SA Mechanical Engineer August 2016

S MECHANICAL A ENGINEER August 2016

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

POWER TRANSMISSION FIRMS MERGE REFURBISHING TIRED VALVES

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Chris Reay

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

Studying the current developments by Sibanye Gold gives one a real level of confidence that this can be achieved

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Council 2014 - 2016

Company Affiliates

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

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

Autodesk as represented

by Worldsview Technologies Ainsworth Engineering (Pty) Ltd Alstom Power Service SA (Pty) Ltd

Megchem Mod-U-Flow CC Osborn Engineered Products SA (Pty) Ltd PaCMan Projects & Maintenance PPS Insurance Co Limited

Mpumalanga Highveld ....................N Lecordier (Noel)

Babcock Ntuthuko Engineering (Pty) Ltd

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

Bosch Projects (Pty) Ltd

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

DCD Group (Pty) Ltd

SA Power Services (Pty) Ltd

Festo (Pty) Ltd

Sasol Technology (Pty) Ltd

Fluor SA (Pty) Ltd

SEW Eurodrive

Green Plan Consultants (Pty) Ltd

Siemens Ltd

KwaZulu Natal .............................R Walker (Raymond)

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

Portfolios: Communications/ Strategic Planning/ Specialist Groups . . .................................. CD Reay (Chris) Company Affiliates. . ...............................................Vacant To be confirmed.................... Prof JL van Niekerk (Wikus) Professional Development

Hatch Goba (Pty) Ltd

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

Howden Power (a div of Howden Africa)

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

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

Howden Projects (a div of James Howden)

PO Box 511, Bruma, 2026

Kelvion Thermal Solutions (Pty) Ltd

Tel: (011) 615-5660 Fax: (011) 388-5356 Email: info@saimeche.org.za

MBE Minerals (SA) (Pty) Ltd

Website: www.saimeche.org.za

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Sven Pietrangeli and Cobus Muller

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Spirax Sarco (Pty) Ltd Tenova Mining and Minerals SA Thyssenkrupp Engineering (Pty) Ltd Ultra-Flow Engineering Services CC Vital Engineering (Pty) Ltd Weir Minerals Africa Winder Controls (Pty) Ltd

Membership Email: membership@saimeche.org.za

Prof Brandon Collier-Reed and Vaughan Rimbault

Rotek Engineering

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Sven Pietrangeli and Bev Bailey

Capital Budgeting for Projects Workshop A Review of the Essentials CPD Validation Number: SAIMechE-0958-12/18

Code Days Start Date End Date Region Booking Closure Date A4716 1 27 Sep 16 27 Sep 16 Durban 13 Sep 16 The course has been developed from the perspective of the Engineer faced with the challenges of conceptualising, designing, specifying, procuring, installing, commissioning, operating, maintaining and decommissioning engineered assets. All too often Engineers are faced with what they see as the narrow and short term demands of the financial managers. Why is it so common that projects are budgeted on the least cost initial procurement basis and the investment horizon of the project ends at commissioning?

How should the Engineer, who can understand the impact of the lifecycle cost of the asset, get the message to the owner on the present value of an asset once its life cycle treatment is taken into account?

At handover, are the assets suitably configured to enable the maintainable items to be monitored, for history to be recorded for future benefit? What history is at our disposal to use for the best selection for future performance?

Do design, build, operate, maintain, and dispose contracts change the conventional practices in approach to lifecycle costing?

We will look at lowest cost procurement, post guarantee periods, factors affecting operations and maintenance, repairs, replacement, decommissioning.

How should ROI be calculated? What factors are used and are they relevant?

Case studies will be used and interactive discussion encouraged.

High Pressure Piping Systems Seminar Accreditation number: SAIMechE-0913-12/16 Expertise supplied by Steinmüller (Pty) Ltd

Code Days Start Date End Date Region Booking Closure Date APS16 1 5 Oct 16 5 Oct 16 Durban 21 Sep 16 CPS16 1 19 Oct 16 19 Oct 16 Cape Town 5 Oct 16 ● High Pressure Piping Construction and Refurbishment – The Technical Side ● High Pressure Pipeworks Supports ● Welding and Fabrication of High Pressure Piping ● Boiler Process Design Interface with High Pressure Piping ● Flexibility analysis of HP pipe work to EN 13480-3. ● Piping Flexibility and Stress Analysis using latest software

Leadership and Management Roles in Engineering Workshop

It is recommended that delegates wishing to attend this workshop first attend the “Leadership and Management Principles and Practice in Engineering” 2 day course (SAIMechE workshop No. 61).

CPD Validation Number: SAIMechE-0977-06/18 Code Days Start Date End Date Region Booking Closure Date C7016 2 5 Oct 16 6 Oct 16 Cape Town 21 Sept 2016 E7016 2 12 Oct 16 13 Oct 16 East Rand 28 Sep 2016 A7016 2 19 Oct 16 20 Oct 16 Durban 5 Oct 2016 A two day interactive course on the Relational, Informational and Decisional Roles of a Leader and Manager incorporating the key tools, processes, examples and practices which are presented in an experiential manner providing a fresh approach to the practice of management within an engineering context and which equips the practitioner with a raised awareness of his/her roles, a raised awareness of his/her own practice and the wherewithal to radically improve on those practices. The course is framed using the management roles definition by Henry Mintzberg.

The method of instruction will include a presentation of the theory, posed questions, one-on-one and group engagement, experiential learning and reflection. It will cover all the primary learning styles in order to engage all participants in a meaningful growth experience. Brief pre-course Notes and an exercise are sent to the delegates before the course. Further handouts and exercise sheets are provided during the course.

ASME VIII Div. 1 and 2: Design, Fabrication and Testing of Pressure Vessels Workshop Code C1516

Days 3

CPD Validation Number : SAIMechE-0940-12/18 Start Date End Date Region 24 Oct 16 26 Oct 16 Cape Town

Booking Closure Date 10 Oct 16

Overview: This course is intended to provide a working-level understanding of the major elements and requirements for the design, fabrication and testing of pressure vessels in accordance with the ASME VIII, Div. 1 and 2 Codes. Calculation workshops are included during the course to reinforce the theory.

Contents: ● Scope, limitations and major historical changes of the Code ● Responsibilities and Certification ● Materials and Allowable Stresses ● Design Criteria ● Post-weld Heat Treatment ● Impact testing ● Design by Rule, including shells, heads, openings, flanges ● Welded fabrication considerations for design ● Non-destructive examination and pressure testing ● Cyclic Service ● Design by Analysis ● User Requirements.

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Bianca centric butterfly valves have a durable plastomer liner suitable for aggressive and corrosive fluids

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Pieter Neethling

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

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Colin Maine

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MARTHINUSEN AND COUTTS - LEADERS IN ELECTRIC MOTOR AND POWER GENERATION REPAIR, MAINTENANCE AND SPECIALISED MANUFACTURE.

Large AC / DC Motors Small AC / DC Motors Traction & Flameproof Motors Transformers Power Generation ON SITE SERVICES

CUSTOMISED ELECTRICAL Coralynne & Associates +27 11 422 1949

AND MECHANICAL DESIGN

Marthinusen & Coutts Your Assets. Your Needs. Your Service Partner.

A division of ACTOM (Pty) Ltd Tel: +27 (0)11 607 170 0

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www.mandc.co.za

commercial@mandc.co.za

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Ryan Croker of KSB Pumps and Valves

Our workshop is specially equipped to deal with any type of valve and we specialise in high pressure steam and technically complicated valves

The valve repair workshop is able to undertake all repairs and refurbishment of large-scale and complex valves, including high pressure steam valves

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SAPPMA

Shell and Tube Heat Exchangers Specialists in design and manufacture of Modular Shell and Tube Heat Exchangers • 24 hours maintenance and repairs • Replacement parts • Technical services

Tel: (031) 702 1972/92 • Fax: 086 568 1515 Email: moduflow@telkomsa.net • www.moduflow.co.za 18

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Nalen Alwar

Year

Site

MW

2012

EDM, Resssano Garcia

107

2013

EDM & Nampower

122

2014

EDM & Sasol

170

Table 2. Deployment of gas-engine technology for grid additions

Figure 1. Progress of Gas Engine Technology in South Africa

Year

Site

MW

2006

Durban Solid Waste, KZN

2.1

2007

PetroSA, EC

4.3

2008

Thos Begbie, M

10.7

2008

Durban Solid Waste, KZN

4.3

2009

ABSA Towers, GP

11.5

2010

MTN, GP

2.1

2011

IFM, M

17

2012

SACC, KZN

6.8

2012

Standard Bank, GP

1.2

2012

Sasol, FS

180

Table 1. Deployment of gas-engine technology in South Africa

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“The simultaneous and sequential use of power and heat from the same fuel source” CHP = “Cogeneration” CHP = “Trigeneration” when waste heat supplies both heating and cooling CHP = “Quad generation” when waste heat supplies both heating, cooling & CO 2

V14843

Figure 2. Conversion of fuel energy into heat and power

Protect Your Driveline with Torque Limiting Couplings Voith Torque Limiting Couplings protect the driveline against excessive overloads.

This allows your equipment to operate safely at maximum capacity thus increasing production output. Torque Limiting Couplings provide protection throughout the lifespan of the driveline, this avoids costly downtime and expensive repairs.

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Benefits: Continuous production process • High utilisation of investment • Minimises standstill and downtime • Increases production uptime • Reduced breakdown costs •

Contact us for more information Or to set-up an appointment Tel: +27 11 418 4000 info.vtza@voith.com www.voith.com

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Figure 3. Heat recovery from a gas engine

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Figure 4. Applications for recovered heat

Suppliers of pumps and valves to the mining and industrial sectors for over 60 years.

Stockists of Tianjin small submersible, vertical multi-stage and close coupled water pumps.

Suppliers of the following: M+P Split Casing Pump

Multi-stage Pump

E.I.M.

Viking Gear Pump

Tel: 011 824 4810

Fax: 011 824 2770

Web: www.matherandplatt.com

26 Nagington Road, Wadeville, 1422, Gauteng mather&platt A5.indd 1

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2015/07/17 11:08 AM

Figure 6. Technology adoption curve – removing barriers and supporting accelerators will close the chasm

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Mark Makanda

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Your boutique business destination Surrounded by lush gardens in the hub of Johannesburg’s northern suburbs, The Peartree in Craighall Park caters for groups of two through to 100 guests in nine well-appointed and equipped business suites.

Breakfast meetings, working lunches, indoor or outdoor dining, halfday and full-day packages including all welcome refreshments, teas and lunches are offered in Standard, Gold and Platinum packages.

Secure parking, business centre, fibre optic broadband AV, lockable space, and an onsite Hair & Beauty Boutique, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.

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

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Kevin Gill, General manager, Bibby Turboflex

The merger has expanded the range into brakes

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TAKE PRECAUTIONS TO PROTECT YOUR PUMPS

SCHROEDER

VEREENIGING Tel: +27 (0)11 397 2833 Fax: +27 (0)11 397 4700

DURBAN Tel: +27 (0)31 579 2593 Fax: +27 (0)31 579 2562

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E-mail: sales@valve.co.za Exports: africaexports@valve.co.za

SEW-Eurodrive works manager, Peter McEvoy

Time interval

Action

Every 3 000 hours of operation – at least every six months

Check oil and oil level Check running noise for bearing damage Inspect seals for leakage Check and replace rubber buffers, if necessary, on units with torque arm

Every three years (At the latest, depending on operating conditions)

Change mineral oil Replace rolling bearing grease Replace oil seal (do not install it in the same track)

Every five years (At the latest, depending on operating conditions)

Change synthetic oil Replace rolling bearing grease Replace oil seal (do not install it in the same track)

Varying (Depending on external factors)

Touch up or renew the surface’s anti-corrosion coating as and when required

This table stipulates inspection and maintenance intervals, and serves as a useful guideline for the appropriate measures to be taken.

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In the hydraulics industry more than 70% of spare parts sold for equipment is to replace defective or worn components. The cause of 80 % of these defects can be traced to dirty oil , improper operation and maintenance. One proactive move can save you thousands and maximize your component life. *Triple R is a unique filter system that is designed to help you solve problems , save money and contribute to environmental conservation. *RRR is the only filter system that is able to remove solid particles, sludge and water with the use of one filter element .

All our products are aimed to provide solutions that reflect the essentials : To Reduce, To Reuse and to Recycle . Our brand says it all TRIPLE R The main function of C.T.Hydraulics(Nqoba)(Pty)Ltd is specialising in the design ,manufacturing and reconditioning of hydraulic cylinders, equipment and components *All repairs to hydraulic equipment done in-house to the highest technical and OEM spec *Turning up to 6m in length and up to 1.2 m swing *Vertical and horizontal honing machine honing up to 750 mm diameter and 12 m length *Milling for all the above *Fully computerised test bench capable of testing up to 400 bar *CNC Centre as well as drafting and design office *Deliveries and collections with our fleet of vehicles *Air-mate pellet hose cleaning system

Air-mate

Contact us on + 2711 873 2342

www.cthydraulics.co.za

MARKET FORUM

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MARKET FORUM

Gerrit van Zyl, MD

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MARKET FORUM

Pic: Sasol

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The Innovation Driver.

Composite Optimization: OptiStruct

Impact Analysis: RADIOSS

Aerodynamic Simulation: AcuSolve

You don’t need 14 clubs in your product development bag, HyperWorks delivers all the solvers you need.

HyperWorks provides the most comprehensive multiphysics simulation environment with the power of OptiStruct for structural analysis and optimization, RADIOSS for impact simulation, AcuSolve for Computational Fluid Dynamics, MotionSolve for Multi-Body Dynamics, FEKO for electromagnetic (EM) analysis plus solutions from the members of the Altair Partner Alliance.

Learn more at altair.com/driver I N N OVAT I O N I N T E L L I G E N C E ®

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All us 20-year Promech service record-holders had a special lunch: Samson Makamo, Simon Shange, Catherine Mokgethi, Susan Custers, Patience Mahamo, Catherine Mahamo, Anne Rotteglia, complete with cold weather blankets.

Patrick Mahamo was the photographer.

On the Move

Alison Townsend has joined SMC Pneumatics as a Sales Engineer at the company’s Port Elizabeth branch.

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Air Products South Africa announced the appointment of Robert Richardson as the new Managing Director.

Arnold Loois has joined Serco as the production manager at the Cape Town branch.

SMC Pneumatics has appointed Stuart Daniels as Technical Sales Engineer servicing the automotive industry in PE.

Liezl Siebrits recently joined SMC’s Cape Town branch as a sales engineer.

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Your Success Is Our Priority GIW Industries, Inc., the leader in the design, manufacture, and application of heavy-duty, centrifugal slurry pumps, commemorates its 125th year of serving the minerals and mining industries. Over time, we have grown in both size and expertise to ensure that KSB’s GIW® Minerals products are always at the forefront of slurry technology. By delivering cutting-edge solutions to your industry every day, GIW strives to be the expert of choice in slurry transport. We value our customers and are proud that you choose us to provide your pumps, hydrocyclones and services.

GIW Industries, Inc. (A KSB Company) · www.giwindustries.com

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Email: evapco@evapco.co.za |

Website: