SAME Jan12

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

1

2

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

AN ENGINEER’S VIEW

Chris Reay

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

Climate Change: Are You a Believer or a Disbeliever?

With COP 17 behind us where are we with this issue? As members of the engineering profession, we should avoid the hype and see whether we can find suitable scientific evidence that may enable us individually to draw conclusions on the current focus, which is to limit the man-made production of greenhouse gases.

As with such matters, it has become influenced by both business and political interests that either promote the need for reduced production or are disbelievers for whatever supporting reasons they can identify. Humans indulge in extremes on viewpoints and few take the time to debate the issues in a mature manner.

T

here is also the tendency to feel that one must be in one or other camp, and that all our rationale for being so is clearly final and proven. Somewhere between the two extremes of being absolutely convinced of the impact of our own production or generation of CO2 and CH4 being causal, and that of being a total disbeliever, lies a range of probability that there is an influence that could cause negative climate effects. We should also consider why we regard any changes in climate to be negative? This has probably evolved because of the human tendency, which is rife and largely emotional, to correlate ANY violent event we witness, to changes in climate.

It is not a good thing when all scientists believe in the same hypothesis because original research declines So what options do we have? I believe it is best to get to the published scientific evidence, read enough of it, evaluate the conclusions, investigate the intent of the fanatics, question the causal links, and be prepared to be uncertain and not doggedly convinced either way.

So far I am bending towards the following hypothesis. There is just not enough bullet-proof scientific evidence to absolutely correlate global warming to the release of man-made CO2. But there are enough models with reasonable assumptions that support this relationship as long as due regard is given to the fallibility of unproven assumptions. Out of the debate comes the question as to why temperature rises have preceded the rise in CO2 concentrations, and what has enabled the temperatures to drop and ice ages to start?

climate issue are becoming convinced that the recent increase in CO2 COULD be providing a positive feedback effect, ie, accelerating the interglacial root cause of climate changes. Anyway, it is not a good thing when all scientists believe in the same hypothesis because original research declines. So the current level of debate needs to continue.

Obscene indulgences

From the risk perspective, the fast developing financial pressures that have evolved politically on enforcing a carbon economy are what we should be concerned with, for herein lies the unavoidable human self- enrichment potential. While we debate whether it is greener to build and operate and dispose of a Hummer or a Prius vehicle, we are not sure of our facts, and whether these are distorted by commercial imperatives. We still are not very good on life-cycle analysis.

Perhaps in the end the move towards a lower carbon or let’s be precise, CO2 environment, could achieve a worthwhile spin-off, and that is a more energy efficient world, and maybe one where we reign in obscene indulgences in energy consumption.

Ultimately, with a growing population that depends upon a world of finite resources, the projections of the Club of Rome’s and MIT’s work on Limits to Growth will become a reality. Being energy efficient and scared of potential catastrophic climate events should make it easier to decide on the potential for our impact on the deterioration of the climate.

Can we risk doing nothing?

What does seem to be happening is that a greater proportion of the scientists who are exploring the THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

3

4

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

January 2012 VOLUME 62 NUMBER 1

Contents

On the cover: Esteq Tel: (012) 809-9500 Fax: (012) 809-3396 Email: info@ESTEQ.com www.esteq.co.za

Monthly Column 9 Prominent

Cover Story

Filters & Filtration

10 Making Design Easier

Computers in Engineering 12 Bomb Proof 4x4s 15 Clever Engineering

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.

25 Too Good to be True?

27 Small but Fatal Particles

Regulars

POWER GENERATION TODAY Copyright

Materials Handling (SMMH) Conference 2012

17 Pivoting on a Bright Future 21 Power Generation News

3 An Engineer’s View 6 Institution News 23 Nuclear Institute (SA Branch)

Structural

24 SAINT

24 Structures for Mining and Related

29 Market Forum

The monthly circulation is 4 242

Produced by:

Official Publication of THE SA INSTITUTION OF MECHANICAL ENGINEERING

PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123 Republic of South Africa Tel: (011) 781-1401, Fax: (011) 781-1403 Email: editorial@promech.co.za Website: www.promech.co.za

and endorsed by:

Managing Editor Susan Custers Editor Kowie Hamman Advertising Louise Taylor Advertising: Power Generation Today Mark Bennett Circulation Catherine Macdiva DTP Zinobia Docrat 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

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

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

5

THE SA INSTITUTION OF MECHANICAL ENGINEERING

Council 2011/2012 Office Bearers

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

Branch Chairpersons

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

Portfolios:

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

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

T

Tel: (011) 615-5660, Fax: (011) 388-5356 Email: info@saimeche.org.za Website: www.saimeche.org.za Membership: Central, Eastern Cape, Mpumalanga & KZN: membership@saimeche.org.za Membership: Western Cape: saimeche.wc@vodamail.co.za

Alstom Power Service SA Babcock Africa Limited Bateman Engineered Technologies Bosch Projects Fluor SA GEA Air-cooled Systems Hansen Transmissions SA Hatch Africa Howden Power Howden Projects Industrial Water Cooling

SAIMechE recently hosted yet another successful John Orr Lecture tour. This year the Lecture was delivered by Wing Commander Andy Green, the ‘Fastest Man on Earth’. Wg Cdr Green, Bloodhound SSC’s driver, holds the current World Land Speed Record (1227 kph). Driving Richard Noble’s Thrust SSC in 1997, Andy set the world’s first and only supersonic land speed record at an astonishing 763 mph, driving literally ‘faster than a speeding bullet’. hrough SAIMechE, a number of prominent meetings, interviews and presentations to school learners were held. But the highlight was the five very well-attended lectures around the country, giving great exposure to this exciting engineering adventure.

PO Box 511, Bruma, 2026

Company Affiliates

John Orr Lecture: Bloodhound SSC

Osborn Engineered Products SA

This year’s lecture was probably the best attended, as each of the five lectures had to be moved to bigger venues to accommodate the overwhelming response.

Apart from the great recent newspaper coverage and magazine write-ups, Andy featured on SABC

Rotek Engineering RSD a division of DCD-Dorbyl S.A.M.E Water Sasol Technologies SEW Eurodrive Siemens SNC-Lavalin SA Spicer Axle SA Spirax Sarco SA Thyssenkrupp Engineering Transvaal Pressed Nuts & Bolts

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

Winder Controls Wing Commander, Andy Green

6

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

THE SA INSTITUTION OF MECHANICAL ENGINEERING

news, Expresso TV talk show and numerous radio interviews.

Needless to say, SAIMechE is very proud of its association with this enthralling engineering adventure.

This project is linked through a major education programme into schools across the UK and (through a hugely successful website, www.BloodhoundSSC. com) to students around the world. The project aims to inspire the next generation of young engineers and scientists, while setting the most remarkable Land Speed Record of all time – 1000 mph.

SAIMechE is sincerely grateful to Wg Cdr Andy

Green for the time and effort put into this lecture, and for contributing to the success of this year’s lecture. It is an honour and a privilege to have a guest of his stature.

We further would like to thank the Wits University for once again hosting the main lecture. The event symbolizes the very close historical association between SAIMechE and the University.

SAIMechE wishes to convey a special thanks to Europcar who have extended very favourable terms on the vehicles we hired during the Lecture tour. Their support of this initiative is noted with thanks and much appreciation.

Faster Than Sound The new land speed record of 1610 km/hr will be attempted at Hakskeen Pan near Upington in 2013.

“SA Mechanical Engineer” was among the media invited to an introductory press event held at the Sci Bono Discovery centre in Johannesburg where the CEO of SaimechE, Vaughan Rimbault, welcomed Andy Green and his team, the premier of the Northern Cape, Hazel Jenkins, and MEC Finance, Economic Development and Tourism Northern Cape Provincial Government, John Block.

Record-breaking

After an extensive global search, the most ideal location for this record-breaking attempt has been chosen as Hakskeen Pan in the Northern Cape Province, offering a near perfect 16 km stretch of smooth surface for the record attempt.

The Northern Cape Provincial Government has endorsed the hosting of the event as it fits in with the province’s extreme sport objectives.

The track preparation is a joint partnership between the Departments of Roads and Public Works, Economic Development and Tourism, the Northern Cape Tourism Authority, the Siyanda District Municipality and the Mier Municipality.

A total of 315 members of the public from the Mier municipal area have been identified to start with work on the track.

Worldwide sharing

The unique nature of the land speed record means the project can share all its data, designs, achievements and setbacks in the process. Consequently, it is already being followed in 207 countries, with about 7-million students able to access the project’s information and lesson materials. Dave Rowley, of the project’s education team, is now based in South Africa to develop links with schools, colleges and universities.

Dave Rowley, Bloodhound SSC, Email: dave.rowley@ bloodhoundssc.com, www.bloodhoundssc.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

7

8

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

MONTHLY COLUMN

Prominent Professionals Christopher Donald Reay, Pr Eng

Academic School

Michaelhouse

Graduate studies

B.Sc Engineering (Mechanical) Wits

Post-Graduate

Senior Executives Programme, MIT Sloan School; TOC Jonah programme.

Professional Bodies

SA Institution of Mechanical Engineering (Hon. Fellow); MIT Alumni; SPE; IoD.

Career Path - First employer

Eskom (Graduate Training Programme) Christopher Donald Reay

Growth path

Merz and McLellan; Murray and Roberts; Group Five; Davy McKee; TUV Rhineland; PGBI; Marstec; Engineer Placements

Most rewarding

Sishen Plant: recovery from near collapse of project to meeting all commissioning dates.

Present employer & position

CEO and owner, Engineer Placements

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

Achievements A design

Manufacturing procedures and quality assurance methods for welded thin wall aluminium components to nuclear standards

Yes, many. Poor graduate training and development, loss of experiential skills that could facilitate mentor programmes.

Scarce skills position exacerbated by non-use of perfectly capable retired or retrenched Engineers.

A project

How would you mend this?

Any awards

UCOR production award in particular

Develop candidate training programmes using the collective skills and expertise in the Voluntary Engineering Associations via structured and remunerated mentoring programmes, funded by the large, dormant skills development funds.

Future – a concept, a dream or a wish

Message to young engineers

Pelindaba Uranium Enrichment plant.

Retention of engineering intellectual capital in SA

Projects Most challenging

Sishen Iron Ore North beneficiation plant

You have a qualification that will be valued internationally and an opportunity to develop a career to be proud of. The world is short of talented Engineers. It is the profession that creates the built environment. It is probable that anything that moves has had the influence of the Mechanical Engineer. If in doubt, refer to the current development on the Bloodhound Supersonic land speed project.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

9

COVER STORY

Simulating the functioning of products is becoming a pre-requisite for all product development

Making Design Easier The graphic interface in software programmes is the gateway to unlocking the full potential of the software with ease, especially when it comes to design software which is characterised by a large number of different functionalities.

C

AD software was the first to embrace user-friendly GUIs (graphics user interfaces) while complex simulation and solver programmes lagged behind a bit, still requiring specialists to use the software to its full potential. However, Cobus Oosthuizen, CEO of Esteq this is now changing, Cobus Oosthuizen, CEO of Esteq, the distributors of Siemens PLM and MSC.Software software range of products in South Africa, tells “SA Mechanical Engineer”.

The user interfaces on these programmes are now a lot easier, familiar and comfortable to use Made to order

“Esteq and their high technology platform NX (Siemens PLM Software), a CAD/CAM/CAE program has kept up with the times through the years in terms of GUI development,” says Cobus. “However, MSC.Software’s Marc, a non-linear simulation solver package and MSC.Software’s Adams, a multidynamics solver system, have had the same interface

10

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

for many years while the developers concentrated mainly on growing the engineering capabilities of the software. The result is that both packages are today recognised as premium products in terms of engineering tools, enhanced further by significantly improved GUIs of both.

“The user interfaces on these programmes are now a lot easier, familiar and comfortable to use,” adds Cobus. “This is particularly important today where younger generation engineers, who have grown up with intuitive software interfaces, are entering the engineering industry. MSC.Software is now really open to suggestions and recommendations through their user conferences. It is now clear that GUIs are what users worldwide expect.”

Solving problems

This philosophy perfectly matches that of Esteq, helping customers to solve their engineering problems, rather than just selling them a software package which is why they employ engineering graduates as opposed to sales staff. Cobus says, “South Africa has serious engineering challenges across all industries and in particular the manufacturing industry. Therefore we’ve made it our primary focus to help customers to solve their difficult engineering problems, be it a dynamic problem, a contact hassle, a flow problem or difficult engineering process challenges. And we’re there especially to assist with detailed highly January 2012

COVER STORY

complex design problems which hamper the client from getting a good product to market.

“In essence, we want every single client to use the software optimally in order to gain the full benefit from their investment,” Cobus adds. “To accomplish this, you need qualified people who are knowledgeable in the various applications of the software across all industries.”

Customised

Although Esteq has been involved with the automotive manufacturing industry in South Africa for many years, they’re now also growing in all the other industry sectors. For example, a cosmetics manufacturer, using the TeamCentre software, has several hundred products which all have a bill of materials and undergo design changes, all of which has to be managed in terms of product data and new product development projects.

We’ve made it our primary focus to help customers to solve their difficult engineering problems, be it a dynamic problem, a contact hassle, a flow problem or difficult engineering process challenges

Although a manufacturing company elsewhere in the world may use exactly the same software as a local company, they usually operate quite differently which requires a certain amount of ‘customisation’ of the software. Cobus adds, “Our market is different from the international market and needs to be configured specifically for our unique production line and manufacturing configurations.

It’s not just a matter of getting the best tool for the job, you have to know how to utilise it to its full potential.”

Looking good too

One of Esteq’s clients is well-known industrial designer, Brian Steinhobel whose designs very often include mechanical functions. Cobus invited Brian to speak at Esteq’s Annual Users Conference recently where over 300 engineers from the South African industry shared information. “This is just another way of bringing something different to our customers,” says Cobus when we asked, why talk about industrial design to mechanical designers?

“Mechanical design engineers sometimes concentrate on the nuts and bolts of a design and then forget that the product has to be sold to consumers in the end. To help them think out the box a bit and get a glimpse into the importance of the ergonomics around products, we introduced Brain’s point of view. Judging by the positive feed-back, it was exactly what the delegates wanted.”

Simulation

Simulating the functioning of products is becoming a pre-requisite for all product development, but it’s not just about simulating one component at a time, designers increasingly want to simulate the workings of an entire system. “Integrated dynamic simulations are complex and highly specialised, but can now definitely be done,” explains Cobus.

“A good example is where we can see how the air flow around a truck affects the suspension of a car when the car passes the truck on the open road.

Adams, a multi-dynamics solver system

Our market is different from the international market and needs to be configured specifically for our unique production line and manufacturing configurations “To build the models for such an integrated simulation takes complex mathematic formulae to bring together all the physic in a model for a simulation,” Cobus says in conclusion. “Through user-friendly interface simulations, the complex becomes the order of the day. It’s becoming a matter of simulating reality.”

Cobus Oosthuizen, Esteq, Tel: (012) 809-9500, Fax: (012) 8093-396, Email: info@ESTEQ.com, www.esteq.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

11

COMPUTERS IN ENGINEERING

Bomb Proof 4x4s

South Africa has become known worldwide for the manufacture of superior armoured personnel carrying vehicles used in military and security operations in war zones around the globe.

E

ven in peaceful areas, as in Texas in the USA and several other countries, police departments are adding South African-made armoured vehicles to their fleet of policing vehicles because of their brilliant track record. This has created a highly-competitive local climate among several manufacturers, each vying for a slice of the cake, yet each bringing something unique to the market.

We can fit anything, from automated firing systems for machine guns to night vision systems and even heavy armoury such as 120 mm mortar guns Armoured vehicles

To find out more “SA Mechanical Engineer” speaks to Shane Nortje, technical manager of ICP, the manufacturers of the Reva armoured vehicle, at the company’s production plant tucked into the quiet, unspoilt landscape of bushveld hills west of Pretoria. “We’re a relatively small company turning out around 30 vehicles a month, but, because of our size, we’re very flexible in terms of customising

Shane Nortje, technical manager of ICP, the manufacturers of the Reva armoured vehicle

vehicles to specific client requirements,” he says. “We have a long wheel base and a short wheel base version as a standard onto which we then design each order for the customer’s specific application and requirements, be it a platform to carry personnel, equipment, weaponry or a combination.”

Shane is the company’s design engineer responsible not only for giving the customer what he or she wants, but also ensuring that their designs comply with the international Stanag standards applicable to armoured vehicles as well as each country’s regulations and road ordinances where the vehicle will operate.

Design software

“Without CAD design software, like the SolidWorks package we use, this flexibility just would not have been possible in the time and given the complexities of clients’ requirements,” he says.

“The same applies to weaponry,” he adds. “We can fit anything, from automated firing systems for machine guns to night vision systems and even heavy armoury such as 120 mm mortar guns. Each vehicle is designed

Just off the production line, the Reva vehicle

12

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

COMPUTERS IN ENGINEERING

specifically for the type of weaponry it will carry and the level of sophistication depends entirely on the customer’s requirements. We have fitted highly sophisticated weapon control systems which are operated from inside the vehicle through a monitor and joystick control, for example.”

However, the main purpose of armoured personnelcarrying vehicles is to protect the people inside the vehicle and so this features first and foremost in all their design work. “Our biggest problem is weight, you’re constantly trying to contain the weight within certain limits, without affecting the ballistic characteristics of the vehicle,” says Shane.

“Bear in mind that we’re working with a vehicle weighing in at about 13 tonne. You can’t just add layers of steel or weaponry without considering a whole lot of other factors such as speed, occupant comfort and styling, it has to look good as well.”

Protection

Contrary to the general public perception that these vehicle are built on the chassis of an existing 4x4 vehicle, the Reva is a unique vehicle which does not even have a chassis. The main body of the vehicle serves as the chassis onto which everything is mounted. The V-hull is manufactured from 10mm armoured steel while the sides of the vehicle are made from 6mm or 8.9mm protection plating, with a double skin of armour for added protection. The bottom plate consists of 10 or 16mm armoured plate, and the roof, back door, fire wall and nose plate contains 6 to 8.9mm armour. Additional 4mm armoured plates are built into the floor plates where specially-designed suspended seats are mounted for added protection.

“Our stuff is built on a solid V-shaped monocoque hull, a unique, combat-proven South African design which has been modified to withstand all types of threats from different types of fire-power encountered in the world today,” explains Shane. “The vehicle hull consists of two layers of armoured steel to leave a 25 mm cavity for increased ballistic properties within the passenger compartment. The upper hull is supported by a V-shaped bottom plate which is internally reinforced by means of a capping plate for ultimate blast protection from mines.”

The special underground vehicle

stage and looks more like a conventional SUV, Reva has The new SUV version from ICP also designed an underground vehicle for the mining industry. “The 350 SUV model is an armoured vehicle with finesse, but with a powerful drive train and

Actually tests the vehicle with a real blast as well as showering it in a hail of bullets from all the types of guns which may be used to try and cripple the vehicle ballistic protection,” Shane says in conclusion. “The underground vehicle, the Scavenger, is purpose designed for underground use and designed to fit into a mine cage. This means it has to be much narrower and to achieve this we had to design special axles to remain within the width of a mining cage.”

Shane Nortje, ICP. Tel: (012) 881-8600, Email: shane@ icp.co.za, www.RevaArmouredVehicles.com

Real testing

Although Shane uses simulation software to check blast and ballistics properties, he doesn’t solely rely on these results to finalise a new design.

Reva actually tests the vehicle with a real blast as well as showering it in a hail of bullets from all the types of guns which may be used to try and cripple the vehicle. “Although a landmine blast is represented by about 300 grams of TNT, we blast the vehicle with 10 kg of TNT in order to ensure it will withstand the worst case scenario,” says Shane, showing us a video as proof.

Other vehicles

Apart from a new model which is in its prototype

A vehicle after the blast test

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

13

14

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

COMPUTERS IN ENGINEERING

Clever Engineering There’s a call to convert to a bigger engine, and here we’re not just talking putting a V6 engines into the VW Kombi to tow the caravan. Industrially, conversions are often undertaken in the drive train for pump applications, or generators sets which are upgraded to bigger engines.

W

hatever the application, an adaptor plate or bell housing has to be designed and manufactured to make the new engine, or gearbox, fit perfectly. The adaptor has to match the mounting holes and brackets between the newly-paired engine and gearbox. To do this accurately, precision reverse engineering is used to ensure a perfect alignment of the engine and gearbox.

Like all the engineering work we do, all conversions are designed on 3D CAD by me Conversions

A company which specialises in this is Gilo Engineering in Booysens Reserve. To find out how they do it “SA Mechanical Engineer” speaks to owner, Guido de Greef. “In fact, we designed the very first Kombi conversions which later became a fairly standard conversion for Kombis, a kit which we produce to this day,” says Guido. “Like all the engineering work we do, all conversions are designed on 3D CAD by me. We were one of Mecad Systems’ first customers when we bought SolidWorks from them about 15 years ago.”

At first glance Guido appears to be anything but the computer fundi he really is. He wears overalls and spends as much time on any one of the CNC machines, lathes or milling machines in the workshop as he does behind the computer.

His list of firsts include designing the conversions

Guido de Greef, owner of Gilo Engineering

on bakkies which paved the way for today’s everpopular 4x4 off-road racing vehicles. He played a key role in designing a new crusher for the mining industry which will be built locally and introduced to the market soon. In the automotive industry in the USA, where conversion is the order of the day, he is well-known for finding a solution to problems others brushed off as impossible to solve.

An inborn knack

“I can’t remember my wife’s birthday, or a telephone number, but give me a mechanical problem of any kind and I’ll find a way to overcome it,” Guido says with a knowing smile. “I go to sleep on the problem and the next day I sit down at the computer and design something that works. It just comes to me naturally, a talent I’m very fortunate to have.”

Some people are described as early adopters of new technology, but it’s quite clear that Guido is a first-adopter of new technology. “We bought one of the first conversional CNC machines into the country and quickly worked out how to exploit the technology to its fullest to make complex components accurately,” he says. “We were also first in bringing in a 7-axis CNC machine which could turn a complete V8 crankshaft out of a single billet.”

Measuring

Janine de Greef using the measuring arm to reverse engineer a component

Reverse engineering requires meticulous measuring, something Guido did manually in his youth.

“We used to use a vernier, rulers and protractors to get the measurements off the original engine block because OEMs to this day aren’t keen to part with their design drawings,” he explains. “You’d then have to draw the engine in order to design the adaptor within the available space.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

15

COMPUTERS IN ENGINEERING

An in-house foundry for castings

Bell-housing of all shapes and sizes for conversion kits

“The moment portable coordinate measuring machines (CMMs) became more affordable, we invested in one,” adds Guido. “CMM is now the norm for all reverse engineering on a component level because the measurements can be fed into the design software directly. We also use it for quality

control on the products we manufacture, and as a quality control service to our clients.”

Prototyping

By now we realise Guido is a total technology junkie and it comes as no surprise when he excitedly tells us about the 3D printer they acquired recently.

“We’re running it as a bureau service, both to print prototypes as well as small one-off custom designed components such as turbo charger housings and so on,” he says. “Tooling is expensive today, making it well worth printing a prototype before you actually start making the tooling. Recently we wanted to reduce the size of a water bottle by simply scaling it down to 60% of its original size. Nobody considered that the thickness of the material scaled down proportionately. When we printed it the walls were so thin, it was almost transparent. If the tooling for that design had already been made it would have been a very expensive exercise.

CMM is now the norm for all reverse engineering on a component level because the measurements can be fed into the design software directly Guido’s daughter and son are in the business with him and they’re both equally at home behind any of the CNC machines or computer stations throughout the place. If they have half the knack Guido has in terms of understanding mechanical equipment, Gilo Engineering is set to be around for many years to come to solve the problems others may turn their backs on. “However, without software, and a thorough understanding of how to utilise to its full potential, none of this would have been possible.”

Guido De Greef, Gilo Engineering, Tel: (011) 835-2915, Email: gilo@icon.co.za

16

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

POWER GENERATION

PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: editorial@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial: Kowie Hamman,

Eleanor Seggie Advertising: Mark Bennett Circulation: Catherine Macdiva DTP: Zinobia Docrat/

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

Copyright

TICKER TAPE

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

While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

Pivoting on a Bright Future

T

he sixth annual Southern African Energy Efficiency Convention 2011 Convention and Exhibition, the Southern African Association for Energy Efficiency’s (SAEE’s) flagship event challenged delegates to choose between a black or bright future for energy sustainability.

Overall, there seemed to be an atmosphere of cautious optimism, expectation and collaboration, but views on the country’s current energy climate were mixed.

Department of Energy clean energy chief director, Mokgadi Mathekgana said that profound changes were beginning to transform the way we supply, transform, deliver and use energy services.

Powering a city

Eskom IDM senior general manager Andrew Etzinger said that demand for energy patterns seem to be changing, with peak demand being experienced just before winter but still slightly coming in lower than 2010.

Further, climate change is taking a toll on power stations, as increased temperatures cause constraints.

Positively, he said that in 2010/11 there were demand savings of 355 MW, of which 204 MW came from the residential sector.

President Jacob Zuma has urged close cooperation with Mozambique to take advantage of its recently discovered gas deposits Wits and the South African Nuclear Energy Corporation (Necsa) have developed technology which turns agricultural waste and solid municipal waste into liquid fuel, electricity, waxes and paraffin. The environmentally friendly plant is called the BeauTi-FueL Project

Total investments in renewable energy in Africa rose from $750 million in 2004 to $3.6 billion in 2011. It is reportedly set to grow to $57-billion by 2020, with key growth sectors being wind power, solar power, geothermal power and foreign direct investment into energy and power infrastructure The United Nations has designated 2012 as the International Year of Sustainable Energy for All

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

17

POWER GENERATION

Aos Consulting Engineers CEO, Olu Soluade • Mechanical engineers and architects need to collaborate first investigate reducing the energy footprint of a project before designing.

• Use passive design opportunities and an integrative approach, combining natural lighting, building orientation, and accommodating the heat island effect, before using technology.

• Getting the most productivity from a HVAC unit involves reducing cooling loads, lifecycle costing, commissioning the building properly, monitoring performance and following a triple bottom line approach.

IDM energy savings target for 2011/12 (1 280 GW) could power a city for a year. To date, the top five energy services companies (ESCOs) have delivered 72% of the demand savings achieved.

Snapshots

Here are snapshots of some of the other SAEEC sessions:

Technology Innovation Agency (TIA) industrial sectors group executive, Pontsho Maruping • There are diverse technology opportunities: Fuel cells, cogeneration plants, uninterrupted power supply, biogas digestors, wind turbine systems, solar photovoltaics (PVs) and heat pumps.

• Lighting systems, energy management systems, HVAC, motors and drives can be more energy efficient.

TICKER TAPE

• Energy efficiency can be stimulated by wellfunctioning markets and innovative systems supported with R&D funding, highly qualified science and technology human resources, effective par tnerships and appropriate framework conditions.

18

Basil Read has the green light from the Department of Energy to erect the MetroWind Van Stadens wind farm in the Nelson Mandela Bay metropolitan area, near Port Elizabeth The majority of South Africa's new renewable energy projects will be located in the greater Cape area with its abundant potential to tap into sun and wind energy

TIA information communication technology GM, Mkhululi Palane •Urbanisation is moving toward ‘mega’ cities, corridors and regions. These cities and regions, not countries, will drive future wealth creation.

•Cities will become ‘smart’, and ‘smart is the new green.’ Smart cities will be able to control emissions and energy consumption; smart cars and materials will also be used.

•These cities will use smart energy: there will be convergence between energy infrastructure players and ICT players and manufacturers bringing about significant innovation and technology.

•Smart grids will deliver key advantages such as a bi-directional relationship between generators and end-users, who will be able to generate and sell electricity back to the grid.

•Current smart grid trends include advanced metering and networking, demand response, grid optimisation/distribution automisation and software solutions and applications, besides others.

•Frost & Sullivan research shows very little activity in smart grids in Africa, although South Africa is the most advanced in this regard. dependent Power Producers programme (IPP) were announced during COP17 including 18 photo-voltaic solar projects, two concentrating solar power projects and eight new wind energy projects. A total of 1415 MW clean energy could then become available for South Africa by 2016 Eskom is going ahead with the construction of the Sere wind farm in Vredendal, set for completion by the end of 2013 with a 1.5 MW capacity

28 preferred bidders for the Renewable Energy In-

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

POWER GENERATION

Germany’s Lahmeyer International CRM executive director, Thomas Kraneis • Germany has moved away from nuclear energy. The first wind farm in Germany was privately- and not government-owned.

• China is making the biggest progress in terms of installed wind power capacity • Africa has many good sites for wind • Current plans for renewable energy in Africa are eg, 13% of electricity in South Africa by 2020, as opposed to 75% in Madagascar by 2020 and 90% in Rwanda by 2012.

• PV prices are decreasing due to mass production worldwide • Worldwide bottlenecks in renewable energy are partly due to insufficient skills capacity.

Emergent Energy’s Jonathan Skeen •Bishops Diocesan College case study: Lots of different systems were replaced with a centralised solar heat pump in August 2011. Results: a 69,5% energy use and R4300-R5500 electricity cost saving with a net COP average of 3.3 that month

Sejamothopo Motau, MP: DA shadow, Minister of Energy

• South Africa is the gateway to the rest of Africa in the green frontier; it has amazing R&D but needs more investment, local beneficiation and seed financing for green entrepreneurs • Green taxes need to cross-subsidise the green economy – lobbying is needed for this.

• Nuclear costs range in the trillions versus renewables which are in the billions and the country may not have adequate skills to ensure nuclear sites are built properly and safely • The ‘Rebid’ strategy requires money upfront and involves significant administration • There is excitement around the proposed independent system and market operator (ISMO) - a company that would take over the system operator function from Eskom and act as a buyer of electricity from suppliers and a seller to customers. However, government states it may take five years for the ISMO to be independent of Eskom.

• As funding is an issue, Eskom should let independent power producers focus on renewable energy, while it focuses on other initiatives like underground gasification and using coal as effectively and environmentally friendly as possible.

Sessa ambassador, Irvan Damon

Irvan Damon, Sessa, says Africa could be on the brink on an economic take-off

Overall

Overall the conference seemed to be a success, provided an ideal opportunity for networking, collaborating and idea-sharing. The “Power Generation Today” team is looking forward to what 2012’s SAEEC brings. www.saee.org.za

• Africa could be on the brink on an economic take-off. The problem is we do not have a plan: we have the what, but not the how THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

19

20

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

POWER GENERATION NEWS side management (DSM) programme, as well as across diverse sectors and projects.

Turbine halls

The appointment followed the achievement of South Africa being the first country in the world to publish a standard for the M&V of Energy Savings, SANS 50 010, in 2011.

Some of the equipment supplied by Actom Air Pollution Control as part of the HVAC contract for the turbine halls at Medupi are shown above in storage on site at the power station. The picture shows booster fan support structures and ducting for Unit 6

Actom Air Pollution Control, which two years ago won the heating, ventilation & air-conditioning (HVAC) contracts for the turbine halls at Eskom’s new Medupi and Kusile coal-fired power stations, has to date produced roughly 50% of the total equipment required on the Medupi contract.

The company site supervisor established site at Medupi near Lephalale in Limpopo Province at the beginning of September last year to commence supervision of installation of the HVAC equipment in Unit No.6, the first of the power station’s six generation units in which the equipment is to be installed.

The two contracts, worth over R100million, were awarded in mid-2009 to Actom Air Pollution Control by Alstom S&E Africa (Pty) Ltd, the contractor for the turbine packages for both of the 4800 MW power plants.

Final delivery of HVAC equipment for Medupi is scheduled for mid-2012, while the first ex-works delivery for Kusile was made in early-December 2011 and final delivery in early-2013.

The equipment, all supplied ex-factory for installation includes ventilation ductwork, fans and accessories, electrical motor control centres, cables and racking. A total of 342 axial flow fans ranging in power from 3 kW to 45 kW will be supplied for each power station.

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

Sound M&V practices South Africa had been appointed as the chair of the International Standards Organisation (ISO) working group to establish a global measurement and verification (M&V) standard. South Africa is viewed internationally as leaders in the field of M&V due to its expertise gained as a result of Eskom’s demand

Gustav Radloff, MD of Energy Cybernetics and SABS representative at ISO, announces the confidence placed in South Africa’s M&V expertise by being acknowledged as global leaders in the field

Gustav Radloff, MD of Energy Cybernetics, who also represents the South African Bureau of Standards (SABS), was elected to chair the working group of ISO to establish the “M&V of Organisational Energy Performance – General Principles and Guidelines” standards for almost 50 countries in the world including Argentina, Australia, Denmark, Canada, USA, UK, China, Japan, Brazil, Norway, Mexico, etc. Gustav says: “South Africa will act as a bridge to bring global perspectives together under one umbrella. The fear is that M&V will be done in different ways, and so there is an important need to introduce coherence globally.”

The objectives of the working group are to ensure international confidence in recorded energy performance results considering other standards, programs and regulations, and a key challenge will be to allow flexibility in the approach to M&V while achieving this.

Gustav Radloff 018 297 5908, Email: gustav@ energycybernetics.com, www.energycybernetics.com

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

21

POWER GENERATION NEWS

Within predictions ment, retrofitting and re-lamping, has also met key objectives, including enhanced safety, timeous installation, pristine quality of fittings and cost efficiency.

Before

Magnet, specialists in the supply, implementation and support of electrical equipment and industrial instrumentation, has recently completed a lighting upgrade project for Dulux, to reduce energy consumption, load and associated costs at the Umbogintwini plant in KwaZulu-Natal.

“Phase 1 of this project involved the design and installation of a new energy efficient lighting system to deliver electrical performance and energy savings within 10% of predictions. In some cases, calculations of savings have been exceeded,” says Brian Howarth, Magnet’s managing director.

“This installation, which included replace-

“A 47.3% reduction in kW`s, as well 50.4% in kWh, allowed for the estimated savAfter ings to be achieved.”

Scope of operations encompassed the replacement and upgrading of lighting in certain areas of the engineering workshop, raw material stores, packaging stores, filling hall, holding area and the national warehouse.

Brian Howarth, Magnet, Tel: (031) 2741096, Fax: (031) 274-1073, Email: brianh@ magnetgroup.co.za, www.magnetgroup.co.za

Hydrogen Technology While hydrogen fuel cell technology points to a cleaner future, hydrogen use is already playing a key role in a number of industry sectors. “Air Products is the largest producer of hydrogen to oil refineries globally which use the gas to produce cleaner burning fuels.

Hydrogen enables refiners to increase the amount of fuel that can be produced from every barrel of crude oil while assisting to remove pollutants from crude oil” says Seelan Gounden, General Manager Supply Chain at Air Products.

prove quality output, optimise performance and reduce costs.

Air Products, which already operates an extensive hydrogen pipeline network around the world and in South Africa is investing substantially in the development of hydrogen as a commercial energy source, notably in fuel cell technology.

“Hydrogen is the cleanest burning and most efficient fuel,” explains Gounden. “It can be used to produce electricity in a fuel cell for the cleanest option, or in an internal combustion engine where emissions are Hydrogen has applications in significantly reduced compared many other industries such with other fuels.” as chemical, electronics, and foods, where it is used Air Products, Seelan Gounden, Tel: on a daily basis. Its dynamic (011) 977-6459, www.airproductsafrica.co.za properties are proven to im-

22

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

NUCLEAR INSTITUTE (SA BRANCH)

Used Nuclear Fuel– What’s to Become of It? One has to be careful these days to get the words right. ‘Spent’ fuel means uranium fuel that has already been earmarked for the dustbin or, to use the more politically correct jargon, to the high level waste repository. ‘Used’ fuel is also fuel that has spent its four years in the reactor but is now in the used fuel storage pool at the reactor site or is already waiting in dry storage while we ponder its future.

T

humbs down and, after ‘conditioning’ which means compaction and encapsulation, it goes to the waste repository. Thumbs up and it goes to the reprocessing plant to be dissolved in nitric acid to have its reusable uranium and ingrown plutonium separated from the viciously radioactive fission product and actinide waste. At least that’s where it would go if we had either a high level waste repository or a reprocessing plant - which South Africa does not. So what is the situation?

It is technically possible to separate the plutonium and reusable uranium from the genuine fission product waste, but ‘reprocessing’ is expensive. The economics of the process is questionable. Moreover, if the process employed yields reasonably pure plutonium, thoughts of weapons proliferation intrude.

A third possibility is to store the used fuel in dry storage casks in on- or near-surface facilities indefinitely. Future generations would then have the chore eventually of disposing of the reprocessed waste but would meanwhile benefit from plentiful energy to be had from the plutonium.

The radioactivity will have decayed to negligible levels Leading the field

It is accepted in all such schemes that ultimately the containers will corrode and that groundwater will reach the fuel. The engineered and natural geological barriers to water movement are such, however, that by the time radioisotopes moving with groundwater can reach habitable areas, the radioactivity will have decayed to negligible levels.

This has to be proved to the safety authority by analyses that must include, in the case of Sweden, seismic activity and excessive groundwater movement due to successive ice ages.

Having accepted that there can ultimately be contamination of groundwater, the safety authority is obliged to determine what is an acceptable level of contamination and be satisfied that it can never be exceeded. The analyses must estimate the risk to communities ‘downstream’ of the repository that might one far off day find themselves using the contaminated water. In the case of Sweden, the quantitative analysis must extend out to 100 000 years.

The level of risk deemed by the Swedes to be acceptable is minute. The risk to any far distant descendant of contracting cancer must be shown to be less than one in a million per year. This, using the highly controversial ‘linear no-threshold’ approach to radiation risk, the Swedes associate with an annual radiation dose of 14 microsieverts, 200 times less than the world average natural background radiation level.

Even later

The Scandinavians lead the field. Earlier this year, the Swedes applied to their national safety authority to construct a repository near the Forsmark nuclear station on the Baltic Coast. The Finns, using a similar concept, are already digging. In this concept, the spent fuel is consolidated, not reprocessed, and welded into corrosion-resistant copper canisters 50 mm thick. The canisters are reinforced internally with cast iron cylinders. The canisters will be sunk into holes in the floors of horizontal tunnels around 500 metres below surface in essentially unfractured granite. They will be packed around with bentonite clay that swells to impede the ingress of groundwater and, eventually, the egress of possibly contaminated groundwater.

Back in South Africa, I find it hard to believe that it would make sense to mine a deep repository just to take spent fuel or reprocessed waste, as the case may be, from Koeberg only. Rather keep it in dry storage casks until the IRP2010’s 9600 MW of new nuclear capacity is operational. We would then not need to invest in a repository (for other than public relations reasons) until around 2060 or even later.

This would be consistent with the current Eskom policy statement which, hopefully, will become the national policy when approved by the Minister of Energy on the recommendation of the embryonic National Radioactive Waste Management Institute.

John Walmsley

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

23

STRUCTURAL

Structures for Mining and Related Materials Handling (SMMH) Conference 2012 Structures play a significant role in the operations of any mine and South African engineers have developed a high level of skill in the design of these structures. In spite of their importance on mining sites and possibly on account of their very common presence on most mines, the specific challenges faced by designers of these structures are rarely covered in any depth at conferences held throughout South Africa.

South African engineers are world leaders in steel construction technology in mining applications

S

ays Southern African Institute of Steel Construction (SAISC) executive director, Dr Hennie de Clercq, “While conferences for structural engineers could potentially include

relevant mining content, there is typically already so much to cover on general buildings, bridges and mega structures, they can rarely accommodate papers on the very specific design demands of headgears, gant- Dr Geoff Krige, long-time prinries, conveyances, cipal structural engineer at c h u t e s , s h a f t s , AngloAmerican and Chairman of the South African Mining stackers, reclaimers Equipment Standards Committee and similar structures that are typically erected or operated in highly corrosive conditions, often in very remote areas, subjected to unusual loads and impact, including accidental loads and unpredictable rock movement.”

Dr Geoff Krige, long-time principal structural engineer at AngloAmerican and Chairman of the South African Mining Equipment Standards Committee adds, “Our miners tend to invest heavily in research in processes which will help get the product out of the rock cheaper and quicker, but much less in the mechanical issues. I hope, from a local perspective, that one of the results of this upcoming conference is the acceleration of the process whereby management increasingly recognises both the human and financial benefits of adopting state-of-the art structural engineering on the mines.”

SMMH2012 will be hosted from 15-18 October 2012 at the Riverside Lifestyle Resort on the banks of the Vaal River, Vanderbijlpark, approximately 50km from Johannesburg and centrally located to major mining activity in South Africa.

SAISC, Dr. Hennie de Clercq, Tel: (011) 726-6111, Fax: (011) 482.9644, Email: info@saisc.co.za, www.saisc.co.za

24

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

FILTERS & FILTRATION

Too Good to Be True?

Fitting an engine oil filter for life sounds too good to be true, but seeing is believing; so “SA Mechanical Engineer” set off to Turffontein to visit Stilko Filters who is prepared to support this claim with a written guarantee.

I

n a workshop cluttered with engineering machinery, old engines and gearboxes of all makes and sizes we find Pierre Sanan, the owner of Sanans Auto Spares, the manufacturers of the Stilko Filters. He’s behind his desk, noisily blowing his nose with a piece of tissue that looks suspiciously like it’s come off a toilet roll.

Our system is like having a small refinery plant on the engine, it actually purifies the oil “Excuse me while I’m making a ‘trunk’ call,” he says before bursting out with laughter about the ‘standard’ line he uses when he starts telling people about his magical filtration system which can be used on any internal combustion engine.

Tissue roll

The piece of tissue he’s using is actually off Pierre Sanan of Stilko Filters the filter element which is at the heart of the roll simply fits into an aluminium housing which Stilko filter system they manufacture. “It may look replaces any standard filter cartridge as is usually like an ordinary roll of toilet paper, but it’s anything fitted on engines, be it a motorcar engine, an aircraft but that,” he says. “It’s a specially-rolled continuous engine or the engine of any industrial machinery length of tissue rolled onto the core at a certain such as caterpillars and graders. “For the bigger tension and it has no perforations or embossing in engines we usually fit a dual cartridge system by the tissue as you’d find on a roll of toilet paper.” piping the oil flow through a special double unit we It takes us a couple of seconds to grasp exactly designed specifically for higher capacity filtration,” what he’s talking about, but in essence the tissue Pierre explains.

“This is fitted for life while only the element is changed at regular intervals of 5 000 to 8 000 kilometres. Contrary to the usual practice of having to replace the engine oil at these intervals as well, there is no need to change engine oil when replacing the element in a Stilko filter. This is only done at around 50 000 to 70 000 kilometres.”

Sceptics

Being as revolutionary as it sounds, most people were sceptical in the beginning, but Pierre has collected a pack of testimonials as thick as a Jo’burg telephone book on tests carried out by oil analysis companies, car manufacturers and OEMs of heavy machinery acknowledging the performance of this filtration system. “Our system is like having a small refinery plant on the engine, it actually purifies the oil,” says Pierre.

An old cut-out of the filter shows how the tissue roll is fitted in the filter housing

“We carried out a test on a tractor engine which needed an oil change. First, we took a sample of the oil first, then fitted our filter and ran the engine for an hour before taking another sample. The two

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

25

FILTERS & FILTRATION

The components of the Stilko filtration system

For heavy duty filtration a dual filter system is fitted

Has collected a pack of testimonials as thick as a Jo’burg telephone book samples were sent to Wearcheck for analysis and they condemned the first sample while the second sample, which had gone through our filter, was declared fit for further use.”

A demo proves the point

To demonstrate the principle, Pierre pulls out a demonstration unit fitted with a standard commercial oil filter on one pump circuit and their Stilko filter on another. He adds carbon to the clean diesel in

a glass bowl and selects for the flow to go through the standard filter first. The flow coming through the standard filter doesn’t change much and comes out the other end still pretty much as ‘dirty’ as it went in. Then he flicks a valve which directs the same flow through the Stilko system and immediately the flow starts clearing. Within seconds it becomes as clear as the original diesel. Thus, we’ve seen and we now believe.

“The only reason engine oil is changed is because the oil gets dirty and contaminated, not because oil wears out or breaks down as such,” Pierre emphasises. “Tissue has always been recognised as the best filtering media for engine oil,” says Pierre.

“Standard automotive filters are inadequate in preventing the circulation of small abrasive particles which are often smaller than one micron in size.

Tissue filters, however, will remove particles as small as 1/100th of a micron. This is why a Stilko filter is 100% more efficient than standard filters.”

Purification

Apart from having fitted this system to all size engines in all types of applications including some underground mining machinery, Pierre builds a special purification system which many companies use just to clean oils, and even diesel, before they use it or package it into smaller containers, especially if the oil has been stored for long periods of time. “Just yesterday an OEM collected a batch of elements for a system they’ve been using for many years now,” says Pierre. “They use large amounts of oil to run in the engines they make. Once the engine is run in, they drain the oil to put in new oil, but they then purify the used oil so it can be used again.”

Although Pierre has sold these filters in South Africa for over 30 years, he’s now embarking on a fresh marketing campaign to re-introduce the system to those who don’t know about. “Although many car manufacturers have tested the system and have given us favourable reports on its performance, they have, for reasons unbeknown to us, chosen not to adapt it as a standard OEM part,” he says in conclusion. “However, apart from our written guarantee for life, those who have used it for many years simply won’t go back. We have the testimonies to support that.”

Pierre Sanan, Stilko Filters, Tel: (011) 683-8383, Email: psanan8@gmail.com

26

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

FILTERS & FILTRATION

Small but Fatal Particles Through a microscope, the small dust particles which are invisible to the naked eye appear as big as the rocky outcrops of the huge boulders on Paarl mountain. By comparison, the tiny hole left by a 1.2 mm thick sewing needle on a piece of cloth appears to be the size of Kimberley’s big hole, thus leaving plenty of room for particles to pass through.

T

his is exactly what’s been found in sewn bag filters, especially on the long seam which has traditionally been stitched together with needle and thread to form a bag. “SA Mechanical Engineer” visits Crosible Filtration west of Krugersdorp to speak to Sebastiaan Buisman, managing director. “We’ve done tests with fluorescent particles which clearly show how they

Sebastiaan Buisman, managing director of Crosible Filtration

Emissions become substantial as either poisonous material escapes or precious material is lost to waste penetrate the stitching on the longitudinal seam of bag filters,” he says. “If this is toxic dust, like lead, it means the bag is emitting poisonous particles into the working environment.

A fused seem on the bag filter

The edges being fused under the hot shoe

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

27

FILTERS & FILTRATION

seem, followed by high pressures rollers to complete the seem. Once set up for a specific size bag, this process is much quicker than using a sewing machine.

“We believe we’re currently the only filter bag manufacturer in South Africa who has this technology from Europe where it has been tried and tested for some time now,” Sebastiaan says. “The pressure on everyone to reduce emissions is increasing all the time and we felt it was time to provide our customers with an opportunity to do so. In addition, it has made our production process faster and more efficient. The saving we make on yarn, for example, allows us to produce the fused seam bag at no extra cost to our customers.

“Some materials cannot be fused and will still have a stitched seam, but we’re constantly testing different fusion methods to try and find The fusion joining system, with the accumulator system and automatic cutting following it a way of sealing materials such as Every bit counts acrylics without the need to sew.”

“Typically the particle size we’re talking about here is between 1 to 6 micron in size while the needle Laser cutting makes holes of about 1500 micron,” he adds. Crosible also has another new machine on the “Even though there is yarn through this opening, factory floor to enhance the production of filtration it still leaves plenty of room for particles to pass materials. It’s a laser cutting system linked directly through, especially while the bag is being pulsed to a CAD design programme on a computer. Tradiwith pressure bursts. The emissions from the bag tionally the layers of filtration cloth which go into a are small, but over time the emissions become filter press were produced by drawing the layout on substantial as either poisonous material escapes the cloth by hand and then cutting it out by hand with a very energy-inefficient hand tool. “The hot or precious material is lost to waste.” knife traditionally used to make the cut also serves There is no beading whatsoever, leaving us with a much to melt the edge of the material to prevent it from fraying. This often causes little beads and when better quality product which is produced much faster, all the sheets are then compressed into the filter more energy efficiently and fits precisely consistently press, the beading tends to prevent proper sealing.

The company has now installed a system whereby certain filtration bag materials made of materials “With the laser cutter there is no beading whatsoever, such as all polyester and polypropylene can be leaving us with a much better quality product which joined in a fusion process for air tight sealing on is produced much faster, more energy efficiently and the longitudinal seam of the bag. “The top and the fits precisely consistently,” says Sebastiaan. “Apart base of the bag are still sewn with a needle and from doing the cut around the edges, all the cutyarn, but those ends are double cuffed to prevent outs such as holes and slots on the sheet, as well any emissions through the seams,” Sebastiaan as all the required markings for fitting purposes, says. “If you take a normal PTFE membrane bag, are drawn onto the material simultaneously. where permissible emissions of 15 to 20 milligrams “We’ve only had this technology in place for a per cubic metre are the norm, the fused seam bag couple of months now, but it has been installed in various applications across all industries with emissions are 5 milligrams per cubic metre less.” great success,” concludes Sebastiaan. “Remember, The welder this technology not only reduces the emission of Crosible’s new technology rests on a machine toxic particles such as lead and uranium, but also which uses the fusion process and is called the retains precious minerals such as gold dust. Every Phaff Welder. Depending on the type of material little bit counts and adds up over time.” being joined, it uses either hot air of about 450ºC or a hot wedge shoe which literally fuses the over- Sebastiaan Buisman, Crosible Filtration, Tel 0861-55 55 lapping ends of the material into a tightly-sealed 67, Email: sebastiaan@crosible.co.za

28

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

MARKET FORUM

New HVAC systems for South Africa Actom Mechanical Equipment has been appointed the sole agent in Southern Africa for Fläkt Woods’ world-class modular heating, ventilation and air-conditioning (HVAC) systems.

components – consisting of fan, filters, silencer, humidifier and heat recovery system – are self-contained, so that during the original design and assembly phase the ready-made modules of the required capacity for the particular application are selected and assembled quickly and efficiently. The same a p p l i e s to repair and

of the consulting engineers on the project, Gaborone-based North Atlantic Engineering Consultants, says; “We specified use of Fläkt Woods air-handling units as our design required a triedand-tested quality product that would combine high levels of energy recovery in 100% outdoor air systems for the hospital project at the University of Botswana’s new Academic Hospital currently under construction in Gaborone.

“The Econet system provides heat/coolth “The agency agreement air-to-water recovery with Fläkt Woods’ between the supply and Climate Control division exhaust air streams, is for their cuttingalong with the facility edge air handling to simultaneously units for HVAC add further heating applications. and cooling. All these The product is features are integrated manufactured VA C into a packaged common and assembled sH o o d u n i t s . circuit as compact W t g in Sweden and in Flak dlin heating/cooling coils, variable of a air-han n terms of the agreement o i r t ura odula speed pumps, insulation and control g i f we provide all the sales nm con cal -prove system, etc.

The result is a shorter and i p y l and marketing services at wel more compact air-handling unit,” Paul ows ng its h s into the local market, plus replacement of am mployi r g concludes.

“The Econet performance a i e after-sales service support on ay d ilding, components, with only taw is further enhanced by use of direct u the product, incorporating spares, T h e c um i n a b the module requiring attention evaporative cooling in the exhaust aire t s repairs and maintenance,” says Nuno s y being dealt with without any of its stream of the air-handling unit.”

Pereira, Actom Mechanical Equipment’s companion components having to be Fred van Hulten, Actom Mechanical EquipProduct Manager, HVAC. interfered with,” Nuno explains. ment, Tel (011) 871-6789, Fax (011) 871-6677, “The modular design means that the Paul Norton, Chief Mechanical Engineer Email: nuno.pereira@actom.co.za

Formal recognition

attempt to protect the seal of a pump involved in a relatively cheap process. “We installed our own seal design in the refurbished pump in June 2009, with the intention of running it for as long as we could.”

Staff at Aesseal have received formal recognition of outstanding service delivered to Sasol’s Secunda refinery.

From management of the Gas Circuit Department came a certificate “in appreciation of exceptional contribution” and recognising the “high standards of excellence” delivered by Aeasseal’s Pieta Engels.

A trophy recognising the ocmpany as best mechanical supplier to Sasol’s coal processing department was presented to Jaco Joubert, who additionally received a medallion recognising his personal contribution to the success of the department’s mechanical team.

Pieta Engels was able to deliver an

effective seal solution to an ex-quota pump that had experienced sealing problems for 20 years. “This pump was costing them money on two levels,” explains Pieta. “One, they had to keep replacing the seal, and two, the process side was incurring costs because of a seal support plan that involved the use of expensive condensate water in an

“The mean time between failures in the case of a bad-actor pump in Sasol’s coal processing department was so poor that it was adversely affecting departmental operating costs because of repeated replacements of not only the mechanical seal, but also the pump itself,” explains Jaco Joubert. “They gave us the opportunity to install our own mechanical seal, with the result that the pump has now run for a year without seal difficulties.”

Rob Waites, Aesseal, Tel: (011) 466-6500, Email: rwaites@aesseal.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

29

MARKET FORUM

Mine traffic control

“A highly sophisticated signalling and communications system is being designed especially for the high speed tramming system at 875mL – Chililabombwe, Konkola Copper Mines Plc Zambia,” says project manger Luther Grobler, Becker Mining Systems, part of the Becker Group of Companies. “This project encompasses the installation of the first underground digital trunking network at this mine, as well as tagging and tracking and the latest technology in collision avoidance - the CAS430.

“These modular Collision Avoidance Systems (CAS) systems, developed by Becker Electronics, prevent fatalities, injuries, damage and down time, resulting from the operation of vehicles in the proximity of personnel - on the surface, or underground.”

There are two control rooms at the mine - one on surface and the other underground – which will be linked via 24 core fibre-optic cable. Each control room will have a server with software and hardware for monitoring and manipulating the pathways of locomotives moving between loading boxes and tip boxes.

These control rooms will also have video

CESA’s

New President

Newly appointed President of CESA, Naren Bhojaram says that he has come into office at an interesting time for the

30

walls fitted for the visualisation of all operations.

traffic signalling and communication for high speed tramming in Africa.

Becker Mining Systems has been instrumental in ensuring the success of the first fully automated underground

Luther Grobler, Becker Electronics, Tel: (011) 801-5900, Fax: (011) 793-7900, Email: info@za.becker-mining.com, www.za.becker-mining.com

Consulting Engineering Sector.

“The World Cup 2010 euphoria is now over and all the exciting projects in which our members participated are past, if not glorious, memories that made us proud! Today the outlook is uncertain with turbulent economic times in both Europe, and in the US. Global economic uncertainty affects African and South Africa’s economies, and our member firms are not immune to this.

“We are encouraged by moves by the South African Government, together with civil society and business, in signing an accord to promote local procurement and job creation for our people. We are also anxious about just how the new Preferential Procurement Policy Framework Act and Regulations, which came into effect on 7 December 2011, will be embraced by our various client bodies.

“My focus therefore, in the next two years as President of CESA will therefore

be procurement and business integrity.

If we get these two elements right in our industry then various things, including service delivery, job creation, poverty alleviation, economic growth, sustainability and capacity building will all fall into place.”

Naren Bhojaram is a Professional Civil Engineer, having obtained a BSc Engineering degree at the University Of KwaZulu Natal South Africa in 1984. His speciality is water supply, sanitation and municipal service delivery optimisation.

Having spent a few years at a local authority, he moved on to SSI Engineers and Environmental Consultants where he rose to the position of CEO from 2006 to 2011.

Abe Théla from Nyeleti Consulting has been appointed as Deputy President of CESA.

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

Graham Pirie, Consulting Engineers South Africa (CESA), Tel: 011 463 2022 Email: gspirie@cesa.co.za

MARKET FORUM

PLC application

helps in hazma When Fire Raiders decided to refine the design and manufacture of a unique solution for hazmat, EMS (Emergency Management Services), fire fighting, rescue, incident command and disaster management monitoring, the company turned to Elquip Solutions for the answers.

“Fire Raiders has developed the Eagle II incident command vehicle (ICV) that allows emergency personnel to safely acquire important visual feedback at the site of fires and disasters, without the risks normally associated with such scenes,” says Fire Raiders’ Training and Marketing Manager, Jubilee Jones.

Fire Raiders uses a Mercedes Benz, Iveco or Scania chassis as the base for its fire trucks and ICV’s. A body is then added and the components are either manufactured in-house or sourced externally. “In the case of the ICV, we installed a PLC (programmable logic controller) and HMI (human machine interface) solution but the previous poducts were not reliable

so we sourced a Hitachi PLC and HMI from Elquip Solutions to replace these products,” says Jubilee.

The Hitachi PLC performs switching of all the controls within the ICV. “The source code was written by Elquip Solutions and this provided one of the differentiators for us as they did not charge for this service,” says Gustav Verster, Technical Manager at Elquip Solutions, who was closely involved

R5m artisan learnership In a move to help address the dire loss of artisan skills in the petrochemical industry, Engen Refinery (Enref) has extended its learnership programme by three years, earmarking R5 million to take on 63 learners over this period to train them to artisan level in the areas of fitting, instrumentation and electrical.

Rob Gasken, maintenance training specialist, Enref Training & Development, says the rolling learnership programme will gather momentum over time until it functions at full capacity. “In the current year, 2011, we will take on 21 learners – seven each in the aforementioned areas,” he says.

To join the programme, candidate learners must have matric with maths and science.

They will be trained at NQF Level 2 in their chosen field at accredited training providers and do experiential training at the refinery. In year two, learners will

study towards their NQF 3 and be given more training.

As these two groups progress to NQF 3 and 4 in year three, they will be joined by a third group of 21 learners at NQF 2 level. Once qualified at Level 4, learners will leave training and take up employment – with Engen or elsewhere in the industry.

“This project has been very successful,” Gasken says. “Hundreds of previously disadvantaged youngsters were trained up through NQF Levels 2, 3 and 4, in various trades. Under the project, Engen trained 102 matriculants. Of these, 96 completed all three levels. These learners are to be found working in industry throughout South Africa today. The top performers are working here at the refinery in their trade.”

Egen Refinery, Tel: (021) 417-5763, www.engenoil.com

from Elquip’s side in this project. “The ICV also contains a backup generator when power supply is a problem; three laptops which monitor the weather to see what effects it will have on a fire or disaster area, for example high winds; and a satellite dish in the event that there is a total communications failure.”

Mike Cronin, Elquip Solutions, Tel: (011) 8267117, Email: mike@elquip.co.za

IFTA turns down Nigerians artisans Black empowered artisan training company, IFTA, has turned down all offers to train over 4000 Nigerian apprentices because the company rather wishes to focus on training much-needed local skills.

“We have a skills shortage problem of tens of thousands of artisans in this country and we really believe our efforts should be focused here first,” says Sean Jones, a co-director of IFTA.. “Committing to train a few thousand Nigerians at this juncture would be contrary to our mandate to focus on the local requirements first.

“We currently cannot accommodate a few thousand foreigners who still don’t meet basic literacy requirements,” he says. “However, even if they were functionally literate, our decision to forego the opportunity would be the same.”

Bryn Evans, BE Agency, Tel: (012) 346-3005, www.beagency.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

31

MARKET FORUM

LifeCycle Savings

“Increasingly environmental and longterm efficiency issues are paramount in the decision to purchase compressed air equipment and Sullair is one of the leaders in this regard,” says Goscor KLG national sales manager, Kevin Miller.

He adds that Sullair’s philosophy of ‘total compressed air systems’ reduces energy costs and improves productivity by analysing, managing and controlling users’ compressed air systems. Sullair’s compressed air offerings include: plant air audits, energy efficient products, compressed air system controls, air distribution products and more.

“Of course part of this equation is strong technical expertise and after sales and support, which the KLG and Goscor merger provides at the highest levels,” says Kevin.

With respect to costs of compressed air systems, Kevin says that energy costs now represent 82% of the total operating expenses and that savings in this area become critical over the life-cycle of the equipment.

“Energy savings from the Sullair ‘S-energy’ compressors are making a palpable difference as these machines significantly reduce operating and energy costs over the entire compressor life cycle. Each component of the system is carefully matched for capacity and pressure to provide maximum performance and energy efficiency,” says Kevin. “By attaching a monitoring device to each compressor, technicians are able to remotely monitor machine running hours as well as other aspects of operation and the company is alerted to any potential problem before it occurs.”

Kevin Moller, Goscor KLG, Tel: 0861 GOSCOR (467-267), Email: compressedair@goscor.co.za, www.goscor.co.za

More spare parts for Africa

Tony Sinclair, CEO, Capital Equipment Group, Invicta Holdings Ltd

32

“Invicta Holdings acquired 100% of the issued shares of Equipment Spare Parts Africa (ESPA), effective 1 January 2012 and subject to Competition Commission and board approval,” says Tony Sinclair, CEO, Capital Equipment Group (CEG), Invicta Holdings. “This acquisition provides further support to Invicta’s strategic focus on building its existing after-market spare parts base by enhancing CEG’s product offering and expanding its service to a broader customer base.”

The components include ground engaging

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

New Goscor KLG national sales manager, Kevin Miller, in company's Alrode workshop.

tools and undercarriage for earthmoving equipment, parts for Caterpillar, Komatsu and other earthmoving equipment, as well as parts for diesel engines.

ESPA also offers a complete undercarriage reconditioning service from its three central workshops based in Johannesburg, Cape Town and Durban. They also do all reconditioning undercarriages, buckets, booms and blades for earthmoving equipment.

ESPA, with an unchanged management structure, will retain its corporate identity and its operations will remain independent, but fall under Tony Sinclair, CEO of the Capital Equipment Group.

Tony Sinclair, Capital Equipment Group (CEG), Tel:(011) 922-2000 or 082 655 3390, Email: tonys@cse.co.za, www.capitalequipmentgroup.co.za

MARKET FORUM

Valves for tankers The KSB Group will deliver cryogenic butterfly valves for 20 liquefied gas tankers by the end of 2012. Each of the ships will be supplied with about 80 of these expensive special valves that are technically demanding to manufacture.

Norwegian and Russian shipping companies are the contractors of the tankers. A well-known Norwegian shipping company has ordered Danaïs TBT butterfly valves for as many as nine gas tankers and one

Coca-Cola to be green

In collaboration with Coca Cola South Africa, Lapp Group Southern Africa (Lapp) has successfully engineered an innovative solution for the installation of a Photovoltaic (PV) solar energy system for the new state-of-the-art Valpré bottling plant in Heidelberg, southeast of Gauteng.

South African National Bottled Water Association (SANBWA) executive director, Charlotte Metcalf, says both the plant and new ‘green’ bottle significantly advance

floating storage and regasification unit (FSRU), with an order option for the delivery of valves for three additional ships.

The KSB Group was awarded the contracts because they could offer the shipyards all-in packages consisting of valves, actuators and control systems. Another aspect was that more than half of the liquefied gas tankers operating worldwide are equipped with KSB butterfly valves.

Christoph P. Pauly, KSB Group, Tel: +49 6233 86-3702, Fax: +49 6233 86-3456 Email: christoph.pauly@ksb.com

Assembly of Danaïs TBT butterfly valves for LNG tankers at the French production site in La Roche-Chalais (KSB Aktiengesellschaft Frankenthal)

the bottling industry’s ‘green’ strategy.

“With the new Heidelberg plant, Valpré will reduce its carbon footprint, lower its water usage ratio, adopt energy efficiency lighting and production technologies.”

installation of the generators to power the plant in the event of a power interruption.

When the consulting engineers of Coca-Cola approached the Lapp Group to provide a PV Solar energy solution for the new Valpré bottling plant their proposal was a custom fit for Coca-Cola.

The usual PV solution would be used as a feed into the system with a battery backup. Because the client already had a backup system in the form of 2 x 1250kW generators, no battery system was required. Instead Lapp advised the

The 30kW PV plant feeds into CocaCola’s internal grid, supplementing its power requirements with solar energy and significantly reducing its reliance on the national grid. The PV plant design consists of 132 x 230w IBC grid-type solar modules and 2 x SMA 15000 TL tri power inverters with a web box for monitoring the performances of the PV plant. Provisions have been made to increase the capacity to 90kW. Dieter Dilchert. Tel: (011) 201-3200, Email: dieter.dilchert@lappgroup.co.za, www.lappgroup.co.za

The world's first

containerised coal grinding plant A brand new solution to reduce operating costs by substituting coal instead of oil or gas in various thermal applications is now available to the African market.

Loesche presented their latest development based on long-term experience in coal grinding technology and plant engineering.

The first containerized Coal Grinding Plant (CGP) is fully automated, ready for operation. By integration of the Coal Grinding Plant into 100 % ISO sea containers the plant is mobile and enables low transport charges for worldwide operation. They have packed more than 100 years of experience in coal grinding technology and plant engineering into a few seaworthy containers, representing a very compact and efficient Coal Grinding Plant.

The CGP plant is designed for the grinding of all types of coal, from dried, lignite to

anthracite with a grain feed size from 5-30 mm. The fineness size range of coal dust will be from 5%R 90μm to 45%R 90μm with a possible production of 2-4 t/h coal dust.

Advantages of this plant include standardized plant design, simplified approval procedure, delivery period of 6 months, installation and commissioning of 3 weeks, adaptation to the required output at the location, high on-site

mobility and short implementationtime.

It has high economic efficiency due to the substitution of gas or oil with coal, transport costs are low and no foundation is required for installation. The plant has weather protection for components and this investement can can be financed or leased.

Alana Ridley, Loesche South Africa, Tel: (011) 482-2933, Email: aridley@loeschesa.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

33

MARKET FORUM

New range

of seals

for SA

A comprehensive range of hydraulic and pneumatic sealing products are available to the South African industrial sector through Ludowici Meshcape, as part of the newly-established venture’s plans to become a powerhouse within the African processing equipment market.

Ludowici Meshcape seals division manager, Ameen Peters, says the company maintains a large and comprehensive stock holding of fluid sealing products in South Africa. “Our integrated stock control system ensures the efficient delivery of our customer’s orders anywhere in Africa,” he says. “Our dedication to continual improvement of quality, cost and service provides our customers with a competitive edge within a global market place.”

The wide range of sealing products include; o-rings, rod and pin wipers, polyurethane u-seals for piston and

rod applications, buffers, chevrons, rod composites, piston composites, five-piece double acting seals, CAT and Japanese equivalent seals and kits, PTFE and plastic manufactured parts, oil seals, special ,mouldings and extrusions and pneumatic seals.

“The Ludowici Meshcape seals division is backed by an experienced sales team with more than 50 years of experience,” Ameen says. “Effectively stocking local branches also ensures that customers are able to purchase within their own

Access to confined spaces

Ameen Peters, Ludowici Meshcape, Tel: (011) 609-1120, Email: a.peters@ludowicimeshcape.co.za, www.ludowicimeshcape.co.za

The Ridgid SeeSnake range is specificallydesigned for general inspection and for identifying any complications in applications such as ceiling and wall cavities, in addition to ducts and engines, notes Terry. “The SeeSnake range of reels and cameras are the best in the industry, due to the fact that they are robustly-built for unrivalled performance and longevity.”

South African contractors and engineers can benefit from a state-of-the-art range of Ridgid SeeSnake drain and sewer inspection equipment, supplied and distributed to the local market by Dowson and Dobson Industrial.

34

“A number of operations find themselves drawn in to the initially lower cost of lesser-quality products, but these always prove to be more costly in the long-term due to problems relating to unforeseen failures and unscheduled downtime,” he concludes.

innovative camera and transmitter system that enables the user to obtain an exact diagnosis of line problems in all types of industries.”

Director Terry O’Kelly

RIDGID SeeSnake

region, ultimately resulting in quicker turnaround times and substantial cost savings.”

Dowson and Dobson director Terry O’ Kelly says. “Our range of SeeSnake inspection equipment consists of an

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

“The small camera diameter size of between 22 mm and 35 mm creates a wide-angle pipe view, which enables the user to clearly see the entire pipe wall,” Terry says. “All SeeSnake monitors and recorders are portable and durable, and are able to withstand the harshest operating environments. The recording accessory line allows the user to purchase a personalised configuration, while maintaining the option to easily upgrade recording capabilities in the future.”

Terry O’Kelly, Dowson and Dobson Industrial, Tel: (011) 392-2367, Fax: (011) 392-3573, Email: terry.okelly@dowson.co.za www.dowson.co.za

MARKET FORUM

Rentals growing in Africa Any South African company wishing to successfully conduct business in pan-African countries needs to be cognisant of and work with the cultural differences which exist there. “After carefully analysing the African market, which is traditionally known for its predisposition towards outright purchase as opposed to the rental of equipment, we have found a business opportunity for our rental operations in cross-border countries,” says Louwrens Erasmus, General Manager of Rand-Air in South Africa.

accounts for surmounting the first big hurdle in African business.We have spent many years cultivating an ethos of becoming intimately involved with the operations and credos of our customers and are able to impart this knowledge in a manner that adds great value to a customer’s way of operating and, ultimately, their bottom line.”

Rand-Air has taken a decision to use only local people in these regions in order to facilitate localised

Louwrens Erasmus of Rand-Air

“Our focus is on the oil, gas and mining sectors which are all very active in Africa, so this is a very synergistic move for Rand-Air. In addition, because we will be operating out of existing Atlas Copco facilities in Malawi, the DRC, Zambia (Kitwe, with a branch in Lusaka), Angola (Luanda), Nigeria (Lagos) and Kenya, we will be able to leverage Atlas Copco’s existing network thus effectively containing operating costs, which ultimately influences the cost of rental.

development and skills empowerment. “We will both utilise these local people to do staff training as well as bring staff to South Africa to train them and to show them how Rand-Air operates in South Africa,” says Louwrens. “This will include training on the full range of equipment being made available for hire pan-Africa, as well as customer service and business-oriented training.”

“Rand-Air is closer to its African customers in terms of cultural understanding,” Louwrens adds. “This alone

Louwrens Erasmus, Rand-Air, Tel: (011) 345-0700, www.randair.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

35

MARKET FORUM

Market share growth

the resultant technical innovations we’ve been able to introduce,” says Multotec’s Fernando Monteiro.

“For instance, we have occupied a space in the gravity concentrator spirals arena since 1987 and this technology has continued to evolve and develop over the years,” Fernando says. “In the past two to three years we’ve achieved Multotec belt sampler success with certain modifications to the spirals that have given us a real competi“We’re delighted with the increases in tive advantage in terms of the efficiency our market share, which we believe is of this equipment.”

Leading mineral process solutions provider Multotec’s market share is at an all-time high, which is attributed to growth achieved during the healthy pre-recession minerals boom which was carefully conserved during the global economic crisis and has since provided a sound platform for continued advancement.

Magnetic Drum Separator

a direct result of our ongoing R&D and

“On the sampling side, we’ve done

Pump liners

ideal for mill discharge applications, particularly in gold mining where there is a high content of silica sand which is too abrasive for metal liners.”

After more than three years in the field handling highly abrasive materials, Weir Minerals Africa’s R55 premium grade elastomer pump liner is receiving excellent feedback from customers.

R55 is a proprietary high-tech rubber developed to operate in severe wear applications. This high grade premium black natural rubber has a low hardness suitable for pump liners, impellers and cyclone parts, and its superior physical properties deliver improved cut resistance in hard, sharp particle slurries.

Rui Gomes, product manager, slurry pumps at Weir Minerals, says: “This higher resistance to tearing makes R55

“Initially the idea of rubber pump liners in this application was initially greeted with a great deal of skepticism,” Rui says. “The mine’s metal liners were lasting a maximum of one-and-a-half months before needing replacement but when we installed these liners they lasted eight months.

“A similar case occurred at another gold operation in Westonaria, where a standard rubber compound was being used and was achieving a life of between four to five months. After introducing the R55 liners, this life was extended to nine months.”

Warman 10/8 AH with R55 throatbush liner combination

36

extremely good work on the Tru-Belt sampler, a dry belt sampler used in minerals processing,” says Fernando.

“This innovative piece of equipment assures sampling theory compliance and delivers a truly representative sample.”

Fernando comments that in the years following Multotec’s purchase of Magnapower in October 2007, the company has put a great deal of energy into mechanical development work to advance this magnetic separation equipment. As a result, certain products in this range have now achieved a dominant role in the marketplace as a result of their excellent performance. “We’ve also done excellent work on drums for the Brazilian market harnessing our medium intensity magnetic separators,” he says.

Bernadette Wilson, Multotec Group, Tel: (011) 923-6193, www.multotec.com

The company is making progress with introducing the Warman WBH range of heavy duty slurry pumps and Warman SLR medium duty slurry pumps also fitted with R55 liners.

“These pumps have been designed with improved wear characteristics in mind, as well as making the changing of liners and efficiency adjustment on the pump easier than ever before for the pump user, “ Rui says. “We’ve recently managed highly successful trials of these pumps at mines in South Africa and Botswana, as well as in West Africa.

All trials were successful and have been converted into orders.”

Rene Calitz, Weir Minerals Africa, Tel: (011) 929 2622, www.weirminerals.com

The new R55 elastomer material pump liner and throatbush combination

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

MARKET FORUM

PneuDrive Challenge for students Festo South Africa, in partnership with SEW Eurodrive, annually offers The PneuDrive Challenge, a mechatronic innovation competition, which is open to all third and fourth year mechanical, electronic, and mechatronic engineering students at universities in South Africa.

Participants stand a chance to win R100 000 worth of equipment for their institution and a trip to Germany for the four-person team.

“We aim to help prepare younger generations as best we can so that, when

New SKF factory in China

SKF officially opened its second bearing factory in Dalian, northeast China. The factory produces medium size bearings, which complement the range of large bearings produced in the existing factory, which opened in 2006. The industrial bearings from the factories will mainly

they enter the job market, they already have a degree of experience working with other individuals, developing new ideas, and practically applying theories they have learnt,” says Brian Abbott, Product Manager, Festo South Africa.

“Besides sticking to the rules of the competition, the judges will also focus on elements such as creativity, business acumen and technical accuracy within the parameters of these components,” says René Rose, General Manager: Communications, SEW Eurodrive.

“As sponsors of the competition, SEW Eurodrive and Festo recognise the importance in partnering with higher education institutions to help address the enormous pressures they are under to prepare engineering students for the labour market. We hope that projects

serve customers within the electric motor, industrial electrical, industrial transmissions, metalworking, mining, mineral processing and cement, offhighway, pulp and paper and renewable energy industries.

"China is a very important market for the SKF Group and the opening of this new factory reinforces our commitment to our customers and distributors here and in the Asian region," says Tom Johnstone, President and CEO of SKF. "Our total investment for the two factories in Dalian

like these contribute to developing highly-skilled and creative engineers for future achievements in technology,” concludes Abbott Tracey Swart, Festo, Tel: (011) 971-5560, Email: marketing.za@festo.com, www.pneudrive.co.za

will be around billion 1.5 SEK and fully supports our very positive development in the industrial market. We are bringing the latest technology to this facility and this combined with our new Global Technical Centre in China will enable us to more quickly develop new products and support the long-term technological development in the Chinese industry."

Samantha Joubert, SKF SA, Tel: (011) 8213500, Fax: (011) 821-3501, Email: samantha. joubert@skf.com, www.skf.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

37

MARKET FORUM

Subscription Please fax us if you wish to subscribe to “SA Mechanical Engineer” at R400,00 (incl postage and VAT) per year; R945,00 per year for Africa/Overseas. We will post you an invoice on receipt of your fax.

Ross Collard

Glenn Robertson

Jaco Bester

PROMECH PUBLISHING

Fax No: (011) 781-1403

From:...................................................................................... (insert your name) Title: ......................................................................................

Company: ..............................................................................

Jenny Heyes

Willem Sullivan

Clive Dicks

Tinus Meyer

Ludwig Maier

On the Move

High Power Equipment (HPE) Africa has appointed Ross Collard as manager of the company’s Durban branch, Glenn Robertson as the latest addition to the company’s ever-expanding sales team and Dave Allen as the company’s new national parts manager.

The OMSA Group has appointed Jaco Bester as their Technical Sales Representative covering the entire Vaal Triangle region.

Hansen Transmissions South Africa (Pty) Ltd has appointed Jenny Heyes, Sales & Marketing Manager, Clive Dicks, Key Accounts Manager, Ludwig Maier, Operations Manager, Willem Sullivan, Engineering Manager, and Tinus Meyer, Project Manager.

Address: ............................................................................... ............................................................................................... ...................................................................Code: ..................

Telephone: ( Fax: (

) ....................................................................

) ................................................................................

Email:.....................................................................................

Index to Advertisers Association of Arbitrators Axiom Hydraulics

22 Inside Back Cover

CDC 16 Clyde Bergemann Africa

Outside Back Cover

Donaldson 20 Engineer Placements Esteq Hewlett Packard

35 Outside Front Cover 8

Horne 32 ILS 14 Martin Engineering Power Africa

Promech Publishing has a BEE rating of 168.75%

Inside Front Cover 4

PPS 9 SAISC 26 WCNDT 24

38

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012

39

40

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

January 2012