They want to wear a suit, drive a smart car and be a gentleman,” says George. “The problem is made worse by the BEE system we have in South Africa. Although well-intended, it results in young black engineers in industry getting promoted very quickly into managerial positions.

Real world

“This poor engineer is lost because he or she hasn’t had a chance to learn anything of the real world out there in terms of engineering,” George adds. “He simply doesn’t get the chance to actually become an engineer in the true sense of the word which is such a waste to the country and the industry as a whole.” The question is, what’s going to happen in the industry? Split units can simply be specified and installed by contractors but there’s much more to HVAC.” These are complex systems which require chillers, pumps, ducting, pipe work, air distribution, control systems etc to be carefully matched and to work together effectively. Today most customers want their system to be green and energy efficient, adding yet another facet to a great design.

April 2012


HVAC

Over sizing

“The biggest mistake inexperienced engineers make in designing an HVAC system is to grossly oversize the machinery usually because they don’t understand the parameters required by the software,” explains George. “There is also an underlying fear that at commissioning, the system won’t deliver according to specified requirements, so they overdesign, usually at an inflated cost.” Another common shortcoming in George’s experience is lack of knowledge about optimum installations. “Let’s take ducting as an example,” he says. “They design ducting without taking into account the most economical size for each specific installation. They don’t bother to call the manufacturer to ask about whether a 300 X 300 is as economical as a 350 X 250 millimetre ducting, for example. The same mistake occurs with piping diameters, a critical factor in designing a system. An oversized pipe, for instance, leads to all sorts of other problems such as corrosion and poor pump performance.”

Just ask!

Most of the challenges young engineers in HVAC will encounter can be overcome simply by asking questions. “They should quiz the manufacturers of components, talk to contractors who do the work every day of their lives, listen to sales people who sell equipment and tap into the knowledge of ex-

Many young engineers today don’t want to put on the overall and get their hands dirty by doing actual work in the field. They want to wear a suit, drive a smart car and be a gentleman perienced engineers,” George says in conclusion. “My advice is to go and work for a contractor or join a reputable consulting firm but to get out from behind the desk to experience first-hand how things work on site. To this day I still learn new things. You only stop learning the day you die.” George Barbic George Barbic & Associates Tel: (011) 648-4617 Email: gbarbic@mweb.co.za

Book Now for June 2012 • Bearings and lubrication • Computers in engineering • Pipes, pumps and valves • Power Generation

Contact Mark Bennett on Tel: (011) 781-1401, Fax: (011) 781-1403 or E-mail: samecheng@promech.co.za for further details

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

35


LETTER TO THE EDITOR

(“SA Mechanical Engineer” published data provided by Eskom on its eta award-winners in February. Either Eskom’s having a blonde moment or this reader has the wrong end of the stick.)

• For electrical energy: Wattsecond, Kilowatthour or even Megawattday. • For thermal energy: Joule, Kilojoule. • For mechanical energy: Newtonmeter.

Ref: SA Mechanical Engineer February 2012, Energy Efficiency, pages 21..23.

The advantage of this unit system is that these expressions are readily convertible:

Quotes:

1 Wattsecond = 1 Joule = 1 Newtonmeter.

2. Simon Grier solar modules provide more than 132 KW “per day”

Therefore, Mr X cannot save Y Kilowatt “per day”. If Mr X takes the trouble of looking at his electricity bill he will find that he is being charged for the number of Kilowatthours he has consumed, not Kilowatts.

1. Solek water heating reduced the grid demand by 450 MW “per year”

3. Weather vertical wind turbine produces 500 KW “per month” 4. Meinhard Fourie pool pump saves 2 KW “per day” All these statements are wrong and therefore meaningless. For your information, in the ISO unit system energy is expressed as follows:

36

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

The above quoted statements are meaningless because it is not clear wether Mr X saves Y Kilowatthours for every hour his invention is operating or whether he saves Y kilowatthours “per day” of full operation. AA Romeijn, Msc, PrEng.

April 2012


HVAC

Fast-track Project The detailed process, mechanical, piping and civil design of a new underground refrigeration system, comprising refrigeration machines, condenser spray chambers and closed circuit cooling coils for Hecla’s Lucky Friday silver, lead and zinc mine in northern Idaho, USA, has been completed. This fast-track project was conducted as a sub-contract awarded by Cementation USA, the main contractor for the construction phase on the mine’s No 4 Shaft Project.

R

aymond Funnell, lead engineer at BBE Consulting, says owing to the complexity of the piping, the entire design was carried out using a 3D model.

Considerable depth

The mine’s shallower reserves have been accessed from the existing Silver Shaft, but new, deeper reserves will be accessed from the new 1 100 m deep No 4 sub-shaft. “The new reserves will be mined at considerable depth, requiring the intake air from the Silver Shaft to be cooled on 5900 Level, which is 1 800m below surface,” says Raymond. “This will be achieved by installing a bank of highpressure cooling coils. The new chiller plant will be located on 4900 Level and about 500m from the No 4 Shaft.

Important to provide some redundancy during shut-down for routine maintenance “The plant will initially comprise three R134a dual screw-compressor machines, providing a total cooling capacity of 3.4 MWR. These machines are relatively compact, which suits the underground layout in terms of installation and future maintenance work. For example, these machines don’t require an overhead crane gantry, as the semi-hermetic

compressors weigh less than a ton. The machines will produce chilled water at about 5ºC, which will be distributed to the 5900 Level bulk air cooler via high pressure pipes in No 4 Shaft.”

Longer-term

Raymond says provision has been made in the design to upgrade the chiller plant in the longerterm to a maximum of six machines, with a total cooling capacity of 6.8 MWR. The smaller module size is important to provide some redundancy during shut-down for routine maintenance. The additional chilled water will be used for secondary cooling nearer the workings. A high-efficiency condenser spray chamber will be constructed near the upcast shaft — No 2 Shaft — to allow the full heat from the six machines to be rejected to the return air. This spray chamber will cool the hot return water from the machines to about 37ºC, before being pumped back to the machines via 1 100 m long HDPE pipeline. “One of the innovative features of the system design is that up to 75% of the chiller plant heat can be rejected directly to cooling water which is piped from a nearby mountain stream,” explains Raymond. “This feature is useful for short periods of operation, when it is necessary to shut down the heat rejection spray chamber to conduct maintenance work in the upcast shaft. “However, this mode of operation is quite energy-intensive, since the cooling water must be pumped out of the mine using high-pressure pumps. Therefore the preferred normal mode of operation will be heat rejection to the return air.” BBE Consulting, Richard Gundersen, rgundersen@bbe.co.za Raymond Funnell, rfunnell@bbe.co.za

Hecla’s Lucky Friday Mine Underground refrigeration system diagram

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

37


MARKET FORUM

HP has introduced more powerful cloudbased solutions, allowing architecture, engineering and construction (AEC) professionals to print where the job takes them.

to print their designs and automatically archive a copy on any web-connected HP Designjet or HP ePrinter. This new feature provides full control over plot styles, paper sizes, layouts and more.

An expansion of HP’s partnership with Autodesk enables remote printing from the AutoCAD WS. By registering for HP ePrint & Share, AutoCAD WS users can use the new Plot to Print function

Additional capabilities for the HP ePrint & Share mobile application, HP’s free, cloud-based printing and sharing tool for Designjet users, include full functionality for the iPad and the ability to send PDF

BMG has been appointed exclusive distributors in South Africa for Garlock Sealing Technologies. “BMG has been an official distributor of the Garlock range of seals and sealing systems since 2006 and we are pleased to now be the exclusive local distributor for these products, which are manufactured in

the USA and Europe to stringent global quality and safety specifications,” says Ken Steel, general manager of BMG’s seals division. “BMG’s seals division offers its diverse customer base a solutions based service which encompasses technical consultation to ensure the selection

e-mail attachments to print. Previously, all documents printed from the mobile app were selected from the user’s HP ePrint & Share library. Now, users can print PDFs received via e-mail as well, providing access to more documents when and where they need them. HP, Tel: (011) 785-1000, www.hp.co.za

of the appropriate sealing solution in every application. Failure to install the correct sealing system is highly dangerous, particularly in extreme conditions.” Included in the Garlock range are internationally-recognised Klozure oil seals and a complete range of non-asbestos gasket materials, which complies with strict environmental regulations. Also available are bearing isolators and mechanical seals which provide optimum bearing protection, ensuring contamination exclusion and extended service life of the entire system. Compression packings ensure reliable sealing in valves, pumps, agitators and other rotary equipment. Expansion joints are designed to absorb movement and dampen vibration, reducing stress on pumps, pipes and anchoring systems. Metallic gaskets and resilient metal seals are designed for extreme conditions.

From left Gerry Morgan, national sales manager, Garlock, Charles Walters, CEO, BMG and Ken Steel, general manager, BMG’s seals division.

Festo was a recent core contributor in the successful cost-effective upgrade of a large beverage bottling plant in Gauteng. Festo became involved in the project in the first quarter of 2010 by supplying a control valve terminal for use in the processing plant’s control and monitoring system, and was present from

38

concept phase through to installation and commissioning. “The system is specifically designed to bridge the gap between electronics and pneumatics. The MPA FB-VI terminal not only improves the plants cost efficiency, but also maximises its productivity,” says Peter Mulock-Houwer,

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

Ken Steel, BMG, Tel: (031) 576-6200, Fax: (031) 576-6584, Email: kens@bmgworld.net, www.bmgworld.net

sales engineer, Festo. The MPA FB-VI valve terminal is designed to be easily configured in order to suit the end-user’s individual requirements exactly. This means that the end-user is free to choose the performance rates, features and communication methods, before the valve terminal is integrated


MARKET FORUM

A local polyurethanes company is lowering the cost of operating slurry pipelines by lining them with Redline, a proprietary formulation that exhibits an abrasion resistance up to ten times higher than HDPE, and six times higher than rubber. Cost savings are achieved through the extension of useful pipeline life, resulting in a return on investment within five years, and an actual lining life of ten years or more. Although the use of abrasion resistant linings is common in mines worldwide, Redline’s manufacturer, Urethane Mould-

Watson-Marlow MasoSine positive displacement pumps are making a big impact in South African industrial applications – and soaring sales have resulted in Watson-Marlow Bredel SA notching an impressive 500 percent real time growth in the brand over the past 12 months. “It’s the biggest real time growth for MasoSine pumps in the entire WatsonMarlow Group worldwide, “ says WatsonMarlow Bredel SA general manager Nico van Schalkwyk. “Our low-shear MasoSine sinusoidal pumps maintain the integrity of whole food products and handle highly viscous products up to 1 million cP with ease. Our sinusoidal rotor overcomes the limitations of conventional rotary lobe, progressive cavity and diaphragm pumps to produce

ed Products (UMP), claims its own product to be unique because of its engineered properties. Redline is characterised by an excellent chemical resistance, and by a monolithic composition that delivers a low coefficient of friction even after wear sets in. This reduces energy consumption and pumping costs, and contributes to a lowest possible cost per ton of mined ore. Hydrolytically stable Despatch of pipe sections lined with Redline and exhibiting excellent cut and tear resistance, Redline will not Trevor Carolin, Urethane Moulded Products, shatter or crack, and is unaffected by Tel: (011) 452-1000, Email: trevor@ump.co.za water hammer and temperature changes. powerful suction with low shear, low pulsation, and gentle handling – all with simple and fast maintenance and 3-A certification,” he says. The MasoSine exclusive single shaft and single sinusoidal rotor are the centerpieces of an innovative, simple design. With a single shaft and rotor, there is no need for the complex timing gears and multiple seals associated with conventional rotary lobe Watson-Marlow Bredel SA general manager Nico van Schalkwyk (left) presents Nick Moraitis with the award, looking on is Werner pumps. Hofbauer, sales support manager from MasoSine Germany “One rotor, one shaft and one seal equate to simple and rate range and handle higher viscosities economic maintenance compared to without shear or cavitation. “ other traditional pump types that have Nico van Schalkwyk, Watson-Marlow Bredel two seals and metal-to-metal contact. SA, Tel: (011) 796-2960, Email: nico@wmbThe pumps also offer an increased flow pumps.co.za, www.watson-marlow.com

into the plant’s processing system. This feature also saves time during installation and commissioning, resulting in lower costs for the end-user. The compact design of the valve terminal also allows over 100 valves to be fitted into the panel, with room to spare for future expansion. Tracey Swart, Festo, Tel: (011) 971-5500, Fax: (011) 974-2157, www.festo.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

39


MARKET FORUM Foundries had to execute delivery of the first two of the three 10-foot sheave wheels on order at the beginning of November 2011, with the remaining one following by mid-December. “The 10week delivery schedule for the first part of the order required a mammoth effort, but our staff pulled out all the stops to ensure we adhered to the agreed dates,” says Goncalves. In stark contrast to the warm African and South African climates - where the majority of orders from KEW Foundries projects are destined for - the wheels for this project have to operate in much colder conditions, being able to withstand ambient temperatures as low as -40°C. The extreme environmental demands necessitated a rewrite of manufacturing specifications and alteration of material to ensure mechanical properties complied with the sub-zero conditions.

KEW Foundries, Africa’s sole manufacturer of cast headgear sheave wheels, has recently secured its first order into the East. The company was awarded a contract worth just under R2 million to supply sheave wheels to a copper and gold mine in the south Gobi region of Mongolia, approximately 550km south of the capital Ulan Bator.

“This project was different to any other we have done before and posed a number of challenges in terms of delivery The first two wheels for the Mongolian order was packaged as half time, the casting material, sheave wheels and dispatched from KEW Foundries’ site in Kimour testing parameters and berley within 10 weeks of receiving the order Jaime Goncalves, KEW Foundthe environment,” explains ries, Tel: (053) 841-0474, Email: jaime@ Jaime Goncalves, technical director, Instead of the standard delivery schedule (depending on its order book), KEW kewfoundries.co.za, www.kewfoundries.co.za KEW Foundries.

Goscor Power Products, sole distributors in southern Africa of Robin Subaru engines have issued a warning about fraudulent Robin engines being imported into South Africa. Mark Bester, Goscor Power Products MD, says there are companies that are importing fake Robin look-alike engines or finished products that are powered by these engines.

Ensure that the Robin brand name is on the starter of the engine

40

THE SOUTH AFRICAN MECHANICAL ENGINEER

“We are extremely concerned about this practise,” says Mark. “Firstly we want to protect consumers from products which we cannot vouch for and for which we could obviously never give a warranty and, secondly, we are concerned that the Robin Subaru brand, one of the world’s VOL 62

April 2012

leading brands, could suffer damage in South Africa.” Bester says that the Goscor group will leave no stone unturned in its quest to take legal action against companies that try and pass these copies off as genuine Robin engines. “We are currently investigating legal routes to counter these fraudsters and we are confident of success. In fact one of our competitors recently won a court case in very similar circumstances to those we now find ourselves in,” he concludes. Mark Bester, Goscor Power Products, Tel: 0861 Goscor (467 267), Fax: (011) 976-4807, Email: powerproducts@goscor.co.za, www. goscor-power-products.co.za


MARKET FORUM Bateman Engineered Technologies recently successfully commissioned a Bateman Dynamic Scrubber system at Debswana’s Jwaneng mine’s Cut 8 project. The project, which will extend the life of the mine to 2024 from its previous date of 2017 at a total cost of US$ 3.5 billion, is the biggest capital commitment in Botswana’s history. According to Debswana, an additional 102 million carats of diamonds are expected to be produced after the extension. Jimmy Tomlin, Bateman Engineered Technologies Air Environmental manager, says that the total extraction volume of 19,5m/ sec, services the apron feeders and the outgoing conveyor from the primary stockpile tunnel. “The Bateman Dynamic Scrubber is a well-proven design. It is a low cost, high efficiency system with an integral self-cleaning fan and is also well known for its low-maintenance requirement and extremely low water consumption,” says Jimmy. Jimmy Tomlin, Bateman Engineered Technologies, Tel: (011) 201-2300, Jimmy.Tomlin@bateman-bet.com, www. bet.bateman.com

Bateman Engineered Technologies recently successfully commissioned a Bateman Dynamic Scrubber system at Debswana’s Jwaneng mine’s Cut 8 project

Ultimate Solutions One of the largest bridge construction companies in Mississippi, was tired of the never-ending cycle of damaged cylinder rods and leaking seals. When the local Caterpillar dealer (Puckett Machinery

Company) introduced them to “Seal Saver” protective cylinder cover, they immediately saw the product’s potential. They purchased one to test on their CAT 320BL bucket cylinder. They evaluated

the product for approximately six months and then proceeded to protect the rest of their fleet. They have not just realised extended cylinder life with less downtime, but they prevent the intrusion of dirt into their hydraulic system via the rod wipers. Keeping this contamination out of their systems will not only give them a longer filter life, but it will also prolong the life of the valves and pumps. Contamination is responsible for 70% of hydraulic component failures. This patented product is being utilised in all types of industries in over 20 countries around the world. Samuel Rapetswa, NKWE Mining Services, Tel: (014) 555-6459, Email: sam@nkwegroup.co.za, www.nkwegroup.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

41


MARKET FORUM The Goscor Group, an Imperial Holdings Limited subsidiar y, has acquired Bobcat Equipment SA and Bobcat Equipment Rental SA. Bobcat Equipment SA is a leading supplier of compact equipment into the construction, mining and agricultural sectors. Bobcat Equipment Rental SA is one of South Africa’s largest compact equipment plant rental businesses.

WeatherSA and the South African Weather Services (SAWS) have jointly developed a web-based, real-time early warning weather detection system which has been setting new standards in forward planning, safety and productivity. The system offers extensive forecast elements and utilises highly accurate graphs that provide hourly wind, temperature, humidity, fog and barometric pressure drop notifications for a specific site. The system has found wide acceptance in the local mining industry and all prominent mining groups currently operating in South Africa have invested in WeatherSA’s early warning weather detection system including BHP Billiton, Anglo Gold, Anglo Coal, Exxaro, Aquarius Platinum, Goldfields, Umcebo, Platinum, ARM and Xstrata. Mines receive prior warning of ap-

42

proaching inclement weather fronts via automated cell phone text alerts, calls and email notifications. This gives them sufficient time to bring people and equipment to safety. The system has been designed to increase safety and reduce running costs for both above and below ground mining operations. The automated weather station, presents up to the minute access to weather intelligence at an exact location. Positioned at a particular premises, it captures and accurately measures real-time weather data such as wind speed, temperature, humidity, barometric pressure, rain, frost, leaf wetness, soil moisture and solar and UV radiation – features that can be customised according to customer requirements.” Barry Gonin, Weather SA, Tel: (011) 300-7480, Fax: (011) 465-8922, www.weathersa.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

Goscor is a diversified industrial equipment business with activities spanning the forklift, access equipment, industrial cleaning equipment, compressor and small construction equipment markets in South Africa. Commenting on the acquisition Neil Wilson, CEO of Goscor, says, “The Bobcat business is a natural fit in the Goscor stable and complements our existing offering of quality products and after sales service. The inherent synergies between Imperial, Goscor and Bobcat SA will enable the group to rapidly develop the acquired businesses. Bobcat SA has offices in Johannesburg (Alrode), Cape Town, Durban, Richards Bay, Rustenburg Pretoria, Lepelale (Ellisras), Kuruman and Witbank. Greg Esprey, Bobcat Equipment SA, Tel: 086 026-2228, (011) 389-4400, Email: gesprey@bobcatsa.co.za, www.bobcatsa.co.za


MARKET FORUM

Zest has set its sights on winning a greater share of the African market following its acquisition by Brazil-based group WEG last year. “We are now responsible for marketing and distributing WEG’s products across the continent, which is experiencing a resurgence in interest from international investors and project houses. The Zambian Copperbelt and West Africa offer significant growth opportunities for the group and we aim to be awarded new contracts in these areas, as well as other areas where projects activities are robust,” says Louis Meiring, group MD. “We plan on investing a great deal of time and resources to grow our African market share, which we believe will result in enhanced revenues for the group.”

WEG motors were included in overall solution supplied by Zest

countries including Ghana, Namibia, Zambia, Kenya, Botswana and Mozambique and in future plans on becoming more active in Angola, Burkino Faso, Cameroon, Ivory Coast, Mauritania, Nigeria and Zimbabwe.

opportunities and challenges in various African countries. “Once we have a good understanding of the priorities, requirements and risks specific to our targeted markets, we can decide how to best service these markets,” Quentin says. Jamie Wilson, Zest Electric Motors, Tel: (011) 723-6000, www.zest.co.za

To date the company has worked in

The company has appointed Quentin Korff as its African business development manager who is evaluating the

In a bid to re-mine the gold tailings dams between the Ergo plant outside Springs and Crown, Fraser Alexander Tailings and mining giant DRDGold commissioned Mocke Pipeline Construction, who collaborated with Marley Pipe Systems in an immense project which involved the installation of the longest known gold slurry tailings pipeline in South Africa.

from several reclamation dumps in Johannesburg along the newly-constructed pipeline to the Ergo plant – one of the largest recovery plants in the country – where it would be pumped to the Brakpan tailing dump and discharged. As a result, several reclamation dumps in the Witwatersrand area will be diminished in the next few years.

lining of a 500mm diameter pipe, 50km long in 12 months using Mocke’s revolutionary new Sureline Technology. Ten months later, the project was successfully completed, 2 months ahead of schedule – an impressive feat considering the unfamiliarity of a project that was being executed for the first time in Africa.

The purpose of this complex project was to ultimately transfer gold slurry material

In January 2011, work began on the intricate project, which involved the

Rand Refinery Limited has rejuvenated and relaunched its brand and corporate identity in line with the organisation’s new growth and diversification strategy, aimed at expanding into new regions, most notably Asia and Western Europe, while offering a wider product portfolio.

gold, nearly one third of all the gold ever mined in the world.

The refinery is the largest single-site gold refining and smelting complex in the world. Since 1921, the organisation has refined more than 50 000 tons of

Having been the refining hub for Africa for 90 years, the past 15 years has seen the company focusing on extending its footprint throughout Africa. The organisation believes that this experience serves as an ideal launchpad into a diverse international arena. It is currently making notable strides on the Asian continent while also looking North, South East

Marley Pipe Systems, Tel: 0861 MARLEY, www.marleypipesystems.co.za

and West to grow its markets. “The refinery’s achievements have afforded it the distinction of being the only London Bullion Market Association (LBMA) accredited precious metals refinery and fabricator in Africa,” says Craig Howard, CE of Rand Refinery. Craig Howard, Rand Refinery, Tel: (011) 418-9000, Email: gold@gold.co.za, www.randrefinery.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

43


MARKET FORUM

Lightweight, taking up less space, quick to fit and multipurpose - these requirements are becoming increasingly important for system components. Complex control of liquids and gases are generally carried out by means of numerous individual valves. These are connected to one another by similar numbers of fittings and piping. But doing so takes up a lot of space and assembly is time-consuming because of countless individual parts. Also, every assembly point and pipe connection is a potential Ieak, which increases the safety risk. Compact plastic multiport valve blocks are the ideal solution here, as they can perform various functions while saving space. Over the past years, Gemü has individually designed and manufactured thousands of versions in stainless steel within the pharmaceutical industry.

This puts the German valve manufacturer in a leading position for multi-port valve blocks for the pharm a c e u t i c a l Multiport valve configuration for the distribution of chemicals (internally industry. This called the “monster block”). experience is now being They can also fulfil safety functions, transferred to other industrial sectors double shut-off (double block and bleed), – using different types of high quality cross connections and control functions. plastics as a base material. These individual functions serve very Multiport valves or multiport valve specific purposes in individual situablocks unite a variety of functions in tions, such as the taking of samples, the the smallest of spaces thanks to their distribution of chemicals, the connection individual design, such as: sampling, of cleaning media (CIP) and ensuring a minimum flow rate. mixing, dividing, diverting, draining, Gemü, www.gemu.com

feeding and isolating.

Situated at Postmasburg in the Northern Cape Province, Kumba Iron Ore’s Kolomela mine is one of global miner Anglo America’s Big Four projects worldwide. “We originally required 10 Atlas Copco lighting sets for the dumping, loading, pit and special needs areas,” says Mine production manager, Nelson Sibisi. “This requirement is currently increasing as the project grows in size. We anticipate that we will shortly require 30 lighting sets on site, situated at intervals of no more than 100 metres.” Nelson points out that the locations are not randomly selected. “We have a schedule in place whereby we regularly visit the loading and dumping areas at night in order to ensure optimal placement of the lighting towers.” The mine does not maintain the lighting units themselves so they rely on the expeditious service provided by Rand-Air. Although the branch is located 120 km from the mine, within a maximum of two hours of phoning Rand-Air, a representative or technician will arrive at site. Louwrens Erasmus, Rand-Air, Tel: (011) 345-0700, www.randair.co.za

44

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012


MARKET FORUM

Miniaturised Formats Miniaturisation is a major focus in the field of medical technology. Less is often more – and even less is now hardly conceivable: solid-carbide micro-milling machines with diameters of just three-hundredths of a millimetre, even capable of milling hardened steels at HSC turbo speeds. Since medical technology has started to boom, machine tools in living-room or even smaller formats are increasingly in demand. The Darmstadt-based Datron AG offers a new high-speed C5 milling

machine for ultra-highprecision five-axis simultaneous machining of small parts, in the fields of medical technology, for example, the watch-making and jewellery industries, or tool and mould manufacturing. All machinable materials up to a diameter of 60 mm can be simultaneously machined in five axes, with an option for milling ultra-complex geometries as well. The directly-driven rotary-swivel axis guarantees good reproducibility coupled with high process dependability – and all this on a footprint of just 1 m². Datron AG, www.datron.de

PSV Mitech’s range of pneumatic rotary actuators is custom designed to suit various applications. The instruments are low maintenance and are available with either a double crank mechanism for modulating control or a scotch yoke mechanism for on/off duty. The double crank provides high run torques, negligible backlash and low friction, while the scotch yoke design has the advantage of high end torques. The actuators are field reversible from clockwise-toclose to clockwise-to-open. A Namur mounting for switch packs or positioners is provided on the top shaft and transfer case lid. With their pneumatic piston design, the actuators are offered in large sizes and can be engineered and fitted to most valves up to a 250 000 Nm torque.

By utilising a square drive, the actuators can be mounted perpendicular to or inline with the pipe work and the adjustable end stops can be externally adjusted in both the open and closed position to within 7º. Greg Walker, PSV Mitech, Tel: (011) 6576000, Email: gregoryw@mitech.co.za, www.mitech.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

45


MARKET FORUM

Horne Conveyance Safety has installed Levelok chairing and emergency braking systems on a cage earmarked for Ivanhoe Mines’ Oyu Tolgoi Shaft Number One in Mongolia. The cage will be used to lower personnel and equipment down the shaft, and to bring them back to surface. Horne’s order was manufactured by the group’s Johannesburg factory in just six weeks, and shipped to North America for supervised installation on the Canadian-manufactured mine cage. The Horne Levelok system was chosen for Oyu Tolgoi because it provides controlled deceleration when operating on the steel shaft guides being used on this project. Additionally, Mongolian mining regulations require an emergency braking system that can arrest the fall of a mine cage carrying personnel under conditions of rope failure. Levelok satisfies both

stipulations, and provides the further benefit of providing a chairing function to overcome the challenge of stretch in the winder rope when heavy materials are loaded.

On the Move Anthony Fouche has been appointed branch manager at Goscor Lift Truck Company Western Cape. Anthony Fouche

Tiaan du Preez

Tiaan du Preez has been appointed Deputy Managing Director of the Genflex Group of Companies. Mark Schäfer has been appointed General Manager for SA Automation (Pty) Ltd, a Randburg-based industrial weighing specialist.

Mark Schäfer

Selomane Maitisa

Selomane Maitisa has been appointed to the Voith Turbo Board of Directors with effect from January 2012. Greg Walker has been appointed managing director at PSV Mitech.

Greg Walker

46

Ron MacLarty

Ron MacLarty, Managing Director of AfriMold, the exhibition for Mouldmaking, Tooling, Design and Application Development in Africa, has been elected as the new chairman of Tooling Association of SA (TASA) Gauteng.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

André du Preez, Horne Group, Tel: (011) 974-1004, Fax: (011) 392-5650, Email: andre@horne-group.com

Index to Advertisers Actom

8

Afrimold 36 Artic Driers

30

Bloodhound

Outside Front Cover

CDC

Outside Back Cover

CMG 27 Energy Cybernetics

20

Engineer Placements

16

Europair 45 GEA Grasso

14

ILS 28 IMS Cape

26

KSB 10 Multi-Alloys 44 PPS 9 Pump & Seal Services Retecon Spectra Carbide

16

Inside Front Cover 4

Verder 42 Weir Minerals

Inside Back Cover


Excellent Minerals Solutions

Would you put your most valuable resource at risk by using non-OEM replacement parts? Our research & development Our quality product Your peace of mind

WEIR is a registered trademark of Weir Engineering Services Ltd

For more information, contact us on +27 (0)11 9292600 www.weirminerals.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

47


48

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

April 2012

SA Mechanical Engineer:April 2012  

SA Mechanical Engineer is the official magazine of the SA Institution of Mechanical Engineering. It is also endorsed by the following bodies...