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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 64

February 2014

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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February 2014


Chris Reay

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

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February 2014

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Excellent Minerals Solutions

Weir Minerals… Expertise where it counts. Weir Minerals is the world leader in the design and manufacture of pumps, valves, hydrocyclones and wear resistant linings, including WARMAN® centrifugal slurry pumps, ENVIROTECH® dewatering pumps and LINATEX® rubber products for the global mining and minerals processing industries. Our reputation is based on engineering excellence applied to innovative, customer focused solutions for processing minerals and aggressive materials. In line with our customer driven focus, Weir Minerals Africa also offers a pump rental concept as an attractive alternative to an outright purchase. For more information contact us on +27 (0)11 9292600

www.weirminerals.com

Copyright © 2012, Weir Slurry Group, Inc. All rights reserved. WARMAN is a registered trademark of Weir Minerals Australia Ltd and Weir Group African IP Ltd; MULTIFLO is a registered trademarks of Weir Minerals Australia Ltd; FLOWAY is a registered trademark of Weir Floway Inc.; GEHO is a registered trademark of Weir Minerals Netherlands bv; WEIR is a registered trademark of Weir Engineering Services Ltd.

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February 2014


Henk du Preez

The monthly circulation is 3 947

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Clem Sunter, Kudzai Nyangoni (SAIMechE President) - handing over medal, certificate and gift

SAIMechE Scheduled Training Workshops –March 2014 Programmes and Registration Forms obtainable from Carey Evans, Tel: 031 764 7136 or Email: carey@saimeche.org.za Event Code

Event Title

H4514

End Date

Region

Solving Standard Engineering and Technical Challenging Problems Using 4 Mar 14 Substance-Field Modelling

5 Mar 14

Rivonia

A5314

Understanding the Refrigeration Design Process

5 Mar 14

5 Mar 14

Durban

C8414

Surface Engineering of Components

5 Mar 14

5 Mar 14

Cape Town

A4514

Solving Standard Engineering and Technical Challenging Problems Using 11 Mar 14 Substance-Field Modelling

12 Mar 14

Durban

E5314

Understanding the Refrigeration Design Process

12 Mar 14

12 Mar 14

East Rand

C4514

Solving Standard Engineering and Technical Challenging Problems Using 18 Mar 14 Substance-Field Modelling

19 Mar 14

Cape Town

E0114

Introduction to Steam; Steam Engineering Principles

19 Mar 14

21 Mar 14

East Rand

A7714

Value Engineering in Projects

25 Mar 14

27 Mar 14

Durban

C6514

Overview of Fans & Air Handling

26 Mar 14

27 Mar 14

Cape Town

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Start Date

VOL 64

February 2014


Conor La Grue

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February 2014

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Speedweek site (Photo credit: MTN)

Wind Energy Summit South Africa WESSA 2014 9–10 April 2014 Southern Sun Cape Sun, Cape Town, South Africa

Procure, construct & deliver successful wind projects GROUND BREAKING STRATEGY SESSIONS > ENEL GREEN POWER & RED CAP ON COMPETITIVE PRICING AS NEW PLAYERS JOIN THE MARKET: Debate with Enel Green Power, Red Cap and the two leading SA banks on how to adapt to the rapidly evolving market > STANDARD BANK & NEDBANK CAPITAL SPEAKING: Get advice from two major SA banks already working in wind on creating a financially attractive project > DEBATE WITH ESKOM & NERSA’S KEY DECISION MAKERS: Discuss grid connectivity and risk absorbance with Eskom’s Head of the Grid Access Unit and NERSA’s Head of the Department of Regulatory Reform

INDUSTRY LEADING SPEAKERS: Government & Associations:

Regulator & Utility:

Developers:

Investors:

> PANEL ON EXPLORING SOCIAL ECONOMIC EMPOWERMENT ISSUES (SEE): Address the core SEE issues head on with our REEEP hosted panel to ensure you are not left behind in this swiftly developing market

OEMS:

Register by 20th January to save €100 on your pass

Research Institutes:

Specialist Suppliers: Lawyers:

Use code WESSA100 & register here: http://bit.ly/1frQsV4

v2x.indd 1AFRICAN MECHANICAL ENGINEER 8 Wind_SA14 THEAdSOUTH

VOL 64

20/12/20132014 16:13 February


Academic

Career Path

Projects

Achievements Commentary

PPS allocateD a recorD r3 billion to itS memberS* for the 2012 financial year. WoUlDn’t yoU liKe to be inclUDeD thiS year? For more info SMS ‘MECH’ and your NAME to 42097, consult a PPS product-accredited financial adviser or visit www.pps.co.za PPS is an authorised Financial Services Provider. *Members with qualifying products share our profits. Standard SMS rates apply.

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The initial layout is in a 2D format, but is integrated with the 3D design software

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February 2014


These what-if scenarios give the manufacturer a whole new perspective on his or her production processes, right now and into the future

The difference with the factory package is that data is entered for each stage of the process

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February 2014

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Pumps Valves Systems ■

MegaCPK. A new era starts here. Experience the start of a new era. With MegaCPK, the best standardised chemical pump of its class and a new global generation of products. Years of expertise in pump design and development have helped KSB optimise a whole set of MegaCPK features. The pump provides particularly high energy efficiency and the best in operating reliability. Its improved hydraulic system ensures excellent operating efficiency. And thanks to our standardised global manufacturing with optimal adaptation to local needs, you’ll benefit from all these advantages wherever you are. See for yourself at www.ksb.com/MegaCPK.

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February 2014


The rubber sleeve inside the valve is in fact a pressure vessel and therefore has to pass the test just as for any other pressure vessel

Once the tooling was completed, special in-house machinery had to be designed and built to handle the oversized components

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•wt4820 verder sa mechanical engineer advert feb 2014.pdf

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2014/02/07

12:16 PM

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February 2014


A ponton pump system for a local mine

Ian Farquhar, manager of the dewatering product line

Pieter Anker, senior design engineer for dewatering products

Howard Jones, manager of rentals and submersibles

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Pontoons are mostly custom designed for each application

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February 2014


A typical pontoon pump design model

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VOL 64

24/7

24/7

1980

Zest Electric Motors established in Jhb

WEG established in Brazil

n

Durban branch opens

1991

Cape Town branch opens

1994

Richards Bay branch opens

1997

We push boundaries to deliver n We listen to our customers n We focus on all our customers, big and small

THROUGH OUR PEOPLE

Trichardt branch opens

1998

who care Access to 26 000 people worldwide who care

Angola Botswana DRC Ghana Kenya Mozambique Namibia

Nigeria South Africa Tanzania Uganda Zambia Zimbabwe

|

www.zest.co.za

Rustenburg branch opens

2002

Middelburg branch opens

Port Elizabeth branch opens

To find out more scan the code or visit: zest.co.za/sustainability

2007

2002

To find out more scan the code 00 ZEST (9378) | www.zest.co.za or0861 visit: zest.co.za/sustainability

Zest acquires IMS Cape

2007

Zest acquires Shaw Controls (est 1986)

2007

BLUE IS THE NEW GREEN

+27 11 723 6000

0861 00 ZEST (9378)

www.zest.co.za

CUSTOMER FOCUSSED

BLUE IS THE NEW GREEN

INTEGRATED SOLUTIONS

AFRICAN MULTI-NATIONAL

9

Power Generation & Energy Solutions Substations & Electrical Infrastructure n Mobile Power Solutions

Electrical, Instrumentation & Control Engineering n Installation

ENERGY

Zest acquires EnI Electrical (est 1984)

2008

Zest acquires Zest Energy (est 2008)

2009

Zest Electric Ghana opens

2010

2013 WEG acquires Zest WEG Group Zest WEG Group acquires Hawker Siddeley Transformers (est 1956)

2010

Manufacturing facilities on 4 continents n 55 000 motors produced per day n 3rd largest electrical manufacturer worldwide n WEG products distributed in over 185 countries n 2.5% of WEG’s annual net income spent on R&D n

n

n

EnI Electrical

n

n

Mini Substations Transformers n Switchgear

WEG Transformers Africa

n

n

Packaged Switchgear Motor Control Centres n E-Housing n Containerised Substations

Shaw Controls

n

n

ZEST Energy

n

n

Electric Motors Variable Speed Drives n Soft Starters n Transformers n Switchgear n Diesel Generator Sets

ZEST Electric Motors

2020 And beyond

PRESENCE IN AFRICA BLUE IS THE NEWMARKET GREENOFFERING

ZEST indentity. Derivative of the proportions of the logo, it is based on a proportion of width and height of 2-to3. The distance between the GRID elements is 1/3 of the height of an element.

WHY TECHNICAL SUPPORT

750 people across Africa

TECHNICAL SUPPORT

PASSION

n

n

24/7 technical back-up Fully qualified technicians n 5 Fully equipped training centres across Africa n 187 site visits into Africa per year

WHERE YOU NEED IT, WHEN YOU NEED IT

SUPPORT

1961

February 2014

Coralynne & Associates +27 (011) 422 1949

THE SOUTH AFRICAN MECHANICAL ENGINEER Coralynne & Associates +27 (011) 422 1949

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POWER

GENERATION

T O D A Y

PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: samecheng@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial: Kowie Hamman Advertising: Mark Bennett Circulation: Catherine Macdiva DTP:

Zinobia Docrat/ Jacquelene Nene

“This factor is linked to all nine countries, meaning they all have the same GEF which will be used to demonstrate a baseline tax on the electricity used off the grid by consumers”

Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.

Copyright

Adam Simcock, CEO of Carbon Check

TICKER TAPE

All rights reserved. No editorial matter published in “Power Generation Today” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

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TICKER TAPE

“Very few companies understand the full implications or have personnel qualified to calculate the offsets which means they should be undertaken by a consulting company”

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February 2014


“Carbon tax is on the horizon, 2015 is around the corner and yet South African companies have to date done very little to find out where they’d stand in terms of carbon tax liabilities”

MAN ITEMS Y BE OFF CAN ER FROM ED STOCK

THE SOUTH AFRICAN MECHANICAL ENGINEER MULTI_ALLOYS_MECHANICAL_ENG_130x1 1

VOL 64

February 2014 12/20/12 9:45:24 PM

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PPS allocateD a recorD r3 billion to itS memberS* for the 2012 financial year. WoUlDn’t yoU liKe to be inclUDeD thiS year? For more info SMS ‘MECH’ and your NAME to 42097, consult a PPS product-accredited financial adviser or visit www.pps.co.za PPS is an authorised Financial Services Provider. *Members with qualifying products share our profits. Standard SMS rates apply.

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February 2014


Conference & Exhibition 17–19 March 2014 Cape Town International Convention Centre Cape Town, Republic of South Africa www.powergenafrica.com www.distributechafrica.com

EQUIPPING AFRICA’S ENERGY FUTURE

For Exhibit and Sponsorship Opportunities please contact:

PRE SHOW GUIDE OUT NOW REGISTER TODAY!

POWER-GEN Africa combines with DistribuTECH Africa for the first time to provide an extensive coverage of the power needs, resources, and issues facing the electricity generation, transmission and distribution industries across sub-Saharan Africa. The Pre Show Guide offers you a comprehensive event overview with everything you need to know to be part of this all inclusive power event. Event highlights include: opening keynote session, worldclass conference, informative technical tours and workshops plus dynamic exhibition and networking opportunities. Owned and Produced by:

Host Utility Sponsor:

Leon Stone Exhibition Sales Rest of the World Phone: +44 (0) 1992 656 671 Email: leons@pennwell.com Andrew Evans Exhibition Sales Africa Phone: +27 (0) 21 930 9515 Email: andrewe@pennwell.com Tom Marler Exhibition Sales Renewables & Hydropower Phone: +44 (0) 1992 656 608 Fax: +44 (0) 1992 656 700 Email: tomm@pennwell.com

Official CPD event of:

EARLY BIRD DISCOUNT Save $200 or more if you register by 18 February 2014! To register for your Early Bird Discount or for more information, please visit: www.powergenafrica.com or www.distributechafrica.com Presented by:

THE SOUTH AFRICAN MECHANICAL ENGINEER

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February 2014

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€100 Exclusive Discount

for SA Mechanical Engineer readers!

RESEARCHED & ORGANISED BY:

BU S I NE S S

I NTE L L I GENCE

CSP Today South Africa 2014

Use the code SAME14 when registering at the website www.csptoday.com/southafrica/mechengineering

3rd Concentrated Solar Thermal Power Conference & Expo 8-9 April, Cape Town

Reduce CSP costs & risk through international experience and investor insight to prove your competitiveness TOP CSP SPEAKERS WORLDWIDE :

• Lower your LCOE by harnessing R&D developments and international know-how to improve competitiveness against competing technologies • Overcome the risks associated with CSP by understanding the investor’s criteria to guarantee your project gets funded • Meet rising local content requirements and fight higher costs through streamlined project procurement and supply chain management techniques • Get the roadmap for CSP in South Africa through top-level official input to help plan your growth strategy • Increase your operational value and capacity for the latest advances in storage to meet South Africa’s peak energy demand

GOLD SPONSOR :

BRONZE SPONSOR :

SPONSOR :

GLOBAL PREMIER EXHIBITOR:

EXHIBITOR:

www.csptoday.com/southafrica/mechengineering Solar Plant Gemasolar, Torresol Energy ©SENER

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A cooling plant underground

100C + 64M + 0Y+60K 71051 Hytec Hydraulic A5 Ad.indd 1

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Ice dams used to help with cooling

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Hot water

5.5 units heat

Heat Pump

1 units electricity

4.5 units heat

Outdoor air Figure 1: Heat pump energy balance for ACU application

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Figure 2: Manufactured ACU

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HVAC

Figure 4: Energy balance – CWC or SC’s as spot cooler

Figure 5: Energy balance – ACU’s as spot cooler

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HVAC

Figure 6: ACU savings potential with varying depth for 4 scenarios

The comparative energy balance shows that the application of ACU’s can save approximately 642 kW per 1 000kW of cooling provided. This represents a 39.5% saving on power requirements

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Figure 7: Economic feasibility vs depth for 4 scenarios

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Generally, you’re using it in summer, and it’s stinking hot, and you don’t really want to be inside

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The proof of the pudding will be in whether or not the Romotow makes it

Customisation would allow buyers to include elements such as horsebox space, tapping into the equestrian market

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Patryk Michalowski

A Well Recognized Distributor in South Africa for Quality Castings from China, 17 Years Experience in the Engineering and Mining Industries • Casting bodies and components for valves and pumps • Couplings, End rings, Adaptors and Flanges for pipe systems • Mill Liners for metallurgical plants in the mining industries • Bowls, Mantles and Jaw plates for crushing and palletizing plants • Machined and hardened Gears for power transmission • Wear components for scrapers • Furnace Ladles for smelting furnaces • Forged steel grinding balls and High chrome grinding balls • SS316 and SS304 Stainless steel investment castings • Material standard to SANS 936, SANS 407, SANS 1465, BS EN 12513 (BS4844), SANS 1338

GOOD METALS CORPORATION TEL: +27 11 455-1085, 455-1086 FAX: +27 11 455-3495 www.goodmetals.co.za

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David Beard

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MARKET FORUM

The delivery of cylinders from Bosch Rexroth in Holland had to be precisely co-ordinated with the arrival of supporting equipment from South Africa

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MARKET FORUM

Delivering Advantages

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MARKET FORUM

Halogen-free wire for public areas

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MARKET FORUM

A Loesche mill type LM 69.6, Idhan, UAE

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MARKET FORUM

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MARKET FORUM

Kuno Kerlen

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[ Engineering Enhanced ] Products:

Value Added Services:

Robor are stockists and suppliers of a wide range of hot rolled, cold rolled, galvanized and pre-painted coil, plate and sheet in commercial, certied and wear resistant qualities stocked in a large variety of sizes. This comprehensive range is sourced from both local and international mills.

• • • • • • • • • • • • • •

Structural carbon steel proles include: • • • • • • • •

Round, Square and Flat Bar Angles Channels Columns Tubing: Round, Square and Rectangular Beams and Joists Window Sections Palisade Sections

Oxy Fuel Prole Cutting Laser Cutting Cut to length (Standard sheets to narrow slit strip) Decoil High Denition Plasma Cutting Drilling, Chamfering and Bending Cold Saw and Mitre Cutting Chamfering (Beveling) Strapping Guillotine (Cut to size) Pressing and Punching Blanks Cold Forming (W-Straps) Slitting and D&R Coiling Galvanizing

Robor operations are ISO 9001 compliant and subscribe to Global Best Practices to ensure the application of internationally recognized quality standards.

For more information: Tel: +27 (0)11 929 5000 or +27 (0)86 166 6999 48 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 64 February 2014 E-mail: engineering@robor.co.za • www.robor.co.za


Same feb14 final changes