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S MECHANICAL A ENGINEER April 2016

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

The Future of Making Things in Manufacturing

75 YEARS - AN ETHOS OF MUTUALITY BOOST FOR LOCAL VALVE INDUSTRY


AN ENGINEER’S VIEW

Delusions of Grandeur I decided for some masochistic reason to take a look at the National scarce skills list - top 100 occupations in demand that was gazetted for public comment on 24 April 2014. There was considerable energy spent at the time (from 2012) during which this list was compiled involving various voluntary groups assembling at workshops to find a sensible way to construct such a list.

Chris Reay

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

A

proven in similar environmental circumstances. They are essentially procure and construct, hardly placing much load on the local management knowledge and initiative.

Measuring progress

With the current expectation of a nuclear development with generation 3 reactors, do we really think we can produce any better results than our national projects are achieving now? Concern over the impact of corruption on this programme is real, based on the endemic status that corruption has acquired in this country on so many big cap projects.

fter many meetings and refinements, the documents were submitted to the Minister who promptly asked for comment from the persons who had compiled the report! That seemed pretty pointless as the onus was then on the Ministry and the DHET to come forth with suggested solutions to enable the recommendations of the report to be implemented. Predictably, it lies in limbo, no doubt gathering dust with all the other reports that have been the result of studious research and plain hard work. According to the SONA in 2012, the President announced that over the next three years, SA would spend R840 billion on the 18 SIPs projects making up much of the early part of the National Development Plan (2010-2030). Well, fast forward from 2012 to 2016. Any signs of progress? At the time they were announced, we asked what metrics were to be used to measure the progress of projects against the plan? Clearly we seem to not need them as it is intuitively evident that not much has happened. More recently the Phakisa maritime development programme was announced and so far, looking at the planned deliverables, not much is evident there either.

What is it that drives this national characteristic to have endless indabas, conferences, issuance of plans, green, white and all colours of papers that results in nothing actually being actioned?

Our gazetted scarce skills top 100 list covers about every engineering discipline we have. It is fascinating that the Ministry targeted “30 000 additional Engineers by 2014”. The list is stuck in a 2014 time warp, open for public comment and then nothing!

What is it that drives this national characteristic to have endless indabas, conferences, issuance of plans, green, white and all colours of papers that results in nothing actually being actioned? The Durban to Gauteng pipeline is years overdue and has escalated from an initial cost of R9 billion to R23 billion, and nowhere near complete. Look at Medupi and Kusile - enough said. There seems to be one apparent factor that pervades all these projects as well as countless late or failed municipal and provincial projects: the quality of the Owner’s team. If the Owner’s team is deficient, one can rest assured that the project will be a failure.

Nuclear development

If we consider the renewables projects, they seem to have generally been successful. However, the technologies have been developed overseas and

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S MECHANICAL A ENGINEER On the Cover Baker Baynes

April 2016  VOLUME 66  NUMBER 4

Tel: (011) 589-9031 info@bakerbaynes.com

Contents Cover Story

Pipes, Pumps & Valves

Company Profile

Local Procurement: Valves & Actuators

8 The Future of Making Things in Manufacturing 11 Purpose-designed Equipment 12 75 Years: An Ethos of Mutuality

CESA Presidential Address 15 Mapping a Sustainable Path

HVAC

16 Water-cooled Chiller

New Endorsing Body: SA Plastic Manufacturers Association

22 Acceptable Sanitation to Rural Areas

25 Minimum Threshold

SAIT

33 Call for Participation

Regulars

3 An Engineer’s View 6 Institution News 34 Market Forum

17 11 New Members Sign up to SAPPMA

POWER GENERATION TODAY 19 Gas Pipeline Operators 20 Power Generation News

Copyright

All rights reserved. No editorial matter published in “SA Mechanical Engineer” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields. Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, Official Publication of THE SA INSTITUTION OF MECHANICAL ENGINEERING 2123, Republic of South Africa and endorsed by: Tel: (011) 781-1401, Fax: (011) 781-1403  Email: samecheng@promech.co.za, www.promech.co.za  Managing Editor Susan Custers Editorial Contributors  Liesl Venter/Patricia Holburn Advertising Sales: Louise Cresswell Cell: 071 886 1263  DTP Lindy Fobian/Anne Rotteglia Circulation Catherine Macdiva  Subscriptions Please email us at accounts@promech.co.za if  you wish to subscribe to “SA Mechanical Engineer” at R550,00 (excl  postage and VAT) per year; R1 380,00 per year for Africa/Overseas.   Disclaimer PROMECH Publishing and The South African Institution of Mechanical Engineering  as well as any other body do not take responsibility for the opinions expressed   by individuals.  Printed by: Typo Colour Printing, Tel: (011) 402-3468/9  FSC (Forestry Stewardship Accreditation)

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

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SA INSTITUTION OF MECHANICAL ENGINEERING

Council 2014 - 2016

Company Affiliates Autodesk as represented by Worldsview Technologies

Office Bearers President................................... KK Nyangoni (Kudzai) Vice President................................... E Zawilska (Ewa)

Ainsworth Engineering (Pty) Ltd

National Treasurer............................... A Roos (Andre)

Branch Chairpersons

Alstom Power Service SA (Pty) Ltd

Central .............................................. C Kruger (Carel) Eastern Cape......................... G van den Berg (Gideon)

Babcock Ntuthuko Engineering (Pty) Ltd

KwaZulu Natal .............................R Walker (Raymond) Mpumalanga Highveld .......... PJ Jansen van Rensburg

Bateman Projects (Pty) Ltd

(Jansen) Vaal........................................ Prof LM Masu (Leonard)

Bosch Projects (Pty) Ltd

Western Cape .............................. S Pietrangeli (Sven)

DCD Rolling Stock A division of DCD Group (Pty) Ltd

Portfolios: Communications/ Strategic Planning/ Specialist Groups . . .................................. CD Reay (Chris) Company Affiliates. . .....................................R Mills (Bob)

ELCIME Engineering (Pty) Limited

To be confirmed.................... Prof JL van Niekerk (Wikus)

Festo (Pty) Ltd

Professional Development

Hansen Transmissions SA

Technology Programme.. ...................... SZ Hrabar (Steve)

Hatch Goba (Pty) Ltd

Chief Executive Officer: Vaughan Rimbault National Office Manager: Anisa Nanabhay

Howden Power

PO Box 511, Bruma, 2026

Howden Projects

Tel: (011) 615-5660 Fax: (011) 388-5356

Industrial Water Cooling (Pty) Ltd

Email: info@saimeche.org.za Website: www.saimeche.org.za

Kelvion Thermal Solutions (Pty) Ltd

Membership Email: membership@saimeche.org.za

Megchem Mod-U-Flow CC Osborn Engineered Products SA (Pty) Ltd PaCMan Projects & Maintenance PPS Insurance Co Limited Rotek Engineering S.A.M.E Water (Pty) Ltd SA Power Services (Pty) Ltd Sasol Technology (Pty) Ltd SEW Eurodrive Siemens Ltd

Fluor SA (Pty) Ltd

Programme........................................ M Black (Malcolm)

MBE Minerals (SA) (Pty) Ltd

Spirax Sarco (Pty) Ltd Tenova Takraf Africa – a division of Tenova Mining Thyssenkrupp Engineering (Pty) Ltd Ultra-Flow Engineering Services CC Vital Engineering (Pty) Ltd Weir Minerals Africa Winder Controls (Pty) Ltd

Forthcoming Training Events Centrifugal Pumps, Systems and Slurry Applications Seminar CPD Validation Number: SAIMechE-0912-12/16

Standard Fee: R4 432.00 + VAT Expertise provided by Weir Minerals Africa

Code

Days

Start Date

End Date

Region

APM16

2

12 Sep 2016

13 Sep 2016

Durban

● Different Pump Types ● Pump Performance and System Curves ● All About NPSH ● Series and Parallel Pumping Principles of Centrifugal Slurry Pumping ● Pump Testing and Case Studies and Affinity Laws ● Principles of Centrifugal Slurry Pumping ● Centrifugal Pumps as Amplifiers of Pressure at ‘Constant’ Flow Rate ● Total Heads (Static + Dynamic + Pressure) ● Slurry Pump Selections by Targeting the Applications ● Site System and OEM Pump Curve-six Zones Subject to Adjustments ● Investigating the Influence of the Eight Infamous ‘P’ Parameters ● Metallurgical Mass Balance - RD Solids, Cm, RD Slurry, Ql/s @ t t/h ● Tailings Disposal Systems - Hydraulic, Mechanical, Electrical Engineering ● Selection of Drives - Wedge Belt, Gearbox, Direct Coupled and VSD ● Wet Gland Sealing Utilising Pressurised Gland Service

Booking Closure Date 29 Aug 2016

Water ● Dry Glad Sealing Utilising Expeller Hold-back Characteristics ● Gland Sealing Utilising Mechanical Seals ● Comparing Capital Costs versus Electrical Cost of a Tailings System ● Exorbitant Factors of Safety Resulting in Oversizing of Circuits ● Devastating Effect of Escalating Electrical Cost on the End User TOC ● Mineralogy/Rheology ● Types of Slurries and Viscosity ● Suction Pipeline Parameter, Discharge Pipeline Parameters, Pipeline Intrusion Philosophy, Suction Vessels/Sumps ● Erosive / Abrasive Features, Mill Circuit Discharge and Cyclone Feed Designs/Installation, Mill Circuit Designs (Hoppers, Direct Drives /Gerbox Driven, Piping, Valves, etc.) ● Flotation Froth Concentrate Pumping / Hopper, Designs / Installations, Thickener Underflow Pumping / Designs

All Enquiries: Tel. 031 764 7136 Fees, Booking Forms: Carey Evans, Email carey@saimeche.org.za In-house Bookings and Special Training Requests: Linda Robinson, Email linda@saimeche.org.za

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SA INSTITUTION OF MECHANICAL ENGINEERING

Welding Technology Series of Workshops Shamsheer Singh - Series Developer/Facilitator

Welding Technology - Processes and Consumables Code Days E1716 1 C1716 1

Start Date 24 May 2016 21 Jun 2016

End Date 24 May 2016 21 Jun 2016

CPD Validation Number: SAIMechE-0944-12/18 Region Booking Closure Date East Rand 10 May 2016 Cape Town 7 Jun 2016

This workshop provides a general appreciation of the various welding processes. Consumables and its general applications in industry. It provides an overview of each welding process and the involvement of various departments within an organisation, such as design, engineering, fabrication, construction and maintenance. This workshop explores the various welding processes, its advantages, disadvantages and limitations. It shall create an overall awareness in the selection of an appropriate process for a particular product form. ● History of welding ● Classification of welding processes ● Joint preparation ● Shielded metal arc welding (SMAW/MMA) ● Gas tungsten arc welding (GTAW/TIG) ● Gas metal arc welding (GMAW/MIG/MAG) ● Flux core arc welding (FCAW) ● Submerged arc welding (SAW)

Understanding the Welding Performance Qualification Workshop

Understanding the Welding Procedure Qualification CPD Validation Number: SAIMechE-0945-12/18 Code Days Start End Region Booking Date Date Closure Date E1816 1 25 May 25 May East Rand 10 May 2016 2016 2016 C1816 1 22 Jun 22 Jun Cape 7 Jun 2016 2016 2016 Town This workshop provides a general appreciation of a welding procedure specification (WPS) and a welding procedure qualification record (WPQR). It provides an overview of the essential and nonessential variables stipulated for procedure qualification. It shall create an overall awareness of the requirements for welding procedure qualification in the South African context using international codes. ● Codes/standards/specifications ● Examples of related codes & standards ● Welding procedure specification (WPS) ● Type of mechanical tests ● Range of qualification ● Procedure qualification record(PQR)

Unpacking the Pressure Equipment Regulations

CPD Validation Number: SAIMechE-0935-12/18 Code Days Start End Date Region Booking Date Closure Date C0716 1 1 Jun 1 Jun Cape 18 May 2016 2016 2016 Town A0716 1 14 Jun 14 Jun Durban 31 May 2016 2016 2016 Understanding and appreciating of the Pressure Equipment Regulations (PER) and the correct application of the legislated requirements found within the South African pressure equipment environment. ● Definitions (Including the role of the Guidance Notes within the PER) ● Scope of application ● General requirements and introduction to SANS 347 ● The role of SANS 347 and brief overview ● Duties of manufacturers ● Duties of importers and suppliers ● Duties of users ● Approval and duties of approved inspection authority ● Registration of a steam generator ● Pressure equipment marking ● Pressure and safety accessories ● Inspection and test ● Riskbased inspection ● Repairs and modifications ● Records ● Access and door interlocks ● Gas reticulation equipment and systems ● Transportable gas containers ● Fire extinguishers ● Offences and penalties, Repeal of regulations and annexures & Short title. Mark Sloan- Workshop Developer/Facilitator

Pressure Vessel Design, Construction, Maintenance and Troubleshooting Workshop CPD Validation Number: SAIMechE-0930-12/18 Code Days Start End Date Region Bookings Date Closure Date A3716 1 9 Jun 9 Jun Durban 26 May 2016 2016 2016 The workshop will explain: • The applicable design codes of pressure vessels • How to specify pressure vessels. • How to design and manufacture a pressure vessel. • Selection of materials for pressure vessel manufacture. • The systems related to the operations of pressure vessels • How to safely operate pressure vessels To do this it will cover: • Pressure Vessel Design Codes • Vessel Geometry & Construction • Strength of Materials • Vessel Specifications • Materials of Construction • Pressure Vessel Design Rules • Fabrication, Inspection and Testing • Maintenance planning and control • Safety aspects considered for pressure vessels - Herbert de Vries, Workshop Developer/Facilitator

CPD Validation Number: SAIMechE-0946-12/18 Code Days Start End Date Region Booking Date Closure Date C1916 1 23 Jun 23 Jun Cape 7 Jun 2016 2016 2016 Town This workshop provides a general appreciation of the requirements for welder qualification. It provides an overview of the essential and nonessential variables stipulated for the qualification and certification of welders. It shall create an overall awareness of the requirements for welder qualification in the South African context using international codes. ● Definitions ● Codes; standards; specifications ● Joint preparation ● Welding positions ● American welding society: AWS D1.1 ● Euronorm: EN 287 ● American Society of Mechanical Engineers: ASME IX.

Business Process Mapping Workshop

CPD Validation Number: SAIMechE-0847-12/17 Code Days Start End Region Booking Date Date Closure Date C3516 2 7 Jun 8 Jun Cape 24 May 2016 2016 2016 Town The workshop is about understanding what Business Process Mapping is about, its crucial role in any organisation, how to use and manage different business processes to reduce waste, improve services, ensure effectiveness, and improve profitability. Jac Spies, Workshop Developer/Facilitator

Heat Exchangers Seminar

CPD Validation Number: SAIMechE- 0915-12/16 Standard Fee : R2 216.00 + VAT Expertise provided by Steinmüller Africa (Pty) Ltd and Front End Technology (Pty) Ltd. Code

Days

Start End Region Booking Date Date Closure Date EHE16 1 22 June 22 Jun Gauteng 7 Jun 2016 2016 2016 ● Basic Heat Transfer ● Types of Heat Exchangers ● Mechanical Design of Pressure Vessels ● Economics of Heat Transfer Technology ● Troubleshooting and Maintenance of Heat Exchangers

Flameproofing of Related Protection Methods in Explosive Environments Seminar CPD Validation Number: SAIMechE-0910-12/16 Standard Fee : R2 216.00 + VAT Expertise provided by Pratley (Pty) Limited Code

Days

Start End Date Region Booking Date Closure Date CFL16 1 15 Jun 15 Jun Cape 1 Jun 2016 2016 2016 Town ● Hazardous Locations ● Protection Types ● Legislation, Standards and Testing ● Marking and Selection ● Equipment Design Considerations Fees, Booking Forms & Terms and Conditions Carey Evans, Tel: 031 764 7136 Email: carey@saimeche.org.za

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COVER STORY

The Future of Making Things in Manufacturing External environments are changing constantly and these changes are dictating the way that products are being made. Forward thinking companies are adopting new product innovation strategies to validate, predict and optimise their designs in order to stay competitive – and Autodesk is providing them with the advanced design technologies to be successful.

Challenges manufacturers face today

will revolutionise your design process? The costs of implementing digital prototyping which includes investing in digital prototyping software, computer hardware, as well as training for staff so that they can use the software – and you might need new business process development – will not only be made worthwhile by the gains that you will receive to your business from introducing digital prototyping but you will also optimise the design process from

differentiation, quality pressure and having to ensure the products add more value are more rife than ever. It is because of these challenges that Digital prototyping and Simulation have emerged.

start to finish. Implementing digital prototyping entails using 3D CAD models, such as the Autodesk Simulation Solutions. Using Simulation solutions for the manufacturing process is not an easy undertaking, and it has been compared with 3D CAD modeling which first began replacing 2D models 10 years ago, but once you begin to enjoy the benefits of this software tool you’ll wonder why you didn’t implement it long ago.

Building successful products is harder than ever and the external pressures are changing what we make, how we make it, who makes it and who we make it for. Manufacturers in today’s day and age need to be more innovative than ever, while also taking into account that there are more options available for building them. On top of this, the market forces dictating price pressures, competitive

Manufacturers in today’s day and age need to be more innovative than ever, while also taking into account that there are more options available for building them Digital prototyping for better designs

How digital prototyping works.

You probably already have an idea of how digital prototyping will provide a return on your investment, but did you know exactly how much this software

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In digital prototyping, a simulation model is built to show every aspect of assembly operations in a 3D virtual environment. The system shows how every part of the design will work with the other

April 2016


COVER STORY

parts when completed and even shows how human models will be affected in this environment so that every detail can be examined. This process helps to avoid unwanted events such as collisions down the line in real world situations.

What simulation adds to your designs?

The most important way that simulation improves the design process is the ability to answer “what if� questions before the product is manufactured. Part of the benefit of using digital prototyping is that you will be able to find faults before the product is created, playing out different scenarios to test what will happen. This saves on time, reduces costs and results in a faster turnaround time.

Thoroughly tested product

Another advantage is that processes are improved before you even start working on real life equipment. There is a reduction in production cost and the overall cost for labour. And, with an improved manufacturing process, there will also be reduced development expense and costs involved in reworking the product will be minimised. This ultimately allows you to create resilient designs that are able to withstand several factors thanks to previous testing.

Whether you are looking at an operating room, an emergency response system, a production line, or any other system, designs can be tested for their effectiveness Processes are tested before manufacturing

Essentially, it comes down to manufacturer’s business pressures and seeing a need for improved performance, quality, and reliability in their products in order to compete in what has increasingly become a very competitive market. At the same time, pressures from shorter project cycles and reduced budgets, as previously mentioned, are dictating faster turnaround times and lower development costs, meaning that opportunities for design exploration and optimisation using traditional prototyping methods become limited. Simulation can offer reliable insight for designers and can be applied by designers onto different systems. So, whether you are looking at an operating room, an emergency response system, a production line, or any other system, designs can be tested for their effectiveness. Or alternatives can be sought and solutions applied. Digital prototyping epitomises the future of making things and can be used in order to validate, predict and optimise your product designs. The software tools that enable digital prototyping will help you to evaluate the different alternatives that would be best in your manufacturing process. Autodesk Simulation Solutions is one of many great products sold by Baker Baynes, the first and only Autodesk

Simulation Specialised partners in Africa, and will provide you with a comprehensive solution for your digital prototyping needs. Baker Baynes, Tel: (011) 589-9031 Email: info@bakerbaynes.com

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COMPANY PROFILE

Purposedesigned Equipment

of a similar nature that may have been supplied by other firms.

1. Maintenance – Service and Repair

We have workshop facilities to undertake your service and repair requirements for all your modular shell and tube heat exchangers. We also offer an on-site service and repair team and would be pleased to discuss the best option to minimise your downtime.

Ray Walker

In this new column, we feature one of SAIMechE’s company affiliates (list on page 6). This month, we get the low-down on Mod-U-Flow.

M

od-U-Flow cc was established in 1999 to provide a service to the modular shell and tube heat exchanger user base in particular and ancillary services associated with the product in general. Our staff comprises personnel who have been associated with the modular shell and tube heat exchanger and allied services in Southern Africa since 1979. Our field of expertise includes primarily the design and manufacture of these exchangers. Our expertise includes all aspects of heat exchanger design with particular reference to “special” purpose designed equipment for the many unique processes found in industry. We are able to provide a maintenance facility for all equipment supplied and a replacement parts holding for on-site and/or in-situ refurbishment. We are also be able to repair/refurbish equipment

2. Replacement Parts

We have a large stock holding of replacement parts and can almost always despatch within 24 hours. All components are manufactured in house to insure quality is maintained at the highest level.

3. Technical Services

Specialist technical advice with regard to all your heat exchanger requirements is available. Typical equipment includes, inter alia: gold recovery “elution” systems, acid heaters and coolers, storage and non-storage calorifiers, oil coolers, water/ demineralised water coolers and heaters, process coolers and heaters, compressed air economisers and after coolers, paint and wax coolers, extended surface heat exchangers, etc. Mod-U-Flow is a Level 4 BBBEE Company and is committed to skills development through our in house training programme. Ray Walker SAIMechE, Dip PM, Tel: (031) 702-1972/92 Email: moduflow@telkomsa.net

find out if you qualify to #joinourtable at pps.co.za PPS is an authorized Financial Services Provider.

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75 Years: An Ethos of Mutuality “SA Mechanical Engineer” attended the 75th Anniversary celebration of PPS, the specialist financial services provider to the graduate professional market. The company revealed strong growth in member numbers and significant new business initiatives, which include the transformation of the current PPS Short-Term Insurance brokerage into a fully registered short term insurance company and the launch of PPS Mutual in Australia.

S

peaking in Centurion at the launch of PPS’ new Five Green Star rated office block, PPS Centurion Square, CEO Mike Jackson says that these milestones once again serve to highlight the benefits to the company and its members of operating under an ethos of mutuality.

Mike Jackson PPS CEO

“Despite the economic challenges in 2015, PPS still had an excellent year with respect to growth in membership. More than 7 500 new members joined PPS in 2015 – up by 35% on the previous year – and the growth among student members from across a broad spectrum of campuses is particularly pleasing. While we only announce our final 2015 results on 26 April, we have certainly experienced significant new business growth this past year.”

Profit share

Nazeer Hoosen CEO PPS ShortTerm Insurance

Mike explains that unlike listed financial services companies, who have to maximise profits for shareholders, PPS operates under the ethos of mutuality, which means

that the company exists solely for the benefit of its members, and allocates the totality of its operating profits and investment returns to its members on an annual basis by way of allocations to their PPS Profit-Share Accounts. Over R21 billion has been paid to members over the last ten years. “The fact that PPS doesn’t have external shareholders means it is able to concentrate on its long-term commitments. Unlike a listed company, PPS also has no need to set aggressive short-term profit targets, which often leads to highly volatile returns to shareholders.” Since the inception of PPS in 1941, the company has focused exclusively on servicing graduate professionals in South Africa, says Mike. “Professionals continue to be in high demand in the country as a vibrant professional sector is critical for economic growth, from graduation to retirement.” A major development for the company this year is that PPS Short-Term Insurance, which has been operating successfully as a brokerage for the past seven years, has been transformed into a registered short-term insurance company. The company will in this new capacity continue to focus solely on the short-term insurance needs of the South African graduate professional market. In addition, PPS will replicate its current life assurance business model by launching PPS Mutual in Australia in the near future. Mike says the decision to expand into Australia followed extensive market research. “The study clearly showed a gap in the Australian market with regards to a specialised mutual dedicated to servicing the insurance needs of the growing graduate professional market in the region.”

Thought leaders

PPS Mutual will operate under an ethos of mutuality. The board will comprise of 50% representation from South Africa, ensuring that PPS’s success and knowledge is shared with the Australian management team. South African members will continue to enjoy returns from PPS’ global portfolio and participate in the operating profit from the local and Namibian concerns. Shaun Tarbuck, CEO of ICMIF (extreme left in foreground)

PPS boasts in excess of 200 000 members who enjoy access to a comprehensive suite of financial and healthcare products that are specifically tailored to meet the needs of graduate professionals. PPS is the largest South African company of its

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kind that still embraces an ethos of mutuality, which means that it exists solely for the benefit of its members. Thus, PPS members with qualifying products share in the profits of PPS Insurance via annual allocations to the unique PPS Profit-Share

April 2016


Globally, the mutual and cooperative business model has been the fastest-growing part of the global insurance market, increasing from a global market share of 23.5% in 2007 to 27.1% in 2014, according to statistics from the International Cooperative and Mutual Insurance Federation (ICMIF). In Africa alone, there are now about 40 mutual/cooperative insurance companies which serve about eight mil-

lion policyholders. At over 200 000 members, PPS is the largest such company in the world. Shaun Tarbuck, CEO of the ICMIF concludes, “Having worked closely with PPS over the last few years I can honestly say they are an excellent organisation with exemplary leadership. Within the mutual sector globally, they are certainly one of the thought leaders at ICMIF.”

Short-Term Insurance According to Nazeer Hoosen, Chief Executive Officer: PPS Short-Term Insurance Company, following the successful growth of the business, paired with a better understanding of the specific risks of the graduate professional market, the business has entered the next phase of its strategic roadmap. “By becoming a short-term insurer, we will be able to design and underwrite new products that provide solutions which address the evolving needs of our members, in both their private and professional capacities,” says Nazeer. “Having been granted a licence by the FSB, our new short-term insurance offering will in due course also add to our traditional profit allocations.” Nazeer explains that in order to operate successfully as a short-term insurance company, PPS Short-Term Insurance will enter into a joint venture with Santam where Santam

will assist PPS Short-Term Insurance to develop the systems required for operation as a short-term insurer and provide claims administration services. “Santam will also be taking up a shareholding in PPS Short-Term Insurance.

By becoming a short-term insurer, we will be able to design and underwrite new products that provide solutions which address the evolving needs of our members, in both their private and professional capacities “Everyone at PPS Short-Term Insurance is incredibly excited for the next phase of the business and look forward to tailoring policies to better meet the unique needs of South Africa’s discerning graduate professional market,” Nazeer concludes.

Account and those who have PPS Investments products can also share in the profits of PPS Investments.

PPS Insurance, PPS Short-Term Insurance, PPS Beneficiaries Trust, PPS Investments and Profmed Medical Scheme.

PPS membership provides access to the following tried, tested and trusted products and services:

PPS is an authorised financial services provider. PPS, www.pps.co.za

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CESA PRESIDENTIAL ADDRESS

Mapping a Sustainable Path In February, “SA Mechanical Engineer” attended a function where Lynne Pretorius, the newly-appointed President of the Consulting Engineers of SA (CESA) gave her presidential address. (A shortened version is printed here) Although the South African government has accomplished much in the last few years, finances are sorely lacking to meet the growing infrastructure challenges. At the 2015 Infrastructure Indaba, three possible avenues were explored to meet these challenges: X X Private sector should increase its investment in public infrastructure development X X Maintenance of existing infrastructure to ensure that it remains serviceable for the duration of its design life and beyond X X Addressing inefficiencies in the supply chain management system.

Ultimately, the employment of qualified and registered engineers in senior engineering positions in government is the solution Technical capacity

Within this environment, can SA’s vision, encapsulated in the National Development Plan, actually be delivered on? Or, it is it pie in the sky, maybe a pipe-dream? Although the implementation may seem to be slow, it provides a much-needed plan and clearer direction for investment in the future and government’s priorities. The technical capacity to deliver on the NDP is also being queried. In 2005 research commissioned by the Department of Labour indicated that about 75% of all engineering professionals were employed in the private sector. The limited engineering capacity in the public sector is also a concern and budgets go unspent; sometimes purely due to the lack of proper planning of infrastructure investments and the capacity to manage these projects properly.

Delivering more with less

√√ Multi-professional teams are required to respond to all the challenges (social, environmental, financial and technical) that might be experienced on large infrastructure projects. √√ The fast-tracking of young engineers with potential through the development process is critical. √√ Improved bids for consulting engineering services and cost estimates will make it so much easier for public officials to facilitate procurement. √√ We have to get it right the first time and be vigilant about quality control. √√ The role of technical specialists and experts cannot be underestimated. This requires continuous research and development to be funded and supported.

Lynne Pretorius, CESA President

√√ Operating and sustaining the consulting engineering industry in a competitive procurement environment. Business as usual will not be sufficient. Profit margins reported in the CESA Bi-Annual Economic and Capacity Survey of June 2015 indicate that the larger firms are experiencing profit margins of just 9%. The majority of firms expect margins to weaken, and sentiments stated point to an industry under higher levels of financial distress. These challenges influence the consulting engineer’s ability to produce quality work and we have to guard against this and maintain CESA’s ethos of quality engineering. • CESA has recently met with National Treasury and signed a MoU to assist with the monitoring of the implementation of the Standard for Infrastructure Procurement and Delivery Management. • The Office of the Chief Procurement Officer also announced at the Infrastructure Indaba National Treasury’s intention to separate the procurement of consulting engineering services from the Procurement of Goods and Services. In addition, one of the major challenges facing the project delivery pipeline is the development of appropriate Project Scope and Specifications as part of the procurement of consulting engineers. CESA has been engaging with the Department of Public Works to find ways of supporting their project delivery offices. This can be achieved through the placement of retired engineers to prepare project specifications, as well as provide the mentoring support that is so critically needed to develop young engineers. It must be acknowledged though that this is perhaps only an interim option. Other options include supporting Project Management Offices, secondments from consulting engineering firms and the use of consulting engineers, etc. However, ultimately, the employment of qualified and registered engineers in senior engineering positions in government is the solution. CESA, www.cesa.co.za

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HVAC

Water-cooled Chiller To meet the demand for a higher efficiency yet compact water cooled chiller range, a range of chillers has been launched which claims to outperform rival products.

I

n addition to Eseer values of up to 8.86, the TurboChill Water Cooled provides a 7% increase in EER, and up to 111% more cooling per square metre than its nearest competitors.

Providing up to 1576kW of cooling (based on 4 modules), this high capacity, water-cooled, single circuit chiller is optimised for use with three module variants (1.96m² footprint per module), including the R1234ze TG310 range which has been specifically developed for use with the low Global Warming Potential (GWP) refrigerant R1234ze.

Component layout

Its scalable modular design, enables multiple

modules to be connected via a common waterside and an integrated multiple module control strategy. This means that capacity can easily be increased at a later date, as capacity requirements grow, by simply adding more modules. Also, component layout is designed to enable several units to be positioned side-by-side in restricted plant rooms, yet still ensuring easy access to essential components. Innovative compact spray type evaporator technology means that the chiller reduces space claim (m²) by 67% and refrigerant charge (kg) by 56% but provides the same performance when compared with a traditional flooded shell and tube evaporator of the same nominal capacity.

This means that capacity can easily be increased at a later date, as capacity requirements grow, by simply adding more modules Near silent operation

All units incorporate the latest Centrifugal TurboCor compressor technology. These intelligent, selfoptimising compressors enable 30 – 100% variable speed control for tighter setpoint management and unbeatable efficiencies at part load. Magnetic bearings within the centrifugal compressor levitate the compressor shaft and, with no mechanical contact or friction between mating surfaces, the need for lubrication is eliminated with near silent operation. AIAC Air Conditioning South Africa, Tel: (011) 794-6290 Email: info@aiac.co.za, www.aiac.co.za

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NEW ENDORSING BODY: SA PLASTIC PIPE MANUFACTURERS ASSOCIATION

Members of SAPPMA’s Technical Committee at a recent meeting

11 New Members Sign up to SAPPMA

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he Southern African Plastic Pipe Manufacturer’s Association (SAPPMA) has welcomed 11 new members since the beginning of the year, of which five are manufacturers of plastic (PVC and HDPE) pipes. According to SAPPMA CEO, Jan Venter, they are very pleased with this growth, despite the fact that members are operating in very difficult economic and market conditions.

We are proud of the fact that we now represent close to 90% of all the plastic pipes being produced in South Africa “A well-engineered pipe system is dependent on good design, high quality pipe, and a strict adherence to standards. We are proud of the fact that we now represent close to 90% of all the plastic pipes being produced in South Africa, and the entire value chain,” Jan says.

New memberships

The following companies have been issued with new membership certificates: Macneil Plastics, Southern Pipeline Contractors (SPC), Amanzi Starway, BLP Rubber, PESC, Borouge, Inkulu Plastic Pipes, Pexmart, Swan Plastics and Pipe-Tech. “We decided to join SAPPMA because it is the only organisation that unites all role players in our industry – from those that supply the raw materials all the way through to end users. It is a body that sets high standards and regulates these standards equally effectively with their audit department. “By joining SAPPMA, we feel we are seen as a legitimate partner in the industry and in the industry organisation,” says Derek Faulds, Managing Director of Cape Town based Macneil Plastics

which produces PVC pressure pipe, sewer pipe, plumbing fittings, irrigation fittings and HDPE pipes and serves both the plumbing industry as well as the civils industry. “All role players in the industry are aware of the quality standards and pledges that SAPPMA holds us accountable to. We want to be seen as being subject to these quality pledges. We are proud to announce ourselves as SAPPMA members to our customers, because of the perceived quality and standards that go with this membership,” Derek explains. This sentiment was echoed by Mike Swanson, of Swan Plastics (Pty) Ltd, who also recently joined SAPPMA. “We saw the UPVC market was in need of a well-structured organisation to ensure that top quality in the manufacturing is maintained.”

Relevant information

Durban-based Swan Plastics was started in 1993, and supplies the building civils, agriculture, mining and electrical industries with SANS, SAPPMA and JASWIC approved plastic pipe products. “We are continuously upgrading our product range by investing in new technology and state-of-the-art manufacturing equipment and never compromising on service or quality. To this end, we have found one of the biggest benefits of belonging to SAPPMA to be the relevant and important information that is shared with members relating to market requirements,” Mike says. Graham Marsberg, Managing Director of Productivity Engineering and Consultants (PESC) says their vision of bringing about positive change and contributing to the plastics industry, resonates with SAPPMA’s vision of uncompromising quality, standards and the pursuit of industry excellence.

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NEW ENDORSING BODY: SA PLASTIC PIPE MANUFACTURERS ASSOCIATION

Real-time monitoring

PESC is a productivity monitoring and enhancement company specialising in the fields of polymer testing, electrical and mechanical engineering. PESC applies the knowledge and experience of productivity enhancement and production monitoring in its own facility with real-time monitoring of laboratory conditions, ovens and pressure units. “We wanted to join SAPPMA because they are a well-recognised organisation equipped with a wealth of knowledge. They are therefore an incredible resource not only to us at PESC but to the whole of the plastics industry in South Africa,” Graham says.

Belonging to SAPPMA is a certain way of differentiating the responsible players in the field from those who are reckless about quality and ethics “For us, we feel it is very important to have a governing body to regulate all the companies within the industry. By joining and being a member of SAPPMA all our clients have the peace of mind that we adhere to the industry standards and regulations regarding manufacturing of HDPE pressure pipe,” adds Renier Pieterse, Sales & Marketing Manager of Pexmart.

Learn about the industry

Pexmart supplies and installs HDPE pipes and fittings for water, sewerage and industrial pipes. They specialise in the manufacture of 20mm – 800mm

pipes in sizes, and also fabricate HDPE fittings such as T-pieces, bends, laterals and reducers. “Clients have that extra peace of mind knowing that we are members of SAPPMA. By joining the association, our company has enjoyed more exposure through the SAPPMA website and their documents which now also have our company logo displayed. Being involved with discussions and SAPPMA meetings has allowed us to learn about the industry, while we can also contribute and plough back into the industry some of our knowledge and expertise.” “Our recent growth in numbers bears testimony to the fact that membership of SAPPMA continues to add value to individual organisations, as well as ensuring quality and peace of mind for the end user. By enlarging our footprint, we can speak with a stronger voice when it comes to matters that directly affect our industry, ranging from non-compliance to industry standards, to protecting our members against inferior imports. “Belonging to SAPPMA is a certain way of differentiating the responsible players in the field from those who are reckless about quality and ethics, unlocks substantial benefits for members, and increases marketing exposure for them through being part of a reputable, regulated association,” concludes Jan. SAPPMA Tel: (011) 314-4021 Email: admin@sappma.co.za www.sappma.co.za

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+27 11 695 2500/3 steamgeneration.co.za

Also visit Cochran at: cochran.co.uk FAX +27 11 312 4710

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Energy Solutions Worldwide

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POWER

POWER GENERATION

GENERATION PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: samecheng@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial Contributors: Liesl Venter and Patricia Holburn Advertising: Louise Cresswell 071 886 1263 Circulation: Catherine Macdiva DTP: Lindy Fobian/Anne Rotteglia Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.

Copyright

All rights reserved. No editorial matter published in “Power Generation Today” may be reproduced in any form or language without written permission of the publishers.

T O D A Y

Gas Pipeline Operators Highly-flexible K couplings and HyGrip connection couplings ensure that the process gas equipment in the USA that generates gas pipeline pressure for transportation or underground storage, continues to remain operational throughout the year and throughout changing power conditions.

Gas compression equipment maintains pipeline pressure in the most cost-effective way possible, ensuring maximum revenue returns. Dual-drive gas compression sets have proven themselves in the market to be a cost-effective means to ensuring this even when power conditions at site are not favourable to maintain process operations.

type K is installed between the gas engine and the electric motor, thus protecting the driveline from the damaging torsional vibrations emanating from the reciprocating motion of the gas engine when in operation.

While single-drive systems customary in the USA use either a gas engine or an electric motor drive, dual-drive compressors combine both alternatives. This allows the package to run on more costefficient electricity by default. However, should the motor become unavailable, or the grid demand rise, thus increasing the price of electricity, the prime mover can be switched over to the gas engine on the fly due to the incorporation of a SSS clutch between the gas engine and electric motor.

Another Voith coupling is installed between the electric motor and the compressor. This isolates the electrical motor from the damaging torsional vibrations emitted by the reciprocating compressor, when running on purely electrical motor operation. The HyGrip connection couplings are installed on either side of the electrical motor to aid in removal and refit.

A dual-drive package from the Standard Equipment Company (SEC) in Houston makes this technically feasible. In this package, a highly-flexible Voith coupling

Dampen torsional vibrations and shift resonance frequencies to below the idle speed

Below the idle speed

SEC has ordered in excess of 35 packages to date from Voith for its BR 210 and BR 260 series K couplings (size 90) with a rated torque of 82 kNm, as well as another ten K couplings of the same series (size 75) with a rated torque of 28 kNm as compressor sets. The most important advantage of these highly-flexible couplings for the operating company is that they dampen critical torsional vibrations and shift resonance frequencies to below the idle speed. This extends the lifespan of all the connected drive components. On new sites in the US, it can take up to 18 months to receive approval and installation of three-phase power. A major advantage of the dual-drive package is that it allows the site to operate solely on the gas engine during this period. After three-phase power is linked, the package can simply be switched over to the more cost-effective electric motor-driven prime mover. Voith, Tel: (011) 418-4000, www.voith.com

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POWER GENERATION NEWS

Local Production ARTsolar has recently completed production of the final consignment of locally produced photovoltaic (PV) modules in the Government’s Round 3 of the Renewable Energy Independent Power Producer Programme (REIPPP). “These PV modules were manufactured at the ARTsolar plant in KZN, for the Mulilo Sonnedix Prieska PV solar plant project. This plant, which supplies the electricity it produces to the Eskom Kromos Substation in the Northern Cape, is the first 75 MW AC size REIPPP project to have PV modules produced by a South African owned company,” says Derek Lawrance, director, ARTsolar.

These PV modules were manufactured at the ARTsolar plant in New Germany, KwaZulu-Natal, for the Mulilo Sonnedix Prieska PV solar plant project. Liam McIntosh is responsible here for framed PV modules, which are rotated into a vertical orientation for earth leakage and sun simulation testing.

“We made a substantial investment in new machinery and increased the total floor space of the plant from 3 500m² to 10 00 m². The single day shift operation was increased to a 24 hour/six day schedule and we expanded our team to 200 staff.” ARTsolar, Tel: (031) 705-7162 Email: sales@artsolar.net www.artsolar.net

Rectify Power Problems Even the slightest variations in power supply can cause vital equipment to crash and essential processes to falter. Worse still, data processing errors can arise as sensitive equipment struggles to cope with any variety of surges, sags and dirty mains. This could result in organisations losing business critical information.

Marco Da Silva

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Enterprises in other sectors should begin following the path of the mining and heavy industry sector, with robust power solutions to filter power and stabilise voltage to prevent potential issues as a result of power problems. Constant Voltage Transformers (CVTs) are a type of ferro-resonant transformer, a highly robust technology that provides power filtering and voltage stabilisation. Power filtration is delivered through galvanic isolation, which is created by isolated primary and secondary coils within

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the transformer. Voltage stabilisation is generated through the ferro-resonance of the transformer. A CVT unit can perform a number of functions, including as a power filter, voltage stabiliser, isolation transformer and a harmonic filter, enabling it to rectify power sags, swells, dips, spikes and harmonics. It provides multiple functions around power conditioning to help organisations protect their equipment from dirty power, making it a very costeffective solution. It effectively acts as a barrier between harsh voltage swings, harmonics, dirty or noisy power, which are fed into the CVT, and ensures clean smooth output of the sinewave, which is then delivered to equipment. Jasco Group, Marco Da Silva, Tel: (011) 746-6800, Email: marco.dasilva@jasco.co.za


POWER GENERATION NEWS

Back-up Power Supply DPI Plastics is installing power generators and back-up UPS battery systems at both its Roodekop, Johannesburg and Bellville, Cape Town manufacturing facilities.

“The power back-up system will be able to keep the machines running without interruption in the event of an unexpected power cut or anticipated load shedding. This will save the downtime

The fuel cell industry has the potential to revolutionise the way power is delivered – from cars to mobile phones and computers, as well as to homes and workplaces. Fuel cell technology is aligned with the Chamber of Mines’ commitment to an agreement reached at COP21, aimed

on the machines and lower the risk of damage, and save us a lot of material that would otherwise have had to be recycled.” Scheduled to be completed in the first quarter of 2016, the project involves 3 MVA of back-up power at Roodekop, which is sufficient to keep the entire extrusion and mixing division and auxiliary services up and running. DPI Plastics, Martine Goodchild, Tel: (021) 957-5600, Email: mgoodchild@dpiplastics.co.za, www.dpiplastics.co.za

(Implats), in partnership with the Department of Science and Technology, the University of the Western Cape and Hydrogen South Africa Systems, unveiled its prototype hydrogen fuel cell forklift and refuelling station at its refinery in Springs, east of Johannesburg. Over the last three years, Implats has contributed R6 million towards the development of the prototype forklift and refuelling station and plans to use hydrogen fuel cell technology as its main source of energy for material handling and underground mining equipment.

Hydrogen Fuel Cell

Renier Snyman, technical manager at DPI Plastics, stresses the serious repercussions of any unplanned load shedding or power outages at its main Roodekop plant, in particular. “When the power goes down, the extruder stops, leaving a certain quantity of PVC inside the machine. This material has limited heat stability, which means it starts to degrade as it cools down.

“When this happens, you cannot simply heat up the extruder and start the process again once the power comes back on. Basically you have to strip the machinery first and break the PVC out of the tooling. Once the tooling and machinery are clean, it then has to be reassembled and heated up to the correct temperature before you are able to restart the line,” Renier explains.

at creating a more environmentally sustainable future through the Sustainable Development Goals. The Chamber of Mines’ office in the Johannesburg CBD continues to be powered by a platinum fuel cell that uses low-pressure natural gas. Impala Platinum Holdings Limited

In the interests of pursuing a cleaner environment, the Chamber of Mines is supportive of Implats’ fuel cell initiative and particularly pleased and proud to be celebrating the first year of continuous and successful use of its own fuel cell. Chamber of Mines, Jane Kamau Appiah-Yeboah, Tel: (011) 880-3924, Email: jane@rair.co.za or Jeannette Hofsajer-Van Wyk, Email: jhofsajer@chamberofmines.org.za, www.chamberofmines.org.za

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PIPES, PUMPS & VALVES

Acceptable Sanitation to Rural Areas A pumping system designed to separate solids and pump waste water over longer distances, holds the key to providing acceptable sanitation to rural villages and sparsely inhabited areas where, until recently, the bucket system and pit latrines were the only alternative.

Hendrik Enslin of KSB Pumps and Valves

D

esigned and developed by KSB Pumps and Valves, the Ama DS allows treatment of wastewater to be undertaken further from treatment plants and makes it viable to collect wastewater from larger collection areas for treatment at centralised plants.

The genius of the system is the ability to immediately remove solids from the system and separate them from the water According to Hendrik Enslin, KSB wastewater projects and applications manager, the system enables wider and more cost-effective collection of wastewater and paves the way for the development of sanitation systems in rural areas or those where sanitation was not deemed possible due to unsuitable geographical location or where gravitational systems could not previously be implemented.

Large area coverage

“The genius of the system is the ability to immediately remove solids from the system and separate them from the water. This enables pumps with smaller free passages to be used. As a result, the system pumps water over much longer distances than previously possible.

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“In addition, with the solids removed, there is nothing to impede or block the impellers etc, which allows for a far more reliable system and cleaner more hygienic pumps for ease of serviceability. Once solids build-up to a predetermined level, some of the processed wastewater is then used to bypass the pumps and flush the solids to the treatment plant. “This effectively frees municipalities or communities to pump waste to more distant treatment plants or to establish centralised plants that can be shared by many different communities in a region. We are hoping that this will play a significant role in bringing sanitation to all parts of the country,” says Hendrik.

Technology

Technology has been used to overcome an age-old problem and provide configurable solutions that can be tailor-made to suit applications. Using smart level meters, the entire system can be managed to ensure it is able to cope with varying demands throughout daily, weekly and even seasonal fluctuations. Both water and solids levels are constantly monitored and purged as and when required. Inflow and outlet April 2016


PIPES, PUMPS & VALVES

This effectively frees municipalities or communities to pump waste to more distant treatment plants or to establish centralised plants that can be shared by many different communities in a region

pumps are only operational when required and the system therefore uses less energy which is an important consideration in far-flung areas. In addition, the Ama DS system is well suited for applications in municipal and industrial wastewater transport, drainage of hotels, hospitals, campgrounds, low density housing projects etc. Systems are available to handle anything from 6-200 cubic metres per hour. Apart from the obvious benefit of providing sanitation in far-flung and rural areas, the Ama DS pumping system is more reliable than traditional pumping systems as a result of solids being removed before entering the pumps, leading to reduced downtime as a result of less wear and blockages, cleaner and safer operation, and less maintenance.

How it works

Hendrik explains that the patented solids separation system removes solids and temporarily stores it in separators. Only pre-treated wastewater, not containing coarse solids, flows through the pumps. The pre-treated wastewater is pumped through the solids separators in the opposite direction and carries the solids out of the separators and into the discharge line. Through this process, the solids separators and pumps are cleaned and ready for the next inflow phase. “During the design stages, our experts also paid great attention to maximising operating reliability in order to keep future maintenance to a minimum. Necessary servicing work can also be carried out while the equipment is in operation and service personnel do their work in hygienic working conditions. Maintenance to the externally installed solids separators can be conducted very easily, quickly and without shutting down the system,� he concludes. KSB Pumps and Valves, Annett Kriel, Tel: (011) 876-5600 Email: Annett.Kriel@ksb.com, www.ksbpumps.co.za

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An accessible and clear guide on how to grow your business through export

E

ngineers receive a broad education in the nuts and bolts of machinery, equipment and systems but not much attention is paid to the commercial aspects of running an engineering concern.

“Engineering World”, a new annual publication being produced by Promech Publishing, in co-operation with the SACEEC (SA Capital Equipment Export Council), will serve to make financial and commercial decisions easier for engineers to make. The publication will focus on the export market but also on local content as a reliable tier of suppliers and supplier industries is vital to local manufacture. SACEEC will share its experience and expertise on a variety of elements that must be taken into account to become a successful exporter, such as:

Freight forwarding Tax matters Forward cover Deciding on what to sell to whom The culture and customs of the export destination country Building a robust supply chain The financial implications of exporting Marketing internationally Building a presence in the destination country Getting the correct legal advice. The SACEEC has assisted many companies in navigating the pitfalls of going over our borders. They remain committed to growing South African exports and have generously agreed to share their knowledge with the readers, in the interests of the country and our economy.

Eric Bruggeman, MD of SACEEC: “What you didn’t think to

ask? We trust that this first-of-its-kind publication will prompt capital equipment companies, who are contemplating the export route, to ask the right questions before setting off on what can only be described as an exciting and potentially lucrative journey.”

Contact the SACEEC on admin@saceec.com For advertising, contact Louise Cresswell on Tel (011) 781-1401 or 071 886 1263 For editorial: contact Patricia Holburn (B Comm BA Eng.Comm) on pathl@mweb.co.za


LOCAL PROCUREMENT: VALVES & ACTUATORS

Minimum Threshold “SA Mechanical Engineer” attended the function where the Valve and Actuator Manufacturers Cluster of South Africa (VAMCOSA) announced that on 11 February 2016, National Treasury published the updated Instruction Note stipulating the minimum threshold for local production and content for valve products and actuators.

T

he updated Instruction Note provides clarity on topics such as how local content should be calculated and what constitutes local content, while providing some protection for major suppliers such as foundries, forge shops, and steel/stainless steel suppliers.

Assuming that by changing the name of the valve in the tender or request for information process, that designation does not apply Clarification regarding how the 70% local content is made up includes the use of locally produced and certified castings, forging and fabrication as well as verifiable manufacturing activities such as machining, drilling, coating, assembly and testing.

No averaging-out

Further, the averaging-out of local content either

across any number of valves and gearboxes / actuator combinations or locally made and imported valves or other items is not permitted. Each individual valve, manual actuator or pneumatic actuator is subject to the minimum 70% local content threshold. In addition, the valve type list has been updated to include the “also known as” names of valves. For example a check valve is also known as a non-return valve or reflux valve or tilting disk valve and so on. This is to curb the number of state-owned-entities, departments, including municipalities as well as contractors working with state-spend, assuming that by changing the name of the valve in the tender or request for information process, that designation does not apply. (See pages 26 to 32 for the full designation document). VAMCOSA, www.vamcosa.co.za

Ithuba Valves manufacture, refurbishment of Water Works valves ranging from 80mm to 3000mm with working pressure ranging from 10 bars up to 40 bars. We also service valves in-situ and supply the following products. • Resilient Seal Gate • Ball valves • Air Valves • Plunger Valves

Products Butterfly Valves from 80mm - 3000mm Wedge Gate valves from 80mm - 1800mm Reflux Non-Return valves from 80mm - 1500mm Sleeve valves from 100mm - 1800mm

Tel: (011) 864-2582 • Fax: (011) 864-2381 Email: sales@ithubavalves.co.za • Web: www.ithubavalves.co.za THE SOUTH AFRICAN MECHANICAL ENGINEER

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LOCAL PROCUREMENT: VALVES & ACTUATORS

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SAIT

Call for Participation Tribology 2010 was a project sponsored by the Department of Science and Technology to determine the cost and energy savings potential of tribology in South Africa. Data for this project was collected by SAIT through numerous face-to-face meetings across all of industry, both Government and private sector, and all forms of mechanisation.

T •

• • • •

ribology is a relatively unknown science in South Africa, and friction and wear are not sufficiently monitored at any level. Major findings of the project were: Tribology is mostly interpreted as lubrication, and lubrication makes up 0.24% of a typical balance sheet. Management is generally short term and profit driven. Maintenance is often sacrificed to production. Lubricant consumption averages 20% of installed capacity against an international benchmark of 10%. Over the past 25 years the average life of both rolling element and plain bearings has dropped by two thirds and gearbox life to overhaul has dropped between 80 to 90%. The major causes of reduced bearing and gearbox life were found to be misalignment, dirt entry throughout the supply chain, and a general reduction in technical skills across industry. Overall, if industry was able to get back to basics and focus on tribology, energy costs could be reduced by between 8 and 20%, and maintenance costs by 30 to 50%.

The working groups will rely on membership from interested parties with specialist skills in the respective working group To further tribology at all levels in South Africa, the Department of Science and Technology has established a Technical Steering Committee Tribology (TSCT), which has five working groups.

1 2

Education, skills and development: To encourage the inclusion of tribology to artisans, technicians, technologists, scientists and engineers at tertiary institutions. Lubricant selection, standards development and quality control: The current SANS for lubricants are based on 1980/1990 performance profiles, and are not meeting the minimum requirements as specified by modern equipment suppliers. This working group will develop comprehensive standards to meet the equipment builders requirements, particularly with reference to conformity, compliance, and quality standards.

3

Materials: As material wear is inevitable it can never be eliminated, however it can be reduced or limited by designing, manufacturing

and then employing the correct material for every component and application. A tribology study which focuses on the development of innovative materials solutions could lead to the establishment of new manufacturing plants which would address job creation, and place South Africa in the global market to either provide competitive products or become leaders in specific materials and components.

4

Mechanical applications: Production occurs at all levels throughout agriculture, mining, industry, quasi government, local government and central government. The essential elements of production are a source of power and production machines. This working group will develop an overview of energy consumption and potential energy savings throughout all levels of production, both if the original equipment builders standards were maintained, and the potential savings that can be expected if current available technology were applied. Further potential savings due to extended component life should be assessed. Areas for potential research that would make South Africa more globally competitive must be highlighted.

5

Condition monitoring and maintenance programmes: Maintenance and life cycle activities are required throughout industry to ensure that manufacturing equipment continues to operate in an as-designed condition, and to eliminate equipment breakdowns which can be both prohibitively expensive, and result in failed shipping schedules with poor customer satisfaction. Properly applied proactive and predictive maintenance programmes can significantly reduce energy costs, and maintain equipment productivity, thereby making industry more efficient, and more globally competitive. The effectiveness of these working groups will depend on input from all levels of industry. The working groups will rely on membership from interested parties with specialist skills in the respective working group. If you feel you have specialist skills and would like to contribute to this project, which has been established to make industry in South Africa more competitive on a global level, please contact: secretary@sait.org.za Patrick Swan, SAIT Vice-President TSCT Vice Chairman and leader of the Mechanical Applications working group.

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MARKET FORUM

Comprehensive Range Sew-Eurodrive Cape Town branch manager, Byron Griffiths, reveals that the company recently supplied ten FF107AM132 parallel helical geared motor units to the Matsapha Greenfields Wastewater Treatment Plant in Swaziland. “These units are ideally-suited for a mixing application in the wastewater treatment plant.” The company also supplied geared motors for the mixers at the Saldanha Wastewater Treatment Works. “We provide detailed calculations that are customdesigned to each and every client’s

individual specifications and preferences,” Byron says. Sew-Eurodrive supplies equipment for applications such as aerators, Archimedes screw pumps, mixers, screen drives, bridge drives and rotary filters. Byron believes that the greatest challenge in the industry is supplying a good quality product that meets the specifications laid out by industry, at the best possible price. Sew-Eurodrive, www.sew.co.za Tel: (011) 248-7000

The South African Competition Commission recently ruled that the practice of using fee guidelines within the Built Environment Industry is non-completive and effectively results in price-fixing. This follows an application, in 2014, by the Council for the Built Environment to have the practice of Fee Guidelines exempted from the Competition Act. Simon Berry, director, Fresh Projects, an online business platform tailor-made for South African built environment professionals, says the rejection of fee guidelines could potentially be

a positive move for the local industry. “South Africa is more than two decades behind international markets in terms of its use of fee guidelines. A decision to move away from using them could be good news for the local industry, although it will probably take a decade to fully eradicate the practice in totality,” says Simon. The Competition Commission claims that the use of fee guidelines reduces price competition and could also result in prices within the built environment

being set above the competitive level to the detriment of consumers. “If we had to follow international practice then we should have scrapped this approach a long time ago. There have been too many guessing games within the industry, with so many professionals relying too heavily on fee scales and not understanding the true cost of a project,” says Simon. Fresh Projects, Simon Berry, www.freshprojects.co.za

Concept Tyre After 117 years of making tyres, Goodyear presented a vision of a future tyre that looks radically different from tyres today —it’s a sphere. Goodyear unveiled its latest concept tyre, Eagle-360, at the Geneva International Motor Show. The spherical, 3-D printed tyre highlights Goodyear’s vision for the future and presents an inspiring solution for the long-term future when autonomous driving is expected to be more mainstream. “By steadily reducing the driver interaction and intervention in self-driving vehicles, tyres will play an even more important role as the primary link to the road,” says Joseph Zekoski, Goodyear’s senior vice president and chief technical officer. “Goodyear’s concept tyres play a dual role in the future, both as creative platforms to push the boundaries of

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conventional thinking and as testbeds for next-generation technologies.” The unique shape of the Goodyear Eagle-360 could contribute to safety and maneuverability to match the demands of autonomous mobility. The spherical shape of the tyre is key to delivering ultimate manoeuvrability. The multi-orientation tyres move in all directions, contributing to passenger safety. Active technology allows the tyre to move as needed to reduce sliding from potential hazards, such as black ice or sudden

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obstacles, so it contributes to staying on a safe path. Goodyear, www.goodyear.co.za


MARKET FORUM

“Water treatment as a whole is becoming more and more relevant in the South African context. While many of the issues around the looming water shortage in the country are related to the risk posed by the diminishing quantity, there is less discussion about the risk posed by water quality,” comments Andrew Officer, water business unit regional director at Hatch Goba. “This is simply because as the water quality deteriorates, there is a commensurate increase in the cost associated with water treatment.” Andrew points to major water-quality issues such as the acid mine drainage problem in Gauteng and other mining-intensive areas, and eutrophication in Hartbeespoort Dam. Hatch Goba is busy in Botswana, Mozambique and Lesotho at the moment from a treatment perspective. The company is currently halfway through construction of the upgrade of

The Darvill Wastewater Treatment Works in Pietermaritzburg

the Darvill Wastewater Treatment Works in Pietermaritzburg, owned and operated by Umgeni Water. This project is aimed at increasing the ultimate design capacity from 50 megalitres a day to 120. In November last year, Hatch Goba completed another major wastewater treatment upgrade for Johannesburg Water, boosting the capacity at the Bushkoppie plant near Soweto from

Safe, Accurate and Intuitive

At the Midmar Waterworks near Howick in KwaZulu-Natal, the company will nominally add 125 megalitres a day of water treatment capacity in a major project that has just commenced construction, with completion anticipated in 2017. Hatch Goba, Tel: (011) 239-5300, www.hatchgoba.co.za

Watson-Marlow Fluid Technology Group has introduced its new 530 peristaltic cased pump for metering and transfer applications such as surface coating, printing and lime addition. The cost-effective pump offers easier operation and greater versatility coupled with high levels of accuracy.

a bright colour display, while an intuitive menu structure makes for confident and easy operator interaction.

The new models meet the demands of rugged and often remote environments and are built to operate 24/7 without interruption. Furthermore, it is possible to quickly check control parameters and avoid expensive errors with visual status through

In addition, the 530 pumps have no expensive seals, valves or diaphragms, and do not suffer gas locking, corrosion or clogging. Furthermore, they require just a single spare part inventory, the tube.

Flexible Couplings

Users will also benefit from the 530 models’ integrated Pofibus networking capabilities. With two-way, real-time communications, the range offers increased diagnostic capability and faster response. This helps to optimise process control and minimise plant downtime.

Watson-Marlow Fluid Technology Group (WMFTG), www.wmftg.com

eter of the gears, which translates into increased reliability. The high permissible hub bore allows more favourable size selection of the coupling for a certain shaft diameter, which makes for a far more cost-effective product selection.

Jaure MT gear couplings, available locally from Bearings International (BI), have been operating successfully in various lines for the processing of fibre pulps, paper, board and tissue machines for over 40 years. “It is part of our strategy of being a total solutions partner for our customers in stocking some of the best products and brands from around the world, and Jaure definitely falls into this category,” says Ross Trevelyan, business unit head, product and engineering at BI.

200 megalitres a day to 250.

“Another product benefit is the high permissible loads for starting and short-circuit peak torque,” Ross notes. Jaure’s significant investment in CNC gear-cutting machinery and automatic charge systems also translates into the highest gear accuracy and quality. Jaure couplings offer maximum torque capacity due to the optimum pitch diam-

Bearings International (BI), www.bearings.co.za

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MARKET FORUM

Submersible Pumps Integrated Pump Technology recently extended its product offering with the inclusion of the extensive range of robustly constructed Faggiolati Pumps. Manufactured in Macerata, Italy, these submersible drainage and wastewater pumps are considered a natural complement to the company’s Grinde pump and accessory range.

Top Award

Afrox has clinched the Department of Science and Technology Minister’s Award for Large Enterprises in the category of Sustainable Performance at the 2015 Technology Top 100 (TT100) Business Awards. Afrox was awarded this accolade for its overall contribution within its markets and to South African society as a whole.

Colin Adams, managing director of Integrated Pump Technology, says, “Faggiolati submersible pumps do not only have application in the mining industry but are also ideally suited to general water transfer in the wastewater, effluent and sewage treatment sectors, as well as in specialised pumping applications found in the paper and pulp industry, desalination plants and marine pumping.” One of the most significant advantages that Faggiolati pumps offer is that all units are equipped with Premium Efficiency IE3 motors. Adams says this

“With this award, Afrox has clearly demonstrated why it is such a wellrespected brand and a leading gas and equipment supplier,” says Andy Gouws, Afrox’s business development manager, “Afrox is able to leverage The Linde Group’s vast global footprint and technology developments, and this is why we continue to be the supplier of choice in sub-Saharan Africa.”

is particularly important on a continent that needs energy efficient products and solutions. The extensive product line-up, more than 800 items, ranges from 0.5kW to 350 kW and pumps are available in grey cast iron as well as marine bronze and stainless steel for specialised applications. Integrated Pump Technology, Colin Adams, Tel: (011) 918 9034, Email: colin@pump-technology.com, www.pump-technology.com

According to the award citation, the essence of this award is the value Afrox contributes to both its internal and external communities. The company not only demonstrates a unique ability to manage the Research and Sustainability (TIPS), elements within its own operations, but also demonstrates an ability to manage its impact on the environment, and its commitment to Broad-Based Black Economic Empowerment, job creation, employment equity and private and public partnerships. Afrox, Andy Gouws, Email: andy.gouws@afrox.linde.com

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MARKET FORUM

Fluid

Technology

BMG’s expansion programme in the fluid technology sector also involves increasing stockholdings through more than 140 BMG branches and a wide distribution network in South Africa and across borders into Swaziland, Zambia, Botswana, Mozambique, Namibia and Tanzania. “BMG boosts its fluid technology services with dependable technical support to ensure optimum safety, efficiency and extended service life of every system, even in corrosive environments. With broad technical capabilities, the team is able to solve problems, in applications where conventional components have failed after short periods of service,” says Wayne

Holton, fluid technology manager, BMG – Bearing Man Group. “BMG’s fluid technology services also cover project engineering and consulting, cylinder design and manufacture, training, repair and testing, as well as onsite container services.” The company’s extensive range of components for fluid technology systems and general industrial applications, includes valves, hydraulic hoses and fittings, accumulators, cylinders, heat exchangers, hydraulic motors and hydraulic plumbing, as well as pumps and reservoir accessories. BMG – Bearing Man Group, Wayne Holton, Tel: (011) 620 1500, Email: wayneh@bmgworld.net, www.bmgworld.net Bianca centric butterfly valves

composition concentration in the slurry and how its flow rate fluctuates. “Often, where engineers have only previously known and used pusher centrifuges, they may not be aware that there is an option which is far more suited to the ZLD process. And more importantly, one that will provide significant benefits, including more reliable performance with associated cost-savings,” Gerrit adds. He recommends that those implementing the ZLD process ensure that they have access to an OEM that understands the entire process and is able to take all factors including flow rate, solids concentration, temperature, particle size distribution, chemical composition and corrosive properties into account.

Two Conturbex centrifuge installations dewatering glaubersalt and mixed salts produced in a ZLD process

Ideal for ZLD Process Zero Liquid Discharge (ZLD) processes are used across a number of industries including mining, pulp and paper, chemical processing and the petrochemical sector. Its application is typically to evaporate and concentrate an effluent or waste stream, however it is also sometimes used to produce a saleable product. The process involves

a suite of equipment from Multotec, including dewatering centrifuges and CleanTeq solvent extraction. Gerrit du Plessis, product specialist, solid/ liquid separation at Multotec Process Equipment, explains that because ZLD is always at the end of a process flow, the equipment used is generally subjected to extremes such as the chemical

The Siebtechnik Conturbex centrifuge has been engineered with a scrolled product transporting mechanism that distributes the solids product evenly across the basket. Gerrit says this allows vibration-free operation ensuring mechanical integrity of the equipment. These machines are also used for water treatment and de-watering of mixed salts, including sodium sulphate in a colliery plant, and in a crystalliser plant de-watering mixed salts at a platinum operation. MultoTec Group, Bernadette Wilson, Tel: (011) 923-6193, Email: bernadettew@multotec.com, www.multotec.com

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MARKET FORUM

Easing Vacuum Generation

On the Move Rittal South Africa has announced that Ute Schoeman has stepped in as acting Managing Director for the local operation.

ZHP Series

In response to increasing demand for integrated vacuum generation systems, SMC has launched its new Series ZHP vacuum pad with ejector. An energy-efficient single compact unit, the ZHP can be easily mounted in confined spaces due to its innovative design that removes the need for further components, making it simple to order and maintain.

at SMC Pneumatics SA says, “the ZHP offers a trio of vacuum port locations which provide a variety of connections for other equipment, like pressure sensors, and creates the opportunity for daisy-chain piping, allowing for multiple devices to be connected in sequence, reducing piping requirements.

The vacuum unit features a lockplate structure that allows easy one-touch replacement of the pad. This means that pads can be easily attached and detached for disposal, minimising maintenance. The use of an enhanced two-stage ejector improves vacuum generation efficiency, delivering an increase in suction flow rate of 50% and a reduction of air consumption of 30%.

The ZHP includes a through-hole silencer that significantly reduces noise levels and the risk of clogging. To improve its life span and reduce the risk of contamination, SMC has also included a strainer that prevents foreign matter from entering the pad suction port. The ZHP can be adapted for a range of applications, making it ideal for a variety of uses including robot handling in palletising, sheet metal working in the automotive industry or case packers.

Brain Abbott, product manager

SMC, www.smcpneumatics.co.za

The AES group has appointed Leapeetswe ‘Papi’ Molotsane as non executive director to the board of AES SA.

Aury Africa announces that Kathryn Van Onselen joins the KZN team as a sales representative.

Marais Nel has been appointed as the MD of Ingersoll Rand SA and Country Leader: Compression Technologies and Services.

Faith Lelaka, took up the position of Unit Head of the Paint Shop at VWSA. This is the first time a black woman has been appointed at this level in the production environment.

Index to Advertisers Aesseal Baker Baynes

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Ithuba Valves

Donaldson Filtration Services

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Steam Generation

Electra Mining

14

The Peartree

Engineering Placements

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Walter Meano Engineering

Engineering World

24

Zest Weg Group Africa

ILS 4

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PPS 10/11

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SA Mechanical Engineer April 2016  

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