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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

Nov/Dec 2012

1


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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62 Nov/Dec 2012


AN ENGINEER’S VIEW

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

Mechanical Engineering at its Best

Following the catastrophic hurricane Sandy that destroyed so much of the east coast of the USA, there seems to be a surge in the debate as to whether global warming and climate change are really now showing their predicted effects. Added to this have been a number of similar events that are demonstrating extremes in weather parameters, accompanied by the evident melting of so much of the earth’s ice caps.

T

he debate is polarized strongly by the believers and the disbelievers, the latter usually applying correlation science in its strict, mathematical form. The problem with this approach is. can we afford to wait and see if we are right or wrong?

Low wear rates, high torque and quiet comfort to the musical throb of the V8 engine in full cry Taking steps to reduce what we believe to be the causes of adverse climate change, while costing us now, may just be an investment we can ill afford to ignore. There is a lot of talk of reducing the emissions of the large capacity auto engines that are commonplace in the USA – where American engines have generally followed the ethos of “there is no substitute for cubic inches”. The pleasures of using such engines can range from the long levity and low wear rates, high torque and quiet comfort to the musical throb of the V8 engine in full cry. Recently a new development from Ford in the form of what they call the ECO engine in a road legal body set the eleventh fastest lap time at the famous Nurburgring in Germany, beating most of the traditional super cars’ lap times. The fascinating thing is that the ECO engine is a 3 cylinder 1 litre capacity engine in standard factory form. It produces 125 horsepower and is turbo boosted with variable cam timing. It is to be fitted in this form to the standard range of their vehicles available off the showroom floor. This technology is likely to replace the current conventional 4 cylinder 1500cc engines that we tend to regard as the minimum power unit in anything larger than the entry segment level. With 125 HP per litre, we may think that this engine will not last, be temperamental and be regarded as “boy racer”

class. However, the Mechanical Engineers behind the engine have subjected it to the following endurance trials and it came out with flying colours. On May 23 and 24 this year, the gathered group of automotive journalists and Ford employees hammered Focus EcoBoost 1.0-litre test cars around the high-banked CERAM oval for 24 straight hours. In the end, the Ford team tentatively set 24 new world speed records (pending official certification). Drivers saw lap speeds as high as 122 mph, the cars averaged 119 mph around the oval for an hour and the average speed for the full 24 hours, including pit stops for driver changes and refuelling, was 107 mph. This all from a car that is rated at 56 mpg, or 4.2 litres per 100 km in Europe. Once it was clear the cars were taking the pounding just fine, they got the green light to drive flat-out for the last three hours of the run.

No fuss, no noise

For these amazing test cars, it was no fuss, no noise, no smoke, smells or other typical signs of stress. The temperature gauges never reached the halfway mark. Clearly the modern turbo charger has become a fully reliable component and the mechanical technology is working hand in hand with electronics and software to monitor and protect the motor from any excursion outside its design limits. Could this successful development of the Mechanical Engineer be a future solution to the undesirable emission volumes of the great American auto engine, while providing such acceptable power levels and reliable performance?

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

Nov/Dec 2012

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MOHLALENG_ESKD_562/ ENG/Demand Response

The Demand Response

Rewards Programme makes

business

sense.

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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62 Nov/Dec 2012


Nov/Dec 2012

John Thompson a division of Actom (Pty) Ltd Tel: +27 21 959 8425 Email: nevilles@johnthompson.co.za www.johnthompson.co.za

VOLUME 62

Contents POWER GENERATION TODAY

Nuclear News 7

Nuclear Fact Sheets

21 Take Heart! 26 Power Generation News

Cover Story 8

Biomass-fired Package Boilers

Steam, Turbines & Boilers 11

Non-polluting Steam Generation

Zinc

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.

Lubrication 29 Managing Lubes on Site 33 Standing the Test of Time

Opinion

14 Harmful to Humans?

35 Soapbox

Monthly Column

Regulars

15 Prominent Professionals Copyright

NUMBER 11

Medical 16 Many More Law Su Suitts Suit

HVAC - Heating & Cooling 17 Air Distribution for Workplaces

3 6 20 36 37

An Engineer’s View Institution News SAIT SAINT Market Forum

The monthly circulation is 4 242

Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123, Republic of South Africa Tel: (011) 781-1401, Fax: (011) 781-1403 Managing Editor Susan Custers Editor Kowie Hamman Circulation Catherine Macdiva Advertising Mark Bennett DTP Zinobia Docrat / Donovan Vadivalu Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R405,00 (excl postage and VAT) per year; R1 020,00 per year for Africa/Overseas. Disclaimer PROMECH Publishing and The South African Institution of Mechanical Engineering as well as any other body do not take responsibility for the opinions expressed by individuals.

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

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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

Nov/Dec 2012

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THE SA INSTITUTION OF MECHANICAL ENGINEERING

Council 2012 - 2014 New SAIMechE workshops for 2013

Office Bearers

President ............................................. KK Nyangoni (Kudzai) Vice President .............................................. D Findeis (Dirk) National Treasurer ........................,................. A Roos (Andre) Immediate Past President............................ G Barbic (George )

In addition to scheduling many of its previous popular workshops during 2013, SAIMechE will introduce the following new topics.

Branch Chairpersons

6 New Developments in Engineering Materials â&#x20AC;&#x201C; Design and Application

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

Portfolios:

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

6 Implementing Continuous Flow - A Methodology for Engineers in Practice 6 Technical Communication and Report Writing 6 Professional Registration for the Candidate Engineer 6 Tank Design, Construction and Installation 6 Fans and Air Handling

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

6 Implementing ISO 9001-2008 for Manufacturing Organisations

PO Box 511, Bruma, 2026 Tel: (011) 615-5660, Fax: (011) 388-5356 Email: info@saimeche.org.za

6 Effective Negotiation Methodologies for Engineers in Practice

Website: www.saimeche.org.za

6 Continuous Improvement of the Organisation (Kaizen) by Engineers

Membership: Central, Eastern Cape, Mpumalanga, Highveld & KZN: membership@saimeche.org.za Membership: Western Cape: saimeche.wc@vodamail.co.za

Company Affiliates Alstom Power Service SA

RSD a division of DCD-Dorbyl

Babcock Africa Limited

S.A.M.E Water

Bateman Engineered Technologies

Sasol Technologies

Bosch Projects

SEW Eurodrive

Fluor SA

Siemens

GEA Air-cooled Systems

SNC-Lavalin SA

Hansen Transmissions SA

Spicer Axle SA

Hatch Africa

Spirax Sarco SA

Howden Power

Technical Systems

Howden Projects

Thyssenkrupp Engineering

Industrial Water Cooling

Transvaal Pressed Nuts & Bolts

MBE Minerals (SA) (Pty) Ltd (previously KHD Humboldt Wedag SA)

Ultra-Flow Engineering Services

Megchem Eng & Drafting Services

Vital Engineering

Mod-U-Flow

Weir Minerals Africa

Osborn Engineered Products SA

Winder Controls

Rotek Engineering

6

6 Total Productive Maintenance for Engineers

THE SOUTH AFRICAN MECHANICAL ENGINEER

6 Developing Effective Standard Operating Procedures and Practices for the Organisation SAIMechE now has 66 individual topic workshops on its books, some of which will be offered during 2013 and all of which may be held In-house by contacting Linda Robinson at Tel (031) 764 -7136 or linda@saimeche.org.za. Whilst some workshops address key engineering aspects, others are designed to assist the engineer through a successful career path. A comprehensive list of the 66 workshops is available on the Website, as is a list of the 2013 scheduled date events. Bookings and individual event enquiries are taken by Carey Evans at 031 764 7136 or carey@saimeche.org.za. Members wishing to develop workshops, for which they will be remunerated, may contact Linda who will guide the developer through SAIMechEâ&#x20AC;&#x2122;s required development process.

VOL 62 Nov/Dec 2012


NUCLEAR NEWS

Nuclear Fact Sheets The provision of the Nation’s electrical energy is a massive undertaking. Around a trillion rand of consumers’ money is to be spent on capital equipment by 2030. It is clearly appropriate for industry to put effort into raising public awareness of energy issues.

W

ith this in mind, NIASA (Nuclear Industry Association of South Africa) has commissioned a series of Fact Sheets on nuclear issues. Most have been completed and now appear on the Association’s website www.niasa.co.za. The available titles are: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

The case for nuclear generation. What is an atom? Radioactivity. Radiation and health. Uranium and the nuclear fuel cycle. How does a nuclear power reactor work? Radioactive effluents. Low level radioactive waste. Spent fuel and high level waste. Radiology and nuclear medicine.

Titles planned are:

Nuclear safety Nuclear weapons proliferation Cost of energy. Radioactive materials – industrial and research applications. X Nuclear generation past, present and future. X X X X

The ‘top document’ is Fact Sheet 1 ‘The case for nuclear generation’. Subsequent Fact Sheets address in more detail the issues raised in the top document. The series is being compiled by John Walmsley with the help of specialists in the areas addressed – hereby gratefully acknowledged. The Fact Sheets are designed to be printed on A3, double-sided, and folded to A4. However, printing as A4 sheets on a desk-top printer is also possible. Ayanda Myoli NECSA

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COVER STORY

Biomass-fired Package Boilers Wood pucks, wood pellets, grape pomace pellets

As the price of biomass fuels on a R/kJ basis is becoming more competitive with traditional fuels such as coal, oil and gas, the need for biomass-fired boilers is steadily increasing. To accommodate this demand, John Thompson (JT), the Cape Town based designer and manufacturer of high efficiency boilers with over 75 years of service to South Africa’s industries, is now able to offer package firetube boilers which can burn a wide variety of biomass fuels. This complements their standard range of coal-, oil- and gas-fired shell boilers and is a result of their long standing policy of continuous product development.

Biomass fuel tests

Nut shells, torrefied biomass, wood chips

To meet the growing need worldwide for a cleaner and more sustainable environment, several biomass fuels have been test-fired on sites, and on the boiler installed in JT’s boiler development centre over the past few years. These fuels include: (1) wood pellets (2) grape pomace pellets (3) wood pucks (4) nut shells (5) sunflower seed husks (6) torrefied biomass and (7) wood chips.

Figure 1. A typical boiler plant installation

The test boiler installation is a fully operational boiler house complete with firetube boiler with chaingrate stoker, fuel and ash handling plant, deaerator, water treatment and chemical dosing, flue-gas clean-up equipment and an integrated boiler plant control system. Biogas produced from the treatment of waste water in certain industries can offset 10 - 15% fuel requirements for the production of steam. JT has supplied a number of biogas boilers into the local market which has reduced the client’s carbon emissions and reliance on fossil fuel.

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VOL 62 Nov/Dec 2012


COVER STORY

Boiler performance

When firing the biomass fuels, steam outputs of between 50 to 85% of the coal-fired boiler rating were achieved under efficient combustion conditions. This was largely due to JT’s modified chaingrate stoker and the Micropac boiler management system which was easily fine-tuned for the different fuels. Both can be retrofitted to existing coalfired boilers when a change from coal to biomass-firing is required. Upgrades and conversions to existing plant can be engineered to achieve optimal boiler efficiency and emissions in compliance with the Air Quality Act.

Spiral-tubes

All JT boilers are currently fitted with spiral-tubes to ensure that the flue-gas temperature leaving the boiler is only 15°C above steam saturation temperature at full load, without installation of an economiser, thereby enhancing boiler efficiency.

Steam outsourcing

For customers who may be interested in outsourc-

ing their steam requirements, JT’s Boilerplant Management Services can provide a range of negotiable contracts from operation of existing plant to a BOOT (build, own, operate, transfer) contract inclusive of all operating and maintenance costs, under which the customer purchases steam on an agreed combination of a fixed monthly rate and Rand per ton of steam basis.

Turnkey projects

In addition to boiler design and manufacturing facilities, JT also specializes in turnkey installations for all of their boilers. This includes responsibility for all civil, structural and electrical works, pipe work systems, fuel and ash handling plant, installation and commissioning. See figure 1 for a typical boiler plant installation. Neville Sharwood, Technical Manager - Package Boilers, John Thompson, a division of Actom (Pty) Ltd. Tel: +27 21 959 8425 Email: nevilles@johnthompson.co.za www.johnthompson.co.za

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Now supplying NEW COAL AND FIRED BOILERS to South Africa Dryden Combustion are now supplying “The Dryden Mk7” coal fired boiler. With outputs ranging from 1 000 kg/hr up to 21 000 kg/hr, and operating pressures up to 2 000 kPa.

Giving the South African Boiler market energy!

Industrial Boiler Partner Proud distributors and marketers for BOSCH THE DRYDEN COMBUSTION COMPANY (PTY) LIMITED Telephone: 011 864-2984 | Fax: 011 864-7471 | E-mail: sales@drydencombustion.co.za 10 THE SOUTH AFRICAN MECHANICALwww.drydencombustion.co.za ENGINEER VOL 62 Nov/Dec 2012


STEAM, TURBINES & BOILERS

Non-polluting Steam Generation One of the main advantages of an electrode steam generating system is that it is ‘clean’, ie, no harmful gas such as carbon monoxide are emitted into the environment.

I

ncreasingly, certain city and industrial areas in South Africa, like the Durban basin for instance, are becoming smoke-free zones where the emission of smoke and harmful gases are taboo. For industry, this means electrode boilers. To find out more “SA Mechanical Engineer” speaks to director of Allmech in Benoni, Allan Cunningham, about the pros and cons of electrode boiler systems in general. “Apart from the emissions factor, an

Apart from the emissions factor, an electrode boiler comes second only to gas in terms of the lowest fuel costs

Allan Cunningham of Allmech

electrode boiler comes second only to gas in terms of the lowest fuel costs,” he says. “We’ve just completed an analysis comparing the cost of coal, light oil, heavy oil, gas and electricity. Gas turned out to be the cheapest fuel for steam generation.” In addition, labour operating costs, initial equipment expenses and maintenance costs of all the other fuels are much higher over the long term than when using electrode boilers. Allan points out, “Our biggest electrode boiler, for example, costs around R700 000 whereas the equivalent capacity in a coal fired boiler will be well over R3 million.”

Advantages

All electrical energy for an electrode boiler is converted to heat, so there is no direct pollution or a pollution control system to maintain. “In fact, you can get carbon credits for running an electrode boiler,” elaborates Allan. “The electrode boiler has a very quick response time enabling online steam within 10 to 15 minutes after switch on. The compact size of the electrode boiler in terms of its smaller volume, makes it better and easy to work with than other types of boiler. “Compared with other boilers, there is little thermal stressing, yet, unlike other types such as a coal-fired boiler or conventional electric boiler, none of the electrode boiler are subjected to high temperatures during operation except for the water itself.” A large boiler, a Model AHW-600 hot water boiler, 600 kw (2160 Mj/hr), was built for a mine

Electricity

Electrode boilers do, however, require sufficient

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STEAM, TURBINES & BOILERS

electrical power for the three phase system to function properly. So electrode boilers are out of the running in rural areas in most cases. “In some instances where power supply falls short we have been able to adapt the system by adding a transformer and

A Model A-1250P Electrode steam boiler being loaded outside the factory has a capacity of 1250 kw or 2000 kg/hr

running the electrodes directly off the transformer,” says Allan. “But where even this won’t suffice, or where the supply from the grid simply cannot be increased, we’ve had to walk away from the job.”

The company has just recently added an in-house designed oil or gas fired boiler which is built entirely locally To fill this gap in terms of the product offering into the market, the company has just recently added an in-house designed oil or gas fired boiler which is built entirely locally. “From the outset we decided to develop a premium product fitted with a top-end, German-made, oil burner which we import. So far we’ve only made these in a one tonne capacity, but we’re busy developing a two-tonne version as well,” Allen explains.

How it works

PLCs are often complemented by an HMI on the front of the panel

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THE SOUTH AFRICAN MECHANICAL ENGINEER

The principle of an electrode boiler is based on the fact that steam is generated when a high voltage AC source, typically between 400 to 550 volts, flows between the three electrodes submerged in

VOL 62 Nov/Dec 2012


STEAM, TURBINES & BOILERS

Final touches to a boiler before leaving the factory

A complete packaged steam solution, from the water treatment right through to steam on demand in the volumes required on the factory floor

the water in the boiler chamber. The conductivity of the water and the voltage applied determines how much steam is generated in each stream of water. Generally the working pressure is maintained at 10 bar. If more pressure is needed for more steam, the control system allows more water into the boiler via a solenoid valve, which when opened, will allow the water to feed to the boiler and when closed, the water then returns back to the feed water tank. As the required pressure is reached, the pump controls the flow of water to maintain the desired steam output at the desired pressure.

through to steam on demand in the volumes required on the factory floor,” he says in conclusion. “Our range covers pressure up to 17.5 bar with models ranging from 20 kg/hr right through to 5700 kg/ hr when operating on 550 volts.” Allan Cunningham, Allmech, Tel: (011) 849-2733, Email: allanc@allmech.co.za

“The basic principle of operation has been around for donkey’s years, but over time we’ve customised our control system to achieve optimum efficiencies,” says Allan. “At the core of our system are PLCs, often complemented by an HMI on the front of the panel, to make checking and monitoring easier for the operator. Each system is designed and built to each specific application to deliver steam at the most efficient energy consumption level.”

Water treatment

Despite its low maintenance requirements, one of the most crucial aspects of an electrode boiler is keeping the water clean. “Because there is a relatively small volume of water in the boiler all the time, it is really critical that the feed water be treated properly,” Allan explains. “We have a dedicated water treatment division in the company, specialising in water treatment systems and chemicals specifically for boilers and cooling towers. “Thus we are able to offer a complete packaged steam solution, from the water treatment right THE SOUTH AFRICAN MECHANICAL ENGINEER

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Nov/Dec 2012

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ZINC

Harmful to Humans? The Hot Dip Galvanizers Association Southern Africa (HDGASA) would like to correct a few misconceptions with regard to the supply of zinc and its possible health risks.

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hen the hot dip galvanizing industry was notified of the intended closure of Zincor Ltd, alternative plans were put into place in order to ensure a continued, reliable supply of zinc into the country. The importation of zinc is not a new phenomenon and as such, the industry was capable of sourcing alternative supplies of zinc in order to continue to meet the demand of our customers. Furthermore, there are alternative suppliers of zinc who are already operating and ably assisting the industry. Therefore, the hot dip galvanizing industry is well

placed in order to continue supplying this valuable service to its customers.

Innuendo

It appears that some innuendo is being leveled that zinc is harmful to humans. Interestingly enough, zinc is a recyclable material and is recovered from process materials such as galvanizing residues. Hot Dip Galvanizing consists of a coating of zinc alloyed to the surface of the steel. Zinc melts at about 420ÂşC (the temperature of the galvanizing bath) and boils at 907ÂşC. When zinc boils, the vapour reacts quickly with the air to form zinc oxide, which is the dense white fume easily visible. Although zinc oxide is an important component of some medicines and creams (particularly for nappy rash), one should avoid breathing zinc oxide; or any other fume for that matter. If one does breathe in zinc fumes, the zinc will be absorbed into the bloodstream, with excess zinc excreted quickly through the kidneys and then in the urine. One may have an acute case of â&#x20AC;&#x153;Zinc feverâ&#x20AC;?, displaying flu-like symptoms for 24 hours. As far as the International Zinc Association (IZA) is aware, â&#x20AC;&#x153;zinc feverâ&#x20AC;? is almost unknown in modern industrial countries which observe basic health and safety precautions. Saskia Salvatori, Hot Dip Galvanizers Association SA, Tel: (011) 456-7960, Fax: (011) 454-6304

Engineer Placements Professional opportunities Our job board continues to display a wide variety of excellent job positions that you can review and apply for on- line. Keep your credentials on our VHFXUHDQGFRQÂżGHQWLDOGDWDEDVHXSGDWHWKHPDW any time. We keep in touch with you. www.engineerplacements.com

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MONTHLY COLUMN

Prominent Professionals Thomas Holtz, Chief Executive Officer, Multotec Group

the world at the time. Another personal milestone project was building our first self-driven trommel screening system, a unit which has now been running for eleven years.

Academic

Future – a concept, a dream or a wish

School:

Any technology around renewable energy is of special interest. I’d focus on developing and supporting anything which will make us less dependent on fossil fuels.

Bryanston High School

Graduate studies:

Started a Mechanical Engineering degree at Wits University, but after getting a bursary from Gencor graduated at Cape Town University.

I also have a very special interest in Bio-Mimicry and will support projects in this field. There is still a lot that engineering can learn from the many mysterious technologies of nature.

Post-Graduate:

Subsequently did a GDE (Graduate Thomas Holtz, CEO, Multotec Group Diploma in Engineering) in industrial engineering in order to strengthen up the commercial and Projects business side of my career. In addition also did various business courses at Wits Business School including the Executive Most challenging The trommel project was the most challenging, not only Development Programme. because we had never built one that size, but also because Professional Bodies we landed the order before we had done proper FEA on the Registered with ECSA as professional engineer (PrEng) design.

Most rewarding

Career Path First employer

Having had a bursary from Gencor, my first official job was at Impala Platinum, but after just a couple of months I bought myself out to go and work for Grinaker Precast.

Growth path

I held various positions at Grinaker until ending up as factory manager for a new product line consisting of lightweight concrete support packs for underground mining. Eighteen years ago I joined Multotec in a project management capacity in operations and held various positions in the company to later become a technical director in one of the divisions.

Present employer & position

Finally moved into the CEO position at Multotec Group.

Achievements A design or a project

From the beginning I favoured industrial engineering because that’s where the line function is, that’s where things happen in terms of manufacturing. Thus I have been involved in many projects in manufacturing environments, setting up factories and manufacturing processes. At Multotec Group, for example, we designed and built a wedgewire screen manufacturing machine which was the largest of its kind in

Also the trommel project, in spite of many other projects for this company which are success stories and which have made us financially strong, putting us above the rest in the international market.

Commentary Are there shortcomings in the Mechanical Engineering Industry in South Africa? Generally we under-value the contributions made by engineers. They don’t get the recognition they deserve. However, engineers are partly to blame for this because they’re generally not good marketers just as they don’t make good accountants or people managers.

How would you mend this?

We need to recognise and support engineers for their technical skills and not make them people managers merely to promote them in a company. If you do, engineers have to be trained for this task more specifically otherwise they tend not to be good people managers.

Message to young engineers

There’s a lot of value in engineering and many opportunities to develop products, not just for the sake of developing new products, but to create useful products which can ultimately be commercialised.

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MEDICAL

Many More Law Suits whose implants had failed. Approximately 7700 Smith & Nephew metal-liners had been implanted since the component was introduced. In Australia there had been a 4.96% revision rate (replacement) at two years, which the company said was above the average rate for metal-on-metal acetabular shells. 153 of the S & M cup replacements had been done in South Africa after it was introduced in 2009. It was withdrawn in line with the “global voluntary withdrawal” on 1 June 2012. The total number of claims currently being handled by the law firm on behalf of patients who had been harmed by metal-on-metal prosthesis currently exceeds R150-million. Following hot on the heels of the more than 60 law suits currently being brought by Pretoria medical malpractice law firm, CP van Zyl Inc. against US hip replacement manufacturer, DePuy, several new cases against British prosthesis manufacturer Smith & Nephew are being investigated. Sunelle van Heerden, a professional consultant with Pretoria-based medical

malpractice law firm CP van Zyl Attorneys Inc. said there was a growing body of evidence worldwide that metal-on-metal hip replacement prosthesis was “problematic” and that other companies who had supplied these devices, including Smith & Nephew would be added to the rapidly growing list of suppliers who were being sued for damages by patients

A study by the British Medical Journal, in partnership with the BBC, revealed that cobalt and chromium ions can seep into the tissues of patients with 'metal on metal' hip implants, causing local reactions that destroy muscle and bone, leaving some patients with longterm disability. CP van Zyl Attorneys, Ralie Roos, Tel: (012) 460-7050

Promech wishes its readers a Peaceful Festive Season and a Great New Year With “D” the theme of this year’s Casual Day, reluctant Diva’s, with Detective Doris marshalling the funds helped keep a beady eye on the celebration. Doctors and Dentists ensured no casualties occurred while the Dolls cheered us on with their merry stories to the tune of the dancing troop. Daphne the Drag Queen ably supported the Director of Movies accompanied by Dairybelle to keep this ship afloat.

Standing back row left to right: Kowie Hamman (Director of Movies); Mark Bennett (Daphne the Drag Queen); Jacqueline Nene (Decidedly Doll); Colleen Cleary (Dingbat); Belinda Siegruhn (Detective Doris); Susan Custers (Dairybelle); Anne Rotteglia (Diva) Surita Marx (Dolly Parton); Zinobia Docrat (Dizzy Doll). Front row left to right: Lelanie Diamond (Dancing Queen); Donovan Vadivalu (Damn Fine Hip Hop); Di Bluck (Diligent); Catherine Mahamo (Doctor)

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HVAC - HEATING & COOLING

Air Distribution for Workplaces

It’s estimated that we spend up to 66% of our time in enclosed places where the air flow is artificially ventilated. The aim of air distribution systems in industrial and commercial buildings is to spread heated or cooled air as unobtrusively as possible without the occupants being aware of the constant flow of air around them. This is where diffusers come in. To talk about the important role of diffusers in air distribution systems “SA Mechanical Engineer” visits Krantz Ambient Systems in Roodepoort.

I

n terms of air, each person in an enclosed space should be comfortable as far as the quality and temperature of the air is concerned,” says Lee Stroebel, a director at Krantz. “This can only be achieved with the selection of the right diffuser for each specific area. First of all, a properly-selected diffuser should disperse the air as noiselessly as possible. Secondly, it should release the air evenly and as gently as Lee Stroebel, a director at Krantz Ambient Systems possible so that people

inside the space cannot feel that the air is flowing or where it is circulating from.”

It should release the air evenly and as gently as possible so that people inside the space cannot feel that the air is flowing or where it is circulating from Customisation

Just a quick flip through the company’s thick product catalogue makes you realise that diffusers are scientifically-designed and precision-made for very specific applications. The locally-manufactured range of products is made under licence to Krantz in Germany from whom special application diffusers can also be imported. “We purely concentrate on the diffusion market and don’t deal in their air handling units, for example, because there are more than enough suppliers locally,” Lee says. Their range of standard diffusers is comprehensive, but they often do special applications where a certain amount of customisation has to be undertaken for out-of-the-ordinary applications. In this regard, the company has just supplied a special aluminium version of one of their standard diffusers for a tobacco processing plant locally where the exceptionally corrosive atmosphere in the tobacco plant destroyed the steel diffusers very rapidly. Lee adds, “We can supply the same product

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AIR DISTRIBUTION | AIR DIFFUSION | AIR HANDLING | AIR CONDITIONING | FIRE PROTECTION PRODUCTS

DESIGN DEVELOP MANUFACTURE

LEADING SUPPLIER OF PARTS & ACCESSORIES TO THE HVAC INDUSTRY Having operated in the HVAC (Heating Ventilation & Air-Conditioning) arena for more than 40 years, Europair is the leader in their field for the sale and service of HVAC products in Africa. With manufacturing facilities in both Gauteng and Cape Town, Europair Africa continues to develop and manufacture quality, cost effective products and services for the industry, whilst ensuring that the products and services supplied by Europair exceed market requirements. Recent successfully completed projects include Gautrain, Melrose Arch, Blue Route Mall, Tyger Valley Centre (Cape Town) and Alice Lane Towers, Sandton. A market driven approach has enabled Europair to determine and develop quality, cost effective products and services. Each step in the organization’s development has only been taken following intensive research and development to ensure that the products and services supplied by Europair are in line with its particular market’s needs and environment.

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18 THE SOUTH AFRICAN MECHANICAL ENGINEER )RUPRUHLQIRUPDWLRQYLVLW www.europair-africa.com

VOL 62 Nov/Dec 2012


HVAC - HEATING & COOLING

with different coatings. One may like the raw metal look while another engineer or architect prefers to have it powder coated for practical or aesthetic reasons.”

Not one for all

ous finishes here in our metal spinning factory. The raw, spun aluminium look has proven to be very popular, but we do supply it in powdered coatings of different colours as well.”

One design which has remained in demand throughout the years is the variable twist outlet diffuser in most of its variations, be it with a core tube or a swirl cylinder

Although not all that common, there are architects who make One design which has remained the mistake of selecting in demand throughout the years a diffuser purely on appearis the variable twist outlet diffuser ance so that it fits in with the in most of its variations, be it with a core building’s design. “Just recently The adjustable swivel nozzle tube or a swirl cylinder. “They have always we had to help out where the with a 60º pivot on the ball outlet been popular for large areas such as shopping architect selected the same malls and large retail stores,” says diffuser from a catalogue for Lee. “This is the type we used for the entire building, arguing the tobacco processing plant which that he wanted a uniform look we made in aluminium for corrosion in terms of the finishings,” protection. The adjustable radial relates Lee. “The only problem outlet with a core tube is a design is the ceilings were not the combining the variable twist outlet same height everywhere and and the adjustable radial diffuser. one of the critical factors in This system has the core tube in the selecting the right diffuser to centre with the adjustable function achieve a specific volumetric around the outside, thus providing a flow is its height from the floor. balance of both diffusion principles. “This resulted in air gusting It’s also very flexible, coming out in noisily out of the diffusers, standard versions for heights between blasting the occupants with 2.8 through to 14 metres.” windy air in the low height Hospitals areas. You can specify difJust like other fittings and trimmings, certain With everybody asking for green fusers of the same design types of diffusers tend to go in and out of fashion products, the demand for Krantz’s to achieve a certain degree Opticlean diffusers is now steadily of uniformity, but they can growing across the world. “This is never all be of the same size popular for hospitals and clean room purely for aesthetic reasons environments in particular,” Lee if the ceilings heights in the says in conclusion. “It’s one of the building vary.” products we import from Germany Trends because of its special design where Just like other fittings and the face has round perforations in trimmings, certain types of diagonally-staggered arrangement. diffusers tend to go in and The perforated face is not affected by out of fashion. “The latest, the indoor air because a layer, acting very popular design locally, like an air cushion, forms under the has been our ‘eye-ball’ nozzle outlet preventing less dust from acwhich has been installed cumulating on the ceiling compared at some of the airports in with high velocity outlets.” South Africa,” says Lee. “It’s Lee Stroebel, Krantz Ambient Systems, an adjustable swivel nozzle The adjustable radial outlet with a core tube Tel: (011) 474-7234, with a 60º pivot on the ball is a design combining the variable twist outlet Email: lee@krantzambient.co.za and the adjustable radial diffuser outlet which we make in variTHE SOUTH AFRICAN MECHANICAL ENGINEER

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THE SA INSTITUTE OF TRIBOLOGY

Metalworking Fluids In October, SAIT hosted a Metal Working Fluids (MFW) seminar at Science Park Kelvin Jhb, to stimulate the interest in the subject among our members and industry in general.

P

resentations were conducted by various suppliers and marketers of MWF fluids which highlighted some interesting facts.

Metalworking

There are several metal working operations used by component manufacturers with metal cutting being the most common. Charles du Bois, Product Development Manager at Status Industrial Solutions, illustrated the many types of metal cutting, from the basic sawing, grinding, turning and drilling operations to other more severe operations including reaming, boring and deep hole drilling. All of these require soluble oil type coolant-lubricants for effective cooling and for protection of tool tips and flanks, where temperatures can reach up to 700°C.

Shawn Pharo

A global solution for misting is a key development area for metal working fluids The most severe operations such as deep hole drilling, gear cutting, shaving, hobbing, tapping and broaching require extreme pressure lubricants to handle these aggressive machining operations on different types of metals such as magnesium alloys, copper and zincbased alloys, aluminium alloys and mild steel alloys, cast iron, and stainless and tool steels.

Additives

A variety of additives are required to formulate the basic soluble oil emulsions and semi synthetic cutting oils and some applications require a combination of additives for producing full synthetic fluids to deal with the extreme pressures these lubricants need to withstand in modern and new technology metalworking and metal working equipment. Rajeen Bothma, Technical Sales Manager at CPS Chemicals, pointed out the old and new product

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THE SOUTH AFRICAN MECHANICAL ENGINEER

components and the challenges facing formulators from an operator and environmental view, such as the restrictions of chlorinated products. A global solution for misting is a key development area for metal working fluids as well as the search more operator friendly fluids. Many machine operators have become ill due to constant vapour inhalation, or suffered from skin irritations and dermatitis from physical contact with these metal working fluids.

Minimum quantity lubrication

Eben du Plessis of Producut Lubrication Technologies has developed a sensible way of dealing with these issues by introducing minimal quantity lubrication (MQL) in specific application areas where massive amounts of fluids cannot be tolerated, especially in the aluminium industry. They have achieved impressive results in critical applications where they significantly reduce fluid consumption by as much as 600 times (592:1). These staggering results have major saving impacts on costs and the environment. In a very sensitive case of waste disposal, MWF users face an enormous challenge. These fluids cannot simply be discarded in a waste oil stream as they contain massive amounts of water. So this industry can benefit enormously by applying this program.

Contamination

Many who work in the MWF industry arena have experienced fluid contamination resulting in rotten smells and bacterial and fungal growth in their machines. Decades ago, soluble oils had a 1-2 month life but in modern day these fluids have a life of 1-2 years in the machines. Advances in raw materials and formulations have increased the life expectancy of MWF’s, but this area can do with even more development. Andy Nickels, Technical Manager at Strub-SA, presented some interesting facts about fighting these bacteria. Symbiotic metal working fluids have been around in Europe for almost two decades now and can add significant benefits to soluble fluids, in that biocides in MWF’s would no longer be required. Biocides act in a similar fashion as antibiotics for humans, killing bacteria. High cost and special care and maintenance are contributing factors limiting the development and introduction of these fluids. REACH has also contributed to the slow development of new technologies. It is interesting to note that human error is the major cause of contamination and degradation of MWF’s globally. Interested parties are urged to contact the SAIT secretary if you want to present future papers or share literature on this subject, with special requests for presentations on fluid monitoring and maintenance or machining case studies. Shawn Pharo, SAIT Executive Committee Member Gill Fuller and Isabel Bradley, Tel: (011) 804-3710 Email: secretary@sait.org.za, admin@sait.org.za

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POWER

POWER GENERATION

GENERATION PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403

T O D A Y

Take Heart!

Email: samecheng@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial: Kowie Hamman Advertising: Mark Bennett Circulation: Catherine Macdiva

Energy costs can be reduced in a wide range of manufacturing operations. While energy may not be the largest cost item in most business’ budgets, energy often has the greatest potential for savings. In the manufacturing arena, labour and material costs are usually greater, but are difficult to reduce.

DTP: Zinobia Docrat/ Donovan Vadivalu Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.

Copyright

TICKER TAPE

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

Example 1: Fans

In just one section of a steel mill, optimising the running time and speeds of the fans

AEG Power Solutions has opened a manufacturing facility in the Western Cape which has the capacity to produce 200 MW of solar inverters a year. The company has equipped and commissioned more than 860 utility-scale solar installations around the world. Used cooking oil from restaurants in the Western Cape is being converted into biodiesel and sold to companies to run a range of trucks, mining equipment and fishing vessels.

produced an estimated annual savings of 2 739 000 kWh, or R 1.15 million using the applicable electricity tariff at the time

Transport cross-borders corridors have been joined by energy corridors as part of the larger Programme for Infrastructure Development in Africa (Pida) portfolio under Nepad. The four corridors include: the North-South Transmission link, from Egypt to South Africa; the Central Corridor, from Angola to South Africa; a North African Corridor from Egypt to Morocco; and the West African Power Corridor, linking Ghana to Senegal.

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POWER GENERATION

Cost and manageability

Fan and system characteristics

If the fan is fine, alternative control systems can be considered, all with the aim of reducing power consumption. The graph shows the difference which these can make.

Example 2: Process Heating

At an agri-processing company which uses steam for process heating, an annual saving of R 154 200 with a payback period of five months was identified. Opportunities observed included: ‡ 5HSDLULQJOHDNV ‡ /DJJLQJSLSHV ‡ &RQWUROOLQJ WKH IORZ UDWH RI DLU WR WKH ERLOHU

Steam leaking from a bare pipe

of the project. This gave a payback period of approximately one-and-a-half years.

TICKER TAPE

In some cases, more work has to be done, such as measuring the pressure profile in the duct downstream of the fan. Hence a duct curve (see fan graph) can be drawn. A comparison will show whether or not the fan is operating close to its best efficiency. If not, an alternative fan can be recommended. Energy and, therefore, cost savings for the alternative fan will be calculated to determine the payback period.

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Waste-to-energy company South African Clean Energy (SACE) will use unwanted forestry residue from the White River area of Mpumalanga as a feedstock to generate 1.25 MW of electricity. The biomass plant will be the first of its size in South Africa to operate on a 24/7 basis. The Department of Mineral Resources recently lifted the moratorium on shale gas exploration in

THE SOUTH AFRICAN MECHANICAL ENGINEER

Where appropriate temperature on the surface of pipes, boilers, ovens and furnaces will be measured. Thus, heat loss from these items can be calculated. This will be compared to the reduced heat loss which results from upgrading the insulation. The energy savings will be compared to the cost of improved insulation so that suitable action can be recommended.

Example 3: Compressed Air System

At a small metal fabrication company, identified savings on compressed air came to R 34 000 annually. This was purely from improved operation and maintenance. The cost of implementation was minimal and thus the payback was virtually immediate.

the Karoo. According to the US Energy Information Administration, this area potentially holds 485 trillion cubic feet of shale gas.

South Africa’s National development Plan 2030 warns against the ban on the export of low-grade coal, saying that it could disincentivise investments into multiproduct coal mines.

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POWER GENERATION

Actual Savings

In other cases, for example, where multiple compressors are in use and/or air needs to be supplied at two different pressures, a more sophisticated analysis is required. Shortage of compressed air is a common complaint. Often the first solution to be investigated is a new, bigger compressor. However, that is usually the most expensive solution. Rather first have a professional undertake a thorough analysis of the compressed air system. In most cases upgrading at a fraction of the cost of a new compressor will produce a quick payback, and ongoing savings.

Example 4: Lighting

The lighting in a large commercial building was investigated. Without reducing the light levels, improved management of the lighting, plus replacement of luminaires with more efficient ones produced an annual savings of just over a million kWh. At current electricity prices, this is more than R 500 000 per year.

Raising awareness

Technical changes are only part of the story. Support from everyone in an organisation is vital. Combining energy saving technology while motivating staff to

do their bit results in magnified savings. Simple behavioral changes include switching off lights which are not needed and machines which are idling. The costs are negligible and the benefits can be immense.

Effect of combining better technology with raising awareness

Excellent companies go further and introduce an Energy Management System, leading to accreditation in accordance with ISO 50001. Thus energy saving becomes an integral part of day-to-day activities, in the same way as quality and safety.

Holistic approach

Carbon and Energy Africa is a small, agile group of professionals, with mechanical and chemical backgrounds. Their engineers have experience in a wide variety of industries. Thus, they not only take a holistic approach, but they identify opportunities for improved utilisation of resources in general, eg, water savings and waste reduction. Denis van Es, Tel: (021) 802-3242, Email: dve@carbonenergyafrica.co.za, www.carbonenergyafrica.com

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SCANIA’S EFFORTS TOWARDS A SUSTAINABLE FUTURE.

Alternative fuels The transport sector needs to tackle a double challenge – to break its dependency on oil and at the same time reduce its increasing CO2 emissions. Scania has been addressing this challenge by producing commercial biofuel solutions for over 20 years, and is actively developing and testing technology for the future. Biofuels are part of the natural carbon cycle and don’t contribute to a net increase of CO2 in the atmosphere. Fossil fuels release carbon from fossil deposits and increase CO2 levels. The use of biofuels will thus help reduce CO2 emissions, particularly in heavy transport, where electrification is not easy to achieve. Only three biofuels today fulfil the important requirements of sustainability, commercial availability and volume production – bioethanol, biodiesel and biogas. Other interesting biofuels will not be commercially available for quite some time. Scania’s unique biofuel portfolio covers all the three major biofuels, providing solutions that ensure the best operating economy and the most cost-efficient CO2 reduction for each individual customer. Scania strongly favours the development of a uniform system for certifying biofuels from a sustainability point of view. A good example of this is the EU's biofuel criteria.

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Technology Truly sustainable transport is our vision. And through continual research and development into new technology and renewable fuels, we’re striving to make that vision a reality. Sustainable, efficient transport

With goods transportation projected to grow by 50 percent in the next twenty years, the European Union has set the target of a 20 percent reduction in emissions by the year 2020. But Scania has set the bar even higher.

To make a real contribution to sustainability, Scania’s vision is that carbon dioxide emissions per tonne transported can be reduced by 50 percent during this period.

How can this be achieved? These are the most important contributions:

Consistently improved logistics with the help of ITS (intelligent transport services). Further developed driver competence and driver support. Continuous optimisation of every aspect of truck technology – from increasingly efficient powertrains, to aerodynamics. Hybridisation with substantial fuel savings and robust technology. Revised legislation to promote the use of longer vehicle combinations that carry more cargo. Gradually introducing alternatives to conventional fuels.

More than half of Scania’s research and development budget is dedicated to refining powertrain technology and increasing sustainability.

Environmental strategy from a life-cycle perspective Scania’s environmental strategy goes way beyond the efficiency of Scania vehicles on the road and resource efficiency in maintenance and repairs. From production to end of life treatment, we actively strive to minimise the environmental impact.

With one of the most efficient production systems in the world, and by using modular components, Scania minimises waste in every form. Hazardous materials are only used where absolutely necessary – and handling and disposal tightly controlled. And for disposal of vehicles at the end of their lives, Scania provides detailed dismantling and disposal protocols. Many parts are designed to be recycled, and are marked for easy identification.

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POWER GENERATION NEWS

Highest SA Rating 500 Report and was the highest rated South African company. Robbie Louw, a director of Promethium Carbon, says Anglo American Platinum (Amplats) significantly increased its score from 85% last year to 96% in 2012. “It is the result of implementing strategic low-carbon initiatives that are in line with the direction of government’s National Development Plan to reposition South Africa towards a low carbon economy.

Robbie Louw

Local carbon advisory firm, Promethium Carbon, contributed to Anglo American Platinum achieving second position in the Materials Category of the Carbon Disclosure Project (CDP) Global 500 Climate Change Report. Overall, Anglo American Platinum was rated among the top-scoring companies of the Global

“These initiatives include energy-efficient programmes and platinum-based fuel cells that Amplat’s has used in electrodes to convert this fuel source into electricity,” Robbie explains.

Solar Power Meters The Iso-Tech product range offers an impressive selection of cost-effective test and measurement equipment, ranging from rugged and water resistant multimeters, through to digital light meters, sound level meters and high performance oscilloscopes. Iso-Tech is distributed exclusively by RS Components and is manufactured and tested to international standards. A three-year warranty comes standard with all Iso-Tech products.

Other South African companies participating were Standard Bank (74%), Vodacom (69%), Sasol (81%), MTN (69%), Kumba Iron ore (88%) and AngloGold Ashanti (78%). Promethuim, Robbie Louw, Tel: (011) 706-8185, Email: Robbie@promethium.co.za, www.promethuim.co.za

M a g n etic B e arin g s SKF is suppling magnetic bearings to two new major gas projects in Australia. SKF’s S2M magnetic bearings will equip the natural gas treatment turbo expanders for the Ichthys Gas Field project and the Prelude first FLNG barge. Vincent Megret, managing director, SKF Magnetic Systems says, "S2M active magnetic bearings are an advantageous choice for the demanding environments encountered in the gas industry, notably in offshore gas fields and onshore gas liquefaction.” The Ichthys Gas Field is located at a depth of 280 m in the Timor Sea, some 200 km off the coast of Western

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Australia. Development costs are expected to be in the region of USD 34 billion. At its peak, the field will produce 8 million tonnes per year of LNG. Liquefaction will take place onshore at a specially-constructed facility at Blaydin Point, Australia. SKF manufactures and markets the oil-free, frictionless and virtually maintenance-free S2M magnetic bearings used in oil and gas exploration and production, often in extreme weather conditions and remote locations. SKF South Africa, Samantha Joubert, Tel: 011 821 3500, Email: samantha.joubert@skf.com, www.skf.co.za

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The ISM series (ISM400 and ISM410) solar power meters are instruments used to measure radiated and transmitted solar power at an installation, in order to determine the optimum positioning and alignment of solar panels and the total solar energy against elapsed time or average solar energy per hour calculation. The range meets the requirements of safety, health and industrial safety officers and determines the percentage of solar power transmission through glass, heat insulation materials, sunshades etc. The solar power meters have the ability to operate at a temperature range of 0°C to +50°C and have a battery life of 100 hours. They are frequently used in solar power research, solar radiation measurement and solar transmission measurement applications, as well as physics and optical laboratories. RS Components SA, Devin Ross, Tel: (011) 691-9300, Email: editorial.za@rs-components.com, www.rsonline.co.za


POWER GENERATION NEWS

Dean of Faculty of Engineering NWU The Southern African Association for Energy Efficiency (SAEE) is proud to announce that its President, Prof

LJ Grobler, has been appointed Dean of the North West University’s (NWU) Faculty of Engineering.

60 m High Downpipes

After 16 years of service as professor in Mechanical Engineering at the NWU’s School for Mechanical Engineering, Prof Grobler assumed his responsibility as Dean from 1 September 2012. As a mechanical engineer from the University of Pretoria, and Pr.Eng with the Engineering Council of South Africa, he has unsurpassed experience in the academic, consulting, as well as commercial and industrial spheres relating to mechanical and energy engineering.

Prof LJ Grobler

Downpipes have to be checked regularly to ensure that the sealant remains effective

Skyriders marketing manager Mike Zinn notes that a total of six power station units required repairs to their downpipe's joints. "The joints and the sealant had been installed more than 20 years ago, and were therefore old, brittle and failing. During heavy rains, water in certain areas leaked onto electrical plant components causing maintenance challenges. “As the downpipes ran from the roof of the power station units down through the power station building in a zig zag formation into the ground, this was a highly challenging job, as it was almost like a maze.” The Skyriders team of rope access technicians were responsible for accessing and inspecting all areas, before taking photos, removing the old sealants, cleaning up the joints, installing new sealants and taking more photos.

In total, 255 joints were repaired by June 2012, more than two weeks ahead of the client's stated deadline. Mike adds, "Although the scope of work was relatively simple, the access constraints with regards to height, confined spaces and a fully-operational plant made for a challenging work environment. The team did an excellent job from a planning and execution point of view. We explained to the client that rope access was a far quicker and more cost effective method than scaffolding, and this method ensured that our team was able to seal the 400 mm pipes from the 30 m level to the 60 m level in 26 days." Skyriders, Mike Zinn, Tel: (011) 312-1418, Email: mike@skysolutions.co.za www.skysolutions.co.za

He obtained his PhD, specialising in retrofitting of commercial buildings with emphasis on energy management and indoor comfort, is a Certified Energy Manager (CEM) and a Certified Measurement and Verification Professional (CMVP) and has trained over 600 individuals in the internationally-recognised Association of Energy Engineer’s (AEE) CEM programme through the local approved trainer, the Energy Training Foundation, a division of Energy Cybernetics. He was the 2007/8 President AEE based in Atlanta (USA)—the first non-American to become president. The SAEE is the local chapter of the AEE. With a background in not only academia, but industry as well, Prof Grobler is well positioned to produce deployable engineers into the economy of South Africa. More recently Prof Grobler was named the Industry Leader Award at the Green Supply Chain Awards in recognition of the significant contribution he has made toward the industry. SAEE, Tel: (041) 367-1041, Email: media@saee.org.za, www.saee.org.za

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LUBRICATION

Managing Lubes on Site An Olympic size pool holds about 2.5 million litres of water. Over three times this volume is consumed on a mine in a year excluding an average of about 120 million litres of diesel.

Thomas Surmon of Total South Africa

C

learly, such volumes of fuel and lubrication require specialised fluid management, not only to control costs and cleanliness but more importantly, the waste generated. Total South Africa pioneered a fluid management system whereby they take over control of lubricant and fuel supply management of a mine. “SA Mechanical Engineer” speaks to mining & techni-

cal manager of fuels and lubricants at Total, Thomas Surmon, about this concept which has been rolled out at mining sites around the world. “We developed the integrated service solution (ISS), whereby we completely take over the fluid management on the mining site,” he adds. “This can be the diesel or the lubricant or both. We handle the supply to site, the storage on site and ensure that the right lubricant goes into the machinery according to the OEM specifications of each vehicle or machine.

We handle the supply to site, the storage on site and ensure that the right lubricant goes into the machinery according to the OEM specifications of each vehicle or machine A service solution

“This takes on the form of a full Total depot on site which, depending on the size of the operation, is also staffed with a qualified tribologist who manages the service right up to the point where the nozzle goes into the machinery,” adds Thomas. “We also manage the filtration systems installed to ensure that there are no contaminants going into the vehicle, thereby extending engine life and reducing downtime in terms of blocked or damaged diesel injectors.” The ISS concept started 13 years ago, growing to a programme which is today utilised by most of the established mining operations locally as well as several prominent mining operations in countries

A pioneering fluid management system

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LUBRICATION

around the world. It is a dynamic programme which is constantly improved as each ISS is tailor-made to each mine’s unique conditions. However, in general, all clients reap the same benefits. Thomas elaborates, “For example, supply is guaranteed, even under adverse conditions such as strikes causing shortages as we’ve had in South Africa in the past.”

The function of our dedicated tribologist on site is to ensure that our products are applied correctly, that filtration is up to standard and to be on the lookout for improvements

Benefits

“Other benefits include not tying up capital in large tanks for storage because we erect our own equipment on site,” he adds, “nor is capital tied up in lubricant and fuel products because the client only pays for product as it’s used. In terms of cleanliness, there are huge benefits because engines last longer and there are significantly fewer breakdowns because we filter both the diesel and the engine oils they’ve used.” Depending on the extent of the agreement and the size of the fleet, Total even offers oil analysis as part of this service. “Many mines have their own established laboratories as part of their fleet management system, but in certain cases we carry out oil analysis for customers by using a commercial laboratory,” explains Thomas. “The function of our dedicated tribologist on site is to ensure that our products are applied correctly, that filtration is up to standard and to be on the lookout for improvements which can be made to the benefit of the customer. This person is also responsible for rationalising products and introducing new products or any new developments concerning lubricants to the customer.”

Fluid management on the mining site

The function of the dedicated tribologist on site is to ensure that products are applied correctly

Training

The tribologist records the consumption of each vehicle onto a fuel management system so that

Supply is guaranteed, even under adverse conditions such as strikes causing shortages

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LUBRICATION

vehicle has not come in for its service on time and alert the mine’s service workshop.” Out in the field the responsibility of greasing machinery regularly is still undertaken by a technician employed by the mine as a lubricator. “Our tribologist on site usually trains the technician to ensure that our products are applied correctly,” says Thomas. “A very important aspect for these technicians is not to mismatch products and apply the wrong lubricant. They’re also taught to understand the importance of cleanliness in terms of lubricants and that you can’t use a gumboot or a hard hat to top up the engine oil, for instance.”

Waste management Benefits include not tying up capital in large tanks for storage because Total’s equipment on site

You can’t use a gumboot or a hard hat to top up the engine oil the mine is provided with regular reports on what’s happening with the fleet. Thomas adds, “Although we’re not responsible for the service intervals, we can, for instance, pick up from this system that a

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Any operation using oil is not complete without addressing the matter of waste management. “Total is part of the Rose Foundation which collects used oil and disposes of it in an environmentally safe way. In terms of the law, although the end user is responsible for waste management and we’re not currently involved in it directly, we’re now looking into ways of adding waste management to the ISS offering.” Thomas Surmon, Total South Africa, Tel: (011) 778-2388, Email: thomas.surmon@total.co.za

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LUBRICATION

Standing the Test of Time As the saying goes, the proof of the pudding is in the eating. Passing this test over time proves that the recipe is correct, that you’re doing it right and that the people out there like the quality of your products.

Recognising the value

“As market awareness of the importance of using good quality lubricants has grown over the past couple of years, so more and more companies have recognised the superior quality of our range of products,” says Bruce. “We’ve grown twenty-fold over the last four years to become one of the biggest independent lubricant blenders in South Africa offering a premium range of lubricants.

Bruce Ireland (Left) and Andrey Mey of Mega Lube

T

he products in question here are the oils and lubricants manufactured by independent blender, Mega Lube in Alberton. “SA Mechanical Engineer” speaks to director Bruce Ireland five years down the line since the company introduced a series of lubricants, oils and greases aimed specifically at the African market and its unique conditions.

Today the mining companies, the trucking industry and the agricultural sector see us as leaders who constantly bring new innovations to the table

“It’s a long road to introduce new products to the market, let alone educating people along the way about the rewards of using advanced performance lubricants,” he adds. “Our thorough approach has paid off though and today the mining companies, the trucking industry and the agricultural sector see us as leaders who constantly bring new innovations to the table. Apart from being the first to bring out a sachet grease gun refill, for example, we were also the first to come up with a fully bio-degradable cutting oil which we developed in-house.”

Growth

Production has soared to 500 000 litres of mineral oil a month, 80 000 litres a month in synthetic products and 90 tonnes of grease a month. “We’ve expanded to full production capacity in Alberton and have now opened another facility in Heidelburg,” Bruce elaborates. “The laboratory is the core of our business, so we’ve recently upgraded with the latest testing technology to ensure the quality we’ve become known for remains consistent.” An automated viscosity metering system and a new spectrometer for faster, detailed oil analysis has also just been added. Bruce explains, “We still make use of third party analysis to obtain an independent analysis report, but also having the capability inhouse extends the service we can offer our customers in terms of condition monitoring of their equipment on a regular basis.”

Special lubricants

Joining the new trend to package oil in plastic drums

In terms of products, the range has grown to include special greases and oils for specific applications. “We have special, low consumption, high wear protection greases and dressings developed specifically for open gearing, highly specialised oils for compressors and a whole range of food-grade lubricants,” Bruce explains. “In terms of biodegradable oils, we have developed special oils and greases used in drilling and can proudly lay claim to the fact THE SOUTH AFRICAN MECHANICAL ENGINEER

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LUBRICATION

The laboratory is the core of our business, so we’ve recently upgraded with the latest testing technology An automated viscosity metering system and a new spectrometer for faster, detailed oil analysis

tem. To refill a grease gun the soft plastic sachet, pre-filled with grease, is simply inserted into the grease gun without any grease being spilled. Refilling in this way completely eliminates wastage or the chance of contaminating the grease.

The lubricant blending industry is not only a highly competitive one, but there are many rogue operators who put very catchy slogans on their inferior products

The sachet grease for a grease gun refill

Warning

The lubricant blending industry is not only a highly competitive one, but there are many rogue operators who put very catchy slogans on their inferior products. “There are many fly-by-night operators out there giving the independent blending industry a bad name,” says Bruce. “For us this means we simply have to work harder to differentiate ourselves in the market. The hard work has paid off though and today we can proudly state that our engine oils are approved by OEMs such as Cummins, MTU, Mercedes, Volvo and Komatsu, a major achievement for any independent blender.

The quality of engine oil is determined by the API standards and this information should be clearly indicated on the container

that we are one of the first companies to develop a complete biodegradable soluble cutting oil which is brand new on the market.” Having often seen the mess caused when re-filling a hand grease gun, we were particularly impressed by MegaLube’s new invention, the sachet-sys-

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“The quality of engine oil, for example, is determined by the API (American Petroleum Institute) standards and this information should be clearly indicated on the container,” says Bruce. “Users should look for this mark or the OEM-approval label when buying oil, forget about the fancy eye-catching slogans on the label. “As good quality blood is essential to human life, so is oil the lifeblood of an engine. It’s the cheapest replaceable component but it can extend the life of an engine considerably,” says Bruce in conclusion. Bruce Ireland, Mega Lube, Tel: (011) 907-0941/2, Email: bruce@megalube.co.za

VOL 62 Nov/Dec 2012


OPINION

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

Will the internal combustion engine become extinct? Chris Coetzee of Resonant Solutions No!

Rudolph Beer of Martin Engineering Yes, but maybe not in my time.

Izak van Niekerk of Bell Equipment

Is perpetual motion possible? But never is also a long time!

Tom Esterhuizen of Tom Esterhuizen & Associates

Not very soon, but hybrids and electric cars are busy gaining momentum and are bound to make a difference in the near future.

Willem Sullivan of Hansen

Can you design another effective way to convert chemicals to motion? If you can then yes, but there needs to be some major renaissance in drive systems before that will happen. But then again, where is steam power today and was it not the driving force of the industrial revolution? So I say yes, it will become obsolete in time, but do not ask me when.

If you were forced to change your job now, what would you rather do? Greg Perry of SEW

Be a guide for canoe trips down some wild river.

Rudolph Beer of Martin Engineering Greg Perry of SEW

Only when the fuel runs out.

Brian Volk of PHC Projects

Possibly, but they are constantly finding ways to upgrade it and if a viable renewable fuel could be found it will probably carry on for a long time.

Phildy Schlotz of DRA

As fossil fuel demands grow and resources becoming depleted, the engine will have to change at some stage in the future.

Thalefang Mtombeni of Schaeffler

That’s difficult to say, but I don’t think that will ever happen.

Be a farmer.

Willem Sullivan of Hansen

Lecturer at university, in the Mechanical Department.

Brian Volk of PHC Projects An architect.

Phildy Schlotz of DRA

A dentist – because you’re your own boss and can work anywhere you like, as opposed to engineering where you usually have to work in groups and have be based in a main centre like Johannesburg where the work is.

Izak van Niekerk of Bell Equipment

Nothing…

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SA INSTITUTE FOR NON-DESTRUCTIVE TESTING

Importance of Signs How important are those radiation warnings signs that must be displayed on vehicles transporting radioactive material?

W

hat would happen if both the technician and his assistant, travelling in one vehicle, are rendered unconscious after being involved in an accident?

Hennie de Wet

The traffic officer will see the signs warning the public that there are radioactive materials in the vehicle. He will then proceed to phone the emergency telephone number displayed on that sign. Let’s say there is no answer. He has to assume that the source is “out of the container” and the possibility of exposure to ionizing radiation exists. His job is to protect the public. So he will barricade the area around the vehicle containing the radioactive material and prevent anybody from going near the vehicle. Even ambulance-men. The technician and his assistant could bleed to death, because the RPO (Radiation Protection Officer) didn’t answer his phone. For this reason the RPO is actually employed 24/7.

the Hazardous Material guys to help him find the source. They will fly in by helicopter. Who do you think is going to pay for this exercise? This situation is even worse than the first. Since no-one will be able to help the occupants of the vehicle until the source is found. The answer, firstly is to ensure that there are two names and two telephone numbers on the warning signs on the vehicle as per the requirements. Secondly, the warning signs must be removed when the radiation source is not in the vehicle to avoid the resulting delay that may occur. Hennie de Wet, African NDT Centre, Tel: (012) 665-3248, Email: hennie.dewet@andtc.com, www.andtc.com Robin Marshall, SAINT, Tel: (011) 719-5717, Email: saint@saint.org.za, www.saint.org.za

They will fly in by helicopter. Who do you think is going to pay for this exercise? The ideal would be for the RPO to tell the traffic officer to find the survey meter, how to operate the meter and to verify the danger of exposure and then to locate the source container.

Scenario number 2

The same vehicle is involved in an accident, there are warning signs on the vehicle but let’s assume that the driver neglected to remove the warning signs at the office and hence no radiation source is in the vehicle. The traffic officer will not be able to find the source container nor the survey meter, so what is the next logical step? He has been trained to barricade the vehicle “containing the radioactive material” and to prevent anybody from going near the vehicle. He will probably contact

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MARKET FORUM

High Lift Range

A trailer mounted diesel driven Warman DWU pump set

The new Warman DWU dewatering pump, designed in conjunction with Weir Minerals operations around the world and manufactured here in South Africa, has been engineered for harsh operating conditions typical of those encountered in Africa. This easy-tomaintain pump can produce efficiencies that are up to six points higher than other pumps in its class under certain conditions. The innovative design of the Warman DWU pump offers customers a high head option encompassing the speeds for diesel and electrical driven applications, with heads exceeding 130 metres. Weir Minerals obtained registered design protection for the unique shape features of the DWU model pump. The DWU pump is able to handle dirty water with a specific gravity of 1.05, and has a casing that is pressure rated at 7000 kPa for series pumping, if required. Weir Minerals Africa, Rene Calitz, Tel: (011) 929-2622, Email : r.calitz@weirminerals.com www.weirminerals.com

Additive Layer Manufacturing A partnership between aircraft manufacturer, Airbus; the CSIR; and South African aviation firm, Aerosud; aims to dramatically cut aircraft component production costs through new technology dubbed, Aeroswift. The partnership will explore the application of titanium powder-based additive layer manufacturing for fabrication of large and complex aerospace components. At the announcement of this partnership in Johannesburg recently, Airbus’s Dale King noted that the CSIR and Aerosud are the only organisations in the world doing work on high-speed, large-volume additive laser manufacturing, making them

unique. “That is why we have decided to forge a partnership with the CSIR and Aerosud,” comments Dale. “We came to South Africa for this project because we believe the country has the necessary skills and competencies in the field of LAM (laser additive manufacturing).” He said that if the technology succeeds, it would flow into Airbus’ supply chain where the parts developed through the LAM project will be used, once tested and evaluated, in Airbus manufactured aircraft. &RXQFLOIRU6FLHQWL¿FDQG,QGXVWULDO5HVHDUFK (CSIR), Tendani Tsedu, Tel: (012) 841-3417, Email: mtsedu@csir.co.za

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MARKET FORUM

Cheap and Nasty

Many companies use high flow, high pressure peristaltic pumps in their treatment processes so it’s no surprise to learn that there are just as many manufacturers out to make a ‘fast buck’ by supplying counterfeit or ‘pirate’ replacement parts for these pumps.

components such as rotors and shoes.”

“Using pirate parts can reduce a pump’s efficiency by up to 30 percent,” says WatsonMarlow Bredel SA general manager, Nico van Schalkwyk. “Numerous problems can occur over time, such as bearing or shaft failures and reduced life cycles on

not understand the impact of pirate parts due to lack of knowledge in this sector.”

Nico points out that tolerances are of utmost importance in any pump technology. “Let’s take a MasoSine pump, for example, which is used primarily in the food processing industry. A difference in 0.3 of a mm is huge, as we discovered It’s easy to understand why recently when we experienced these low-cost offerings – as problems. much as 50 percent less – are “Fortunately, we could solve attractive, but buying non- this problem as we are in standard replacement hoses the pump industry. Other for pumps is false economy. engineering companies would

Every Watson-Marlow Bredel hose is precision-machined to ensure repeatable performance

Watson-Marlow, Nico van Schalkwyk, Tel: (011)796-2960, www.watson-marlow.com

Dynamic sector BMG has further expanded its business into the gaskets sector, with the recent acquisition of Gasket & Allied Products (Pty) Limited (GAP). “This strategic investment in a dynamic sector of the engineering business, which is estimated to be worth over R500-million per annum in South Africa, broadens BMG’s product range and extends the company’s service offering,” says Ken Steel, general manager of BMG’s seals division. “This acquisition will also be strategic to the growth of the existing GAP business; advantageous for product development and will certainly provide greater opportunities for the team. With the backing of BMG - which has an accredited level 3 B-BBEE status - GAP will enhance its Broad Based Black Economic Empowerment scorecard. “BMG’s new specialist gasket division

38

From left: Ken Steel, general manager, seals division, with Rodney Leigh, general manager of BMG’s new specialist gasket division.

will be headed by Rodney Leigh, who established GAP in KwaZulu-Natal over 12 years ago. This operation is likely to relocate to the BMG engineering hub in Mahogony Ridge, Durban, later this year.”

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


MARKET FORUM

Ongoing Vigilance “A fire risk assessment helps identify potential fire hazards and risks in a property which is critical in every industry,” says Duncan Boyes, chairman of the Centa Group. Potential sources of ignition include welding; friction from conveyor belts, sparks from grinding and deliberate igni-

tion. Potential sources of fuel are solids (textiles, paper and wood), liquids (petrol, diesel, thinners and paint) and gases. Centa’s fire risk assessment focuses on the likely speed and growth of a fire, the number of people in an area, fire warning arrangements and a clearly defined plan of how people should make their escape.

‘Wonder Material’ World-class welding standards have enabled top liner-plate expert Rio-Carb to manufacture a wide variety of long-life Chromium Carbide (CrC) liner plates, chutes, hoppers and slides for the South African heavy materials handling industry. Rio-Carb director Martin Maine points out that the company is the only liner plate manufacturer in South Africa whose welding standards are compliant with the internationally-recognised specifications drawn up by the American Welding Society (AWS). He adds that welding standards in South Africa do not yet make provision for Chromium Carbide welding. “Local welding standards are predominantly based on carbon-based martensitic 400 and 500 BHN materials. Chromium Carbide, however has been proven in laboratory testing to provide up to ten times the

wear resistance against abrasion than the industry-standard 400 and 500 BHN steel, which are susceptible to annealing when heated to 350°C or more.” When used correctly, Martin points out that Chromium Carbide is literally a ‘wonder material’. “By making use of exclusive technology, Rio-Carb is able to take the properties of the material and cast it via welding process onto a mild steel backing plate, which gives it an optimum hardness of 54 RC, and additional flexibility for moulding and shaping. Rio-Carb CrC materials also do not lose their hardness at higher temperatures, and are unaffected by heating and cooling cycles.” Rio-Carb Contact, Martin Maine, Tel: (011) 908-1014, Fax: (011) 908 4139 Email: info@riocarb.co.za

There are always various solutions to reducing a fire risk, depending on the nature of the situation, which is why Centa’s assessments include an action plan to monitor and review all fire safety arrangements. The accurate recording of findings includes information on who is at risk, official compliance to national acts and standards, documentation of the adequacy of existing control measures, additional measures required to reduce risk to an acceptable level and the inclusion of a simple floor plan of the establishment. The Centa Group, Duncan Boyes, Tel: (031) 569-1175, Email: centa@centa.co.za, www.centa.co.za

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MARKET FORUM

Very Precise Coating

PSV Mitech has invested in a new Plasma Transferred Arc System (PTA), a process that deposits very precise coatings of perfectly controlled alloys on mechanical parts that are subject to intense wear, significantly extending their service life. PTA technology can quickly restore a worn part to an almost new condition, generally between 20 - 70% of the cost of a brand new replacement part. The process prolongs equipment life and reduces downtime as parts last longer. The PTA system works with different metal powders as filler material, such as chrome carbide, tungsten carbide, and nickel- and cobalt-based powders (such as Satellite 6 and Satellite 21). Using these hard-wearing materials can improve the durability of the weld. The result is an extremely high quality deposit offering optimal protection with minimal dilution or deformation of the base material with no porosity or inclusions. PSV Mitech Control Valves (Mitech), Greg Walker, Tel: (011) 657-6000 Email: gregoryw@mitech.co.za, www.mitech.co.za

KZNâ&#x20AC;&#x2122;s Tool & Jig Manufacturing Industry

In June 2009, Design South Africa was invited to quote and put forward a technical submission to Ford South Africa for the introduction of the new Ford Ranger in the body shop at the Ford Silverton plant. The contract was awarded to Design South Africa in December 2009 after an extensive elimination process with other overseas competitors. The line was designed and manufactured in Durban, where testing also took place. The whole facility was then relocated to Silverton and commissioned at Ford.

The plant went into full production in 2011 and has now been in production over a year. This led to Ford South Africa recommending Design South Africa for the Ford Venezuela project, which was recently shipped from Durban and will be commissioned in November. TIKZN, Umash Ramkalawon, Tel: (031) 368-9600

40

Pictured at the handover between Design Group and Ford Venezuela are from left: Nick Herrmann, Marco Chacon, Luis Tellez, Valdemar Arellano, Dave Brookes, Mike van Heerden and John Mulgrew

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MARKET FORUM

Becker Mining South Africa’s comprehensive range of personal protection equipment includes the Blocfor, a retractable fall arrester block, designed to offer maximum protection to workers at heights

Considerable Spoils Engen Mozambique has been awarded a significant share of commercial tenders as major new mining projects come on stream in Mozambique, which together are expected to consume up to 300 million litres of diesel and 5 million litres of lubricants per annum by 2015. The company won the total supply of fuels and lubricants in a tender floated by global mining giant Rio Tinto for operations of a mine it acquired in Moatize (Tete Province).The deal is for the supply of 200 million litres of diesel and three million litres of lubricants over the next five years, says Moises Alberto, Commercial Manager of Engen Mozambique.

Maximum protection Becker Mining South Africa’s comprehensive range of personal protection equipment includes a retractable fall arrester block, designed to offer maximum protection to workers at heights. “The Blocfor range, which conforms with stringent international quality and safety specifications, is a ‘hands-free’ anchoring system, that offers the user maximum safety and total freedom of operation,” says Charlotte Megannon, Product Manager, Becker Mining South Africa. “ The lifeline is usually attached to a structure via a connector, which enables vertical movement,

perpendicular to the lifeline.” The Blocfor unit, which is easy to transport and install, is designed for use indoors and outdoors, as well as in aggressive and explosive environments. Because all components are made from corrosion resistant materials, maintenance requirements are minimal. It is critical however, that after use in arresting a fall, the system is repaired by Becker Mining South Africa. Becker Mining South Africa, Charlotte Megannon, Tel: (011) 617-6300, Email: info@za.becker-mining.com, www.za-becker-mining.com

In another tender, Engen won the rights to supply five years’ worth of lubricants to Brazilian mining giant Vale for the first phase of the development and production of its mine in Moatize. The lubricants volume for the tender is five million litres. The fuel portion – 300 million litres of diesel – was awarded to state-owned company Petromoc. The lubricants business was secured with support from Petronas Brazil, a subsidiary of Engen’s majority, Petronas. With the conclusion of logistic rail lines in four years’ time, namely the Moatize-Nacala rail line, which has 40 metric tons (MT) p.a. capacity; and the Moatize-Macuse rail line, which has 20 MT p.a capacity, as well as the expansion and upgrade of the current infrastructure, Mozambique will be able to export about 70 MT p.a. This will result in an increase in the consumption of fuels and lubes to 300 million litres of diesel per annum. Apart from Vale and Rio Tinto, other mining companies are also developing concessions in the area. Jindal, an Indian group, and London-based ENRC jointly have an estimated diesel requirement of 34 million litres per annum from 2014. “All these concessions require massive investments from the oil industry in Mozambique and represent a major challenge to all players to sharpen up expertise in the mining market,” says Moises. Engen Petroleum, Tania Landsberg, Tel: (021) 403-5258, Email:tania.landsberg@engenoil.com

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MARKET FORUM

New water atomising plant South Africa’s minerals research and development organisation, Mintek, has completed commissioning its water atomisation plant; a construction intended to research and develop atomisation technology for the precious and base metals industries. Situated at Mintek’s Randburg campus, the water atomisation plant will provide an effective means for the production of solid metal powder from 6 ton batches of molten metal. According to Rodney Jones, a Specialist Consultant at Mintek, many smelting processes that selectively recover metals, yield an alloy that is too malleable

to be crushed or milled. However the downstream processing of the alloy often requires it to be in powder form and atomisation provides an effective means of producing metal powder from liquid metal. The molten alloy is tapped into a ladle furnace where its temperature is controlled before it is discharged by using a slide-gate valve into a tundish that feeds the water atomiser. Inside the atomiser, high-pressure jets impinge on the molten stream to break it down into fine particles, which can vary in size, depending on the alloy and the pressure of the jets.

The solidified particles are initially separated from the water by a magnetic separator, followed by a dewatering screw. The final drying of the powder takes place in a rotary kiln. These powders are well suited for subsequent leaching operations where surface area is an important consideration. It is also suitable for pneumatic conveying and other material handling systems that require accurate feed rate control. Mintek, Ulwazi Mgwadleka, Tel: (011) 709-4308, Email: UlwaziM@mintek.co.za

Sustainable Award The SKF Group has received the “Sustainable Supplier Award” from Bombardier Transportation for integrating CSR in business principles and in management standards. Says Henrik Lange, President, SKF Industrial Market, Strategic Industries, “SKF Care, our sustainability program, drives how we integrate sustainability

42

into our business, into our environment projects, into how we support our employees, and how we work with the communities where we do business.”

18001); labour conditions and business ethics (SA 8000); as well as general CSR commitment (GRI level B reporting) including philanthropic engagement.

The Bombardier Transportation Sustainable Suppliers Awards are based on a selection criteria that covers quality systems (IRIS); environment, health and safety systems (ISO 14001 and OHSAS

SKF South Africa, Samantha Joubert, Tel: (011) 821-3500, Fax: (011) 821-3501 Email: samantha.joubert@skf.com, www.skf.co.za

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Big 5H¿QHU\2UGHU Ecochem Pumps has secured the dosing pumps contract for Sasol Synfuels’ water recovery growth project. The order comprises Milton Roy dosing pumps worth approximately R2-million to be supplied to Uhde, a division of ThyssenKrupp Engineering.

capacities of up to 2500 litres per hour. A major feature of all the pumps for Synfuels is the double diaphragm with rupture detection mechanism to provide increased safety and operational redundancy. If the process diaphragm is perforated, the rupture is immediately indicated by means of a pressure gauge installed on the liquid end to detect such a fault. The remaining, unruptured diaphragm allows the pump to continue running with only negligible attenuation in hydraulic efficiency, and prevents ingress of the process chemical into the gearbox. The benefit to the customer is that he or she has time to plan for repair of the ruptured diaphragm without pump downtime.

Ecochem sales engineer Darren Cox says “The Milton Roy dosing pump is a reliable, long lasting, API 675-compliant product with very low overall cost of ownership.” “We have refinery installations still working after twenty years because of leading double-diaphragm technology and the relatively small number of working parts in the design.” Milton Roy’s dosing pumps for Sasol Synfuels comprise a mix of twelve stainless steel models from the MaxRoy, mRoy and PrimeRoy ranges. The largest pumps in the order will deliver dosing

Darren Cox, sales engineer at Ecochem Pumps

Ecochem Pumps, Richard Rudling, Tel: (011) 455-5710, Fax: (0 11) 455-5842 Email: richard@ecochempumps.co.za

Rock Solid Performance Hansen Transmissions has recently secured an order for the supply of a large “S” winder drive to replace an existing drive at one of South Africa’s leading platinum mines.

“With an installed power of 1490kW @ 750 rpm down to 55.1 rpm, and a special drive ratio of 13.6/1, the “S” winder drive will be designed and engineered with a similar footprint as

the drive it will be replacing,” explains Colin Thornton, Contract Coordinator, adding that delivery of the winder drive is scheduled for January 2013. Colin believes that successful and long lasting customer relationships are built on strong foundations of exceptional engineering capabilities and bestin-class products and services and says, “We are rightfully proud of our many sound customer relationships that we have developed over the past four decades.” In conclusion, Colin says that low total overall cost of ownership (TCO), maximum uptime and optimum productivity are direct results of high performance, reliable and efficient equipment, backed by 24/7 aftersales service and technical support Hansen Transmissions, Fritz Fourie, Tel: (011) 397-2495, Fax: (011) 397-2585 Email: ffourie@HansenIndustrialGearboxes.com, www.hansenindustrialgearboxes.co.za

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MARKET FORUM

Wi-Fi Printing HP is offering the industryâ&#x20AC;&#x2122;s first webconnected, entry-level printing solutions for engineers and architects, making inhouse, large-format printing accessible to more users.

Delivering large-format printing through the cloud from virtually anywhere, the new HP Designjet T120 and T520 ePrinter series provide on-the-go professionals with simple and affordable printing

solutions. The compact, 24-inch HP Designjet T120 ePrinter series is ideal for students and freelancers, while the 24- and 36-inch HP Designjet T520 ePrinter series is designed for small teams in need of fast, professional printing. HP has also introduced the second generation of its free web service for AEC professionals, HP Designjet ePrint & Share, which makes it easy to access and print large-format documents using an iOS or Android tablet or smartphone, a laptop or ePrinter touch screen. The HP Designjet T120 and T520 ePrinters are the only large-format printers available with built-in Wi-Fi connectivity, so users can install the printer where it is most convenient. True print previews from the new HP Designjet driver ensure accurate prints on the first try, resulting in time and cost savings when printing from a computer. HP South Africa, Hedy Gorton, Tel: (011) 785-1060, www.hp.com Email: hedy.gorton@hp.com

Advanced Centrifuge Range Ludowici Meshcape sales manager for coal, Leon Toerien points, out that the companyâ&#x20AC;&#x2122;s range of centrifuges have established an estimated 80 percent market share in the South African and Mozambican coal mining sectors, due to their quality and reliability.

mm and greater than 0,5 mm in size.â&#x20AC;? The number behind each VM model represents the diameter of the basket, which dictates the tonnage throughput.

â&#x20AC;&#x153;Ludowici Meshcape manufactures a range of centrifuges that have established an unrivalled track record of performance and reliability in dewatering coal, which is fed into a rotating basket and the resultant G-forces aid in expelling the moisture adhering to the coal. Our range of models include coarse and fine coal centrifuges, which boast impressive capacity, advanced technology and industry leading durability,â&#x20AC;? Leon explains. He highlights the fact that Ludowici Meshcape is recognised as a world leader in coarse coal centrifuges, with models that include; the VM1300, VM1400, VM1500 and VM1650. â&#x20AC;&#x153;The VM range of coarse coal centrifuges are ideal for applications where the coal is nominally less than 50

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Ludowici Meshcape, Leon Toerien, Tel: (011) 210-4849, Fax: (011) 210-4050 (PDLOOHRQWRHULHQ#Ă&#x20AC;VPLGWKFRP www.ludowicimeshcape.co.za


MARKET FORUM

Pneumatics in Water Technology

Brian Abbott, Pneumatic Product Manager Festo, says: â&#x20AC;&#x153;Compared with electrical installations, pneumatic automation technology reduces investment, installation and operating costs by over 50% in some cases. Pneumatic drives require no maintenance for their entire lifespan. As process valves are operated irregularly in water technology, deposits or caking can form, which lead to much higher breakaway torquesâ&#x20AC;&#x2122;. The overload protection of the pneumatics is a crucial feature here. If the drive comes to a stop, the pressure on the pressure regulator can simply be increased to enable more force to be applied, which eliminates the need for costly maintenance.â&#x20AC;? Another advantage is that the compressed air is obtainable even in the event of an electrical power failure, as an air reservoir, as well as a compressor to generate and supply compressed air, are always available. The valve terminal is at the core of pneumatic systems in water technology, as a decentralised element. Near the process valves, it is ideal for rapid and simple

The Psyttalia wastewater treatment plant, near Athens, Greece

automation solutions in which process valves, pneumatics and electronics interact optimally. The modular valve terminals can be expanded depending on the number of process valves. With the fieldbus, this system solution has just a single, clearly defined and standardised interface between the controller (PLC) and the valve terminal. The advantage of the system concept is

that extensions or changes can be made at the control level without replacing the hardware. In addition, all components of the machine technology are compatible. Festo pneumatics are used worldwide in waterworks and water purification plants. Festo (Pty) Ltd, Tracey Swart, Tel: 08600 FESTO (33786) Email: sales.interaction@za.festo.com, www.festo.co.za

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MARKET FORUM

Dust Control Contract Desiree Chetty BLT SA, a newly-established predominantly women-owned BEE level three company specialising in bulk materials handling, has appointed Desiree Chetty as financial director.

A bag filter produced and erected by Actom Air Pollution Control for a similar application as that covered by the recently-awarded contract for ASA Metals’ chromite pelletising and sintering plant.

Actom Air Pollution Control has been successful in winning a closely-contested dust control contract to provide and install a high-performance reverse pulse bag filter for ASA Metals’ chromite pelletising and sintering plant near Burgersfort, Limpopo Province. The contract, awarded in June this year, is due for completion by the end of the year.

to sintering, the aim being to increase dust control performance in accordance with current plant requirements, which require emission levels of less than 20 mg/Nm3. The bag filter, with a capacity of just under 30 m3/sec, will collect oxidised chromite dust at screens, storage bins and conveyor transfer points.

The bag filter to be manufactured and installed by Actom Air Pollution Control will replace an existing wet scrubber used for collection of oxidised chromite prior

Actom Air Pollution Control, Des Tuck, Tel (011) 478-0456, Fax (011) 478-0371 Email: des.tuck@actom.co.za, www.actom.co.za

Cyril Pillay Stirling Accessories, specialists in the manufacture and supply of automotive components, has appointed Cyril Pillay as factory manager.

Index to Advertisers Afzeilia

30

Immanuel Works

32

Compressed Air

13

Indutec

28

Dryden

10, 12

John Thompson

Engen

45

Eskom

4

Scania

Europair

8

Symbiosis

Gea

46

Outside Back Cover

Mining Indaba

Yellotec

THE SOUTH AFRICAN MECHANICAL ENGINEER

Outside Front Cover Inside Front Cover 24, 25 Inside Back Cover 14, 0

VOL 62 Nov/Dec 2012

Vincent Chirouze Vincent Chirouze recently joined water technology specialists, Xylem South Africa as the company’s Managing Director.


You have real engineering vision. Now you’re ready for a whole new perspective.

Contract Advisor, Scheduling, Estimating, Cost, Chemical, Civil, Mechanical, Electrical, Health & Safety, Instrument and Communication Engineers. With a career in Project Management at Saudi Aramco, a global leader in the energy industry, your expertise will be a key lynchpin in our operation – and what an operation. Unrivalled in scale, pushing the boundaries of innovation and harnessing world-class technology, we can promise you the exposure you need to excel. We have the model for generations of sustainable energy. But it all begins with a huge investment in your expertise. The limits to what you achieve are up to you. Saudi Aramco offers an excellent compensation and benefits package, as well as an unbeatable lifestyle and a high level of job security. To find out more and apply, please visit www.symbiosis.co.za or email/fax your CV or SMS your details for a return call. Contact Numbers:(011) 300-2200 / 465-5560 / 083-654-8579 / 083-609-6049 / 082-320-7597 Fax:- (011) 465-4318. Email: info@symbiosis.co.za

uncommon opportunities

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Nov/Dec 2012

VOL 62

THE SOUTH AFRICAN MECHANICAL ENGINEER


GEA Grasso V-Series Reciprocating Compressor r Superior COP values at full and part load operation r High reliability and high quality wear resistant parts r Modest investment and low maintenance cost r Easy to install and to package r Wide capacity range

GEA Refrigeration Africa (Pty) Ltd 19 Chain Avenue, Montague Gardens, 7441 PO Box 36815, Chempet, 7442, South Africa Tel. + 27 21 551 4034, Fax + 27 21 551 4035 industrial@gea.com, www.grasso.co.za

GEA Refrigeration Technologies

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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62 Nov/Dec 2012


SA Mechanical Engineer NovDec2012