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S MECHANICAL A ENGINEER Jan 2014

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

l GREAT NEW COURSES BEING OFFERED BY SAIMECHE l

l WIND TURBINE TOWERS: MANUFACTURED THE SOUTH100% AFRICANLOCALLY MECHANICAL ENGINEER VOL 64 January l 2014

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BENDING AND FABRICATION S ! LIMITATIONS LIFTED H NEW S A FL COUNTRY WIDE!

REDUCE FABRICATION COSTS AND IMPROVE ENGINEERING DESIGN BY UTILISING OUR NEW 12 METRE X 2 000 TON PRESS BRAKE We bend mild steels up to 25mm over 12 000mm We bend Q & T steels up to 22mm over 12 000mm We bend stainless steels up to 20mm over 12 000mm

WE CAN BEND MUCH THICKER OVER SHORTER LENGTHS. Please call to enquire.

• We also cut (Laser, Plasma, Flame) up to13 000mm long & 3 000mm wide • We now roll up to 50mm over 3 000mm (much thicker over shorter lengths) • We carry a comprehensive range of stock in ferrous and non-ferrous metals • Contact our sales team to discuss your individual requirements • Please visit our website for full details • Trade buyers are welcome

PEOPLE WORTH KNOWING

• We deliver

CONTACT US +27 11 062 3200 • www.generalprofiling.co.za • sales@generalprofiling.co.za 2

THE SOUTH AFRICAN MECHANICAL ENGINEER

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January 2014


Chris Reay

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

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LEADERS IN CLOSING THE SKILLS GAP Scarce skills in the engineering and manufacturing sectors in South Africa The merSETA’s major focus in respect of new skills development and the alleviation of skills shortages is the development of artisan skills. To this end, the merSETA has a wide spectrum of registered learnerships and apprenticeships in place. In the 2012 financial year, the merSETA registered 5 168 apprenticeship contracts, 6 051 learnership agreements and 5 808 skills programme learners. In the same period, 4 194 learners obtained full qualifications and 2 559 skills programme learners obtained statements of results towards various levels on the National Qualifications Framework (NQF). Challenges within the public basic education and FET systems have impacted the availability of engineering skills, directly through their impact on the generic skills levels within the workforce and through the generation of quality artisans, as well as indirectly through the negative effect on the quality of higher education qualifications. Low levels of labour productivity not only drive capital-intensive growth within the sector, but are also considered one of the major factors undermining South Africa’s ability to embrace new technology and innovation and thus compete internationally. The perceived economic growth, massive infrastructural development, government policies and global advances in manufacturing technology have also increased skills demand. Engineering qualifications now generally equip graduates with skills in new technology. However, for the existing workforce, skills gaps in these areas must be filled with additional training. For more information visit: www.merseta.org.za

HEAD OFFICE merSETA House, 95 7th Avenue, Cnr Rustenburg Road Melville Johannesburg Tel: 010 219 3000 Fax: 086 673 0017 Call Center: 086 163 7738

LIMPOPO & MPUMALANGA

EASTERN CAPE Pickering Park Office Suites, 14-20 Pickering Street Newton Park, Port Elizabeth, 6045 Tel: 0861 637 734 Fax: 041 363 0144

merSETA House, 95 7th Avenue, Cnr Rustenburg Road Melville Johannesburg Tel: 010 219 3000 Fax: 086 673 0017

FREE STATE & NORTHERN CAPE

WESTERN CAPE

46 Second Avenue Westdene Bloemfontein, 9300

3rd Floor, Fassifern Old Mutual Building, 35 Ridge Road, Berea

Tel: 0861 637 733 Fax: 051 447 8873

Tel: 0861 637 736 Fax: 031 201 8732

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GAUTENG SOUTH

THE SOUTH AFRICAN MECHANICAL ENGINEER

GAUTENG NORTH & NORTH WEST Automotive Supplier Park 30 Helium Road Rosslyn Ext. 2 Tel: 0861 637 731 Fax: 0866 700299

KWAZULU-NATAL

Section 1 No.8 Corridor Crescent Route N4 Business Park Ben Fleur Ext 11, Witbank

5th floor, Catnia Building Bella Rosa Office Development Bella Rosa Road, Tygervalley

Tel: 0861 637 735 Fax: 013 656 4629

Tel: 0861 637 732 Fax: 021 914 8131

VOL 64

January 2014


S MECHANICAL A ENGINEER Jan 2014

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

The monthly circulation is 3 947

l GREAT NEW COURSES BEING OFFERED BY SAIMECHE l

l WIND TURBINE TOWERS: 100% LOCALLY MANUFACTURED l

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Council 2012 - 2014 Office Bearers

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

Branch Chairpersons

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

Portfolios:

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

Chief Executive Officer: Vaughan Rimbault National Office Manager: Anisa Nanabhay PO Box 511, Bruma, 2026 Tel: (011) 615-5660, Fax: (011) 388-5356 Email: info@saimeche.org.za Website: www.saimeche.org.za Membership: Central, Eastern Cape, Mpumalanga, Highveld & KZN: membership@saimeche.org.za Membership: Western Cape: saimeche.wc@vodamail.co.za

Company Affiliates Ainsworth Engineering (Pty) Ltd Alstom Power Service SA Babcock Africa Limited Bosch Projects DCD Rolling Stock A division of DCD Festo (Pty) Ltd Group (Pty) Ltd Fluor SA (Pty) Ltd GEA Air-cooled Systems Hansen Transmissions SA Hatch Goba (Pty) Ltd Howden Power Howden Projects Industrial Water Cooling Inenzo Water (Pty) Ltd MBE Minerals (SA) (Pty) Ltd

Rotek Engineering S.A.M.E Water Sasol Technologies SEW Eurodrive Siemens Ltd SNC-Lavalin SA Spicer Axle SA Spirax Sarco SA Tenova Mining and Minerals SA (Pty) Ltd Tenova Takraf Africa Thyssenkrupp Engineering Transvaal Pressed Nuts & Bolts

Ultra-Flow Engineering Services (previously KHD Humboldt Wedag SA) Vital Engineering Megchem Eng & Drafting Services Wedag SA (Pty) Mod-U-Flow

Osborn Engineered PPS Insurance Co Limited

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Weir Minerals Africa Winder Controls

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Guests from Fluor (and their partners)

Guests from Howden (and their partners)

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BMG has extended its range of heavy industrial couplings to now include Rexnord Falk Steelflex

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Academic

Career Path

Projects

Commentary

Achievements

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

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Andreas Stubel of Airgas Compressors

Using bronze and stainless steel, the new single stage design uses water instead of oil, guaranteeing absolute oil-free air

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The conveying and oil chambers in the new design are completely separated by means of a shaft seal arrangement, guaranteeing both uncontaminated water and air

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Technicians are trained in all air-related installations including piping, inline coalescing filter systems, air refrigerant systems, electronic timed auto drains and turbo drains

In terms of new compressors, the company can supply all makes of rotary screw compressors including their own imported range of Bouwa air compressors, from 2.2kW up to 350kW

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Fitting of top hats to air-end housings on both the suction and the delivery side

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The training material is visual and animated

Courses also cover electric motor diagnostics, alignment, balancing

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►► EIA Process ►► Geographical Information Systems ►► Project Managment ►► Natural Resource Services ►► Ecological/Biodiversity Services ►► Application Assistance ►► Developement Research, Monitoring and Evaluation ►► Environmental Risk Assessments ►► Agricultural Assessment and Advise ►► Wetland and Riparian Services ►► Visual Impact Assessments ►► Public Participation Process ►► Game Ranch Management

l Tel: (031) 303-2835 l l Fax: 086 692 2547 l l Email: info@afzelia.co.za l l www.afzelia.co.za l THE SOUTH AFRICAN MECHANICAL ENGINEER

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Cobus Kruger of BTO Bearing Transmission

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POWER

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

Zinobia Docrat/ Jacquelene Nene

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.

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T O D A Y


TICKER TAPE

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Venturing into the wind tower manufacturing business came about after DCD designed and manufactured a complete wind tower on a trial basis last year

The plate for the bottom can is made of several thick steel plates between 35 to 60 mm

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Kabompo Gorge

Siva Chetty

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3-6 FEBRUARY, 2014

Cape Town, South Africa

Cape Town South Africa

Where the World Connects with African Mining. Mention offer code M14SAME and save US$100 through 24 January 2014

twitter.com/miningindaba Presented By:

miningindaba.com/linkedin facebook.com/africanminingindaba youtube.com/miningindaba

MINING INDABA, LLC

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THE SOUTH AFRICAN MECHANICAL ENGINEER

www.m in in gin daba.co m January 2014

VOL 64


Certified Energy Managers (CEMs) for 2013

Energy Managers in Training for 2013

Certified Measurement and Verification Professionals (CMVPs) for 2013

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

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Speeding up to 160 kilometres per hour, just four millimetres off the tarmac

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Disc brake on the front wheel for fast karts

The large air cleaner

Weights fitted to the driver’s seat to equal the weight of all the racers

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The total life cycle cost over a given period would work out to approximately 47 percent that of HDPE

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Figure1: Abrasive wear resistance as a function of hardness for annealed un-alloyed metals and steel

Figure 2: Wear resistance as a function of hardness for several classes of material

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our company wants

to be part of Demand Response Rewards Programme because…

MOHLALENG_ESKD_562 / E25 / Demand Response

Yes,

We don’t use all our electricity all the time We want to increase our bottom line We want to help conserve the environment

If you’ve ticked most of the boxes then join the Demand Response Rewards Programme today. The programme offers a financial incentive to businesses that minimise their electricity consumption at critical times or generate their own power. This will help relieve the pressure on the national grid. To join the programme simply cut out this page, scan and e-mail to drrewards@eskom.co.za or contact your nearest Eskom Energy Advisor by calling 08600 37566. You can also scan the QR code below or visit ww.eskom.co.za/idm for more information.

Company name: Contact name: Tel:

e-mail:

Powering your world Eskom Holdings SOC Limited Reg No 2002/015527/06

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Strong material

Weak material Approach

Adhesion

Transfer

Figure 3: Schematic illustration of adhesive wear

Figure 4: Schematic illustration of 2-body (top) and 3-body (bottom) abrasive wear

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Figure 6: Effect of impact angle on the wear resistance and erosive wear of different types of materials

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MARKET FORUM

KSB includes a mag-drive pump type series in its API range.

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MARKET FORUM

L – R: Rob Deane, GM EBH SA; Rob King, MD DCD Group; Graham Parnell, financial director, EBH SA; Ruusa Shipiki-Kapolo, director EBH Namibia; Minister of Works and Transport Erkki Nghimtina; Mayor of Walvis Bay Uilika Nambahu; Bisey Uirab, CEO Namport; Hannes Uys, CEO EBH Namibia

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MARKET FORUM

The Multotec bonded warehouse will concentrate on supplying consumable equipment

Rexroth’s VarioFlow S chain conveyor system

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MARKET FORUM

Part of the pumping station at Chileka

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MARKET FORUM

Clean Air Award

AfriSam’s Ulco Cement operation in the Northern Cape Province

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MARKET FORUM

From Left_Louw Kriel,Willem Mare and Rob King

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MARKET FORUM

Suzette Botha of Tega Industries South Africa

Abe Thela

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

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SAMHYDRAULIK, which is one of the leaders in the field of hydraulic transmission, has been operating for over 25 years in the international market, offering a complete range of orbital hydraulic motors and power steering units, axial pumps and motors for medium and high pressure ranges, all characterised by excellent performances. SAMHYDRAULIK employs 120 people who operate inside a very modern and efficient plant that spans over 6 000 square metres to assure a high standard and flexible production capacity. The latest computer technology is used for both design and production, combined with strict quality control procedures during all production phases, which translates into innovative, reliable and functional products that meet the various needs of the market. Its ISO 9001 certification, held since 1994, is the result of a qualityorientated philosophy on which SAMHYDRAULIK has always based its operation.

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AXIOM HYDRAULICS (PTY) LTD Tel: (011) 334-3068 / 334-3086 Fax: (011) 334-4543 E-mail: axiomjhb@mweb.co.za 17 Heidelberg Road, Village Main, Johannesburg, 2000 P O Box 260248, Excom, South Africa, 2023

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Same jan14 final