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S MECHANICAL A ENGINEER May 2017

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

ENERGY-EFFICIENCY ON THE SHOPFLOOR HIGHLY PROFITABLE VARIABLE SPEED DRIVES


Chris Reay

THE SOUTH AFRICAN MECHANICAL ENGINEER

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havas 15030/E

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1. The formula p=m•v is used to calculate. 2. The SI Unit for Pascals (the derived unit to quantify internal pressure).

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3. The letter S in S=d/t is used to notate which scalar quantity?

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4. Formula for the volume of a cube.

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ACROSS 5. The equation stated by Émile Clapeyron in 1834 as a combination of the empirical Boyle’s law, Charles’ law and Avogadro’s Law commonly known as the ideal gas law.

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S MECHANICAL A ENGINEER

Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, Official Publication of THE SA INSTITUTION OF MECHANICAL ENGINEERING 2123, Republic of South Africa and endorsed by: Tel: (011) 781-1401, Fax: (011) 781-1403 Email: samecheng@promech.co.za, www.promech.co.za Managing Editor Susan Custers Editorial Contributors Liesl Venter/Patricia Holburn Advertising Sales: Louise Cresswell Cell: 071 886 1263 DTP Lindy Fobian/Anne Rotteglia Circulation Belinda Siegruhn

Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R550,00 (excl postage and VAT) per year; R1 380,00 per year for Africa/Overseas. Disclaimer

PROMECH Publishing and The South African Institution of Mechanical Engineering as well as any other body do not take responsibility for the opinions expressed by individuals.

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

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CONSULTING ENGINEERS OF SA CORROSION INSTITUTE OF SA INSTITUTE FOR CERTIFICATED MECHANICAL AND ELECTRICAL ENGINEERS NATIONAL SOCIETY OF BLACK ENGINEERS NUCLEAR INSTITUTE SA ASSOCIATION FOR ENERGY EFFICIENCY SA CAPITAL EQUIPMENT EXPORT COUNCIL SA INSTITUTE FOR NON-DESTRUCTIVE TESTING SA INSTITUTE OF TRIBOLOGY SA PLASTIC PIPE MANUFACTURERS ASSOCIATION SA PUMP MANUFACTURERS ASSOCIATION SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION VALVE & ACTUATOR MANUFACTURERS CLUSTER OF SA

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Council 2016 - 2018 Office Bearers President............................................ Prof JL van Niekerk (Wikus) Vice President........................................................ A Roos (Andre) National Treasurer...................................................G van den Berg

Branch Chairpersons Central ................................................................. C Kruger (Carel) Eastern Cape........................................... G van den Berg (Gideon) KwaZulu Natal .. Dr J Padayachee (Jared)Mpumalanga Highveld . N Lecordier (Noel) Vaal......................................................... Prof LM Masu (Leonard) Western Cape ..................................................S Pietrangeli (Sven)

Portfolios: Communications/ Strategic Planning/ Specialist Groups................................................. To be announced Education (Universities of Technology).............E Zawilska (Ewa) To be confirmed...........................................G Bartholomew (Bart) Technology Programme..................................... SZ Hrabar (Steve)

Chief Executive Officer: Vaughan Rimbault National Offic e Manager: Anisa Nanabhay PO Box 511, Bruma, 2026 Tel: (011) 615-5660 Email: info@saimeche.org.za Website: www.saimeche.org.za Membership Email: membership@saimeche.org.za

Company Affiliates Autodesk as represented by Worldsview Technologies

Osborn Engineered Products SA (Pty) Ltd

Ainsworth Engineering (Pty) Ltd

PaCMan Projects & Maintenance

Alstom Power Service SA (Pty) Ltd

Plant Design & Project Services (Pty) Limited (PDPS)

Babcock Ntuthuko Engineering (Pty) Ltd Bosch Projects (Pty) Ltd

Rotek Engineering

DCD Group (Pty) Ltd

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

Festo (Pty) Ltd

SA Power Services (Pty) Ltd

Fluor SA (Pty) Ltd

Sasol Technology (Pty) Ltd

Green Plan Consultants (Pty) Ltd

SEW Eurodrive

Hatch Africa (Pty) Ltd Howden Power (a div of Howden Africa) Howden Projects (a div of James Howden) Kelvion Thermal Solutions (Pty) Ltd MBE Minerals (SA) (Pty) Ltd Megchem Mod-U-Flow CC

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PPS Insurance Co Limited

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

THE SOUTH AFRICAN MECHANICAL ENGINEER

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LEGAL CONSULTING FOR YOU AND YOUR BUSINESS

^ B3E2 Consulting & Analysis ^ B3E2 Seminars & Workshops ^ Skills Development Facilitation ^ Employment Equity Compliance ^ Employment Policies & Procedures ^ Commercial Contracts ^ Commercial Agreements Tel: +27 (11) 346 2422 E-mail: admin@oriole.co.za / reception@oriole.co.za Twitter: @orioleconsult www.oriole.co.za THE SOUTH AFRICAN MECHANICAL ENGINEER

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Lewis Hiepner, Product Manager

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THE SOUTH AFRICAN MECHANICAL ENGINEER

Burtie Roberts, CEO

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Need a tough clean up pump? Try the high performance LCV. The rugged LCV - heavy duty vertical pumps combine long wear life with high sustainable hydraulic efficiency for the lowest total cost of ownership. Wear components are available in a wide range of proprietary hard iron alloys. The V-Belt drive system accepts high horsepower motors and the structural parts in corrosion resistant alloys. KSB Aktiengesellschaft · Johann-Klein-Straße 9 · 67227 Frankenthal · www.ksb.com

GIW LCV Pump


havas 14530/E

Chris Reay

RARE IS REWARDING The Narina Trogon - One of Africa’s most elusive birds. A rare breed indeed. Rather like graduate professionals. Contact your PPS-accredited financial adviser or visit pps.co.za to see if you qualify.

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POWER GENERATION

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POWER GENERATION

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POWER GENERATION

The ETA factory possesses an authentic production line for pump components

Prof. Dr.-Ing. Eberhard Abele

PTW senior engineer, Stefan Seifermann

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POWER GENERATION

EMO Hannover 2017

From 18 to 23 September 2017, international manufacturers of production technology will be spotlighting “Connecting systems for intelligent production” at the EMO Hannover 2017. The world’s premier trade fair for the metalworking industry will be showcasing the entire bandwidth of today’s most sophisticated metalworking technology, which is the heart of every industrial production process. The fair will be presenting the latest machines, plus efficient technical solutions, product-supportive services, sustainability in the production process, and much, much more. EMO Hannover, www.emo-hannover.de

www.promech.co.za * Easy navigation through the site * Comprehensive archive * Free to users ECHANICAL * No registration ENGINEERING BUYERS GUIDE * Searchability

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S MECHANICAL A ENGINEER April 2017

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

2017

TACKLING ACID MINE DRAINAGE AT THE COAL FACE HUGE REDUCTION IN DOWNTIME WITH NEW PUMP

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STEAM TURBINES & BOILERS

We constructed the first and still the only operational dry flue gas desulphurisation plant in South Africa

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STEAM TURBINES & BOILERS

A move towards smaller power generation projects especially in rural Africa where there is no grid and little chance of being connected to a grid

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What could’ve made this timeless beauty, just a little more beautiful? In 1889, the Eiffel Tower cost $1 495 137.43 to build. Since then, this iconic landmark has been painted every 7 years, (a total of 18 times), using 60 tonnes of paint, every time, taking 25 painters up to 18 months to complete the job. What is clear is that if the Eiffel Tower had been made from stainless steel, the maintenance of this global symbol of engineering ingenuity would’ve been easier, more cost effective and even more staggeringly beautiful. Of course, in stainless steel, it would never have to be painted, but considering that stainless steel wasn’t even invented in 1889, we can forgive Gustave Eiffel this little oversight.

Enter to win a trip to Paris, all expenses paid, worth R125 000! To enter the competition, you have to make use of the Life Cycle Costing App, or use the Life Cycle Costing software on the Sassda website. You will have to decide whether to use more expensive lean duplex stainless which has the advantage of retaining the original stainless steel look and finish over 100 years. Or you can select a utility ferritic stainless steel, which will weather over time to form a brown patina. Both stainless steels are equally suitable for building the Eiffel tower and both answers are equally eligible for winning the competition. Then using the information provided calculate the answers to the following questions. 1.

Calculate and compare, in US Dollars, what the initial costs would be to build the Eiffel Tower in 2017 out of mild steel and utility ferritic stainless steel or lean duplex stainless steel.

2.

Calculate and compare, in US Dollars, what the operating costs would be for the Eiffel Tower over the next 100 years if it were built out of mild steel and utility ferritic stainless steel or lean duplex stainless steel.

3.

Calculate the total life cycle costs (Total LCC) of the Eiffel Tower in mild steel, and lean duplex or utility ferritic stainless steel.

What you have to do: •

Download the Sassda Life Cycle Costing Application available from the Google Playstore, or Apple App Store. You can scan the QR code to download the app.

Alternatively, you can use the LCC application on the Sassda website.

Download The Android App

Download The Apple IOS App

Eiffel Tower Competition Information

Stainless Steel. It’s Simply Brilliant. Call 011 883 0119 or see sassda.co.za. Your complete stainless information source.


STEAM TURBINES & BOILERS

A schematic drawing of an industrial watertube boiler

Another new development is the helical coil boiler for base load power generation and small packaged wood chip-fired boilers for saturated process steam

Etienne de Villiers, John Thompson divisional technical manager, general manager Martin Reck and John-Paul AndrĂŠ, divisional finance executive

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STEAM TURBINES & BOILERS

A Europac coal- or biomass-fired boiler

Tough demands have met their match.

With a Hägglunds hydraulic drive system you get compact, durable power - without foundations or gearbox. A full range of rugged motors and complete solutions for monitoring and control give you total assurance, even in the most demanding applications. Let us know your demands.

Hägglunds Drives South Africa (Pty) Ltd, Johannesburg, Tel. + 27 (0)11 454 4933 E-mail: info@za.hagglunds.com www.hagglunds.com

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The Boiler and Steam Specialist for 80 years in South Africa

Watertube boilers: fossil fuel- and biomass-fired up to 200 t/h and 350 t/h respectively and 110 bar, 540°C Utility boilers: installation, maintenance and upgrades for boiler and gas clean-up plant for coal-fired power stations Firetube boilers: coal-, biomass-, oil-, gas- and wood-fired up to 40 t/h and 32 bar, and bespoke waste-heat boilers

At John Thompson we design, manufacture, install and maintain watertube & firetube boilers and associated plant for process steam and power generation applications.

Email: sales@johnthompson.co.za Tel: +27 (0)21 959 8400 | www.johnthompson.co.za John Thompson a division of ACTOM (Pty) Ltd

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Figure 1: Johannesburg - From the graph above it can clearly be seen that significant savings on power is available from March through to November.

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Figure 2: Durban - From the graph above it can clearly be seen that significant savings on power is available from April through to November.

RELIABLE ENERGY SOLUTION for the entire mining sector.

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Power Tranformers Tiger RMU Overhead Lines MV Switchgear Mini Substations Mobile/Containerised Substations MV Motors E-Houses Distribution Transformers Motor Control Centres MV Slipring Motor MV Drive Automation Control Room Invicta Vibrator Motors Diesel Generator Electrical Construction LV Motors & Drives

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The Zest WEG Group, a subsidiary of leading Brazilian motor and controls manufacturer WEG, started out as a South African company and maintains its strong commitment to contributing to the development of the African region.

An in-depth understanding of the harsh conditions found within the mining sector and years of experience on the African continent, have ensured that the Zest WEG Group service offering is fit-forpurpose.

The Zest WEG Group has been servicing the mining sector for more than 35 years and by leveraging best practice engineering and manufacturing capabilities, the group is able to offer a range of standard off-the-shelf products as well as endto-end energy solutions.

From single product installations to individually customised solutions, which are application specific, the latest technology is used to ensure optimum performance and reliability without compromising on energy efficiency.

Supporting customers is key and the Zest WEG Group operates a strategically situated network of branches and distributors across the continent. This ensures the highest levels of technical support as well as easy access to product and parts.

THE SOUTH AFRICAN MECHANICAL ENGINEER

ZestWeg_771_mining_adv_SAMechEng_176x130.indd 1

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WEG products are engineered to facilitate a safe and reliable mine and plant with operational stability and the highest possible production levels as an objective. Reduced maintenance and ease of serviceability assist in lowering the total cost of ownership for the mine.

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SCAN HERE for more about our offerings in the mining sector

Tel: +27 11 723 6000

www.zestweg.com

May 2017 2016/11/30 10:39 AM


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For the user, he wants a buyer with extreme technical skills right at the location where things happen, so he has control regarding the stuff ordered (as close as possible to the “coal face�)

Martin Bailey

Quickly the legalese and contractual paperwork overtakes the core functions of buying the right stuff at the right time and the right quality and at the right cost

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Typical purchasing department – What you want versus the process

If the purchasing guy is part of the team that is responsible when the final product is switched on and commissioned, he is much more likely to focus on buying stuff or services that will work properly

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MARKET FORUM

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FCB CAPE TOWN 10013882CT/E

MARKET FORUM

Keeping Africa running smoothly. Engen is committed to an African success story. In Africa, industries operate under extreme conditions different from any other place in the world. That’s why we do more to develop our tailor-made range of lubricants. We use top-of-the-line technology and only the best ingredients. The result is an advanced technology product that meets industry requirements and reliability expectations. And our dedicated team on the ground ensures that you have access to what you need when you need it. Contact the Engen Customer Service Centre (CSC): +27 21 403 5090 or visit www.engenoil.com.

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MARKET FORUM

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MARKET FORUM

INFO: VDW – Generalkommissariat EMO Hannover 2017 Verein Deutscher Werkzeugmaschinenfabriken e.V. Corneliusstraße 4 · 60325 Frankfurt am Main · GERMANY Tel.: +49 69 756081- 0 · Fax: +49 69 756081-74 emo@vdw.de · www.emo-hannover.de 17164_SAME_SA_180x130_za.indd 1

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MARKET FORUM

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MARKET FORUM

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MARKET FORUM

On the Move Tectra Automation has appointed Jason Saunders to the position of Branch Manager for its Port Elizabeth branch

Advisian, the independent advisory business line of WorleyParsons, has appointed Dr Gary Mocke as its Managing principal of Ports and Marine Terminals, with responsibility for managing the Ports and Marine Terminal Advisory sub sector in Sub-Saharan African region and supporting the Middle East & North Africa Region

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The JSE-listed Dawn Group has appointed Edwin Hewitt to the Board of Directors. He assumed the role of the new Chief Executive Officer on 1 April 2017

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Johan Goosen has been appointed managing director of Osborn Engineered Products SA


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


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