SA Mechanical Engineer May/June 2020 by Promech Publishing

S MECHANICAL A ENGINEER May/June 2020

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

from

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VOL 70 May/June 2020

AN ENGINEER’S VIEW

Left Behind

ost articles that pop up on my newsfeed recently have been in relation to the 4th industrial revolution (4IR). Each article details innovations and developments taking place around the world, propelling us into an unknown future. Each time I read one of these articles, I cannot help but think that engineers in South Africa are being left behind. South Africa simply lacks the infrastructure and resources to support some of the technologies which form the basis for 4IR. Although engineers can learn through research, seminars, webinars and articles, this does not provide sufficient exposure for SA engineers to fully grasp the extent of 4IR’s capabilities. The result is we are limited when it comes to adopting these technologies locally to address the challenges facing our society. Thus engineers in SA need to become creative in an effort to develop the skills necessary to support the new technologies.

Taking into account the challenges related to the affordability and accessibility of the 4IR technologies, what can local engineers do to ensure that they develop the necessary skills to be able to participate meaningfully in the future? Sewela Portia Moketla I have thought about this in my personal capacity and have come up with a few ideas: • Be proactive, practice skills which will form the backbone of the 4IR technologies, eg, data analysis and big data processing. • Explore new ideas of what society will need in the future. • Build a solid network in order to collaborate with experts in various fields. • Participate in the legislative activities within the discipline. • Participate in talks, seminars and training events. • Should the opportunity present itself, study further.

Mechanical engineers have always been good at adapting to change, 4IR is another opportunity for us to show our versatility and adaptability Hungry to learn

From the various talks, seminars and engagements I have been a part of, it is clear that South African engineers are hungry to mine all the advantages. However, the reality is that most of us will not be able to participate in these opportunities any time soon.

Even given my list above, I realise that what I need most is to be flexible and adaptable. The way we work as mechanical engineers is going to change. Change is simply a requirement for survival. Mechanical engineers have always been good at adapting to change, 4IR is another opportunity for us to show our versatility and adaptability. In all we do, we must stay true to the fundamental laws of science and the need to solve society’s most pressing problems. by Sewela Portia Moketla

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 70 May/June 2020

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 70 May/June 2020

S MECHANICAL A ENGINEER May/June 2020

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

S MECHANICAL A ENGINEER May/June 2020 VOLUME 70

Contents from

Cover Story

Remote Witness Testing

28 A Pioneering Step

Delivering the Goods

Flexible Solution Carl-Hamm PPS Tel: (010) 900-2005 Email: chris@carl-hamm.co.za www.carl-hamm.co.za

11 Robot Loading System

3D Automated Paint Defect Detection System

Condition Monitoring

29 Finer than a Grain of Salt

12 Controlling Maintenance Costs

Tribology

Africa

31 Locked Down but not Locked Up

14 Renewable Energy Projects

Safety

Automation

32 Effective Traffic Management Plans

16 Robots in the time of Covid-19

Hazardous Environments 19 High-risk Koeberg Clean-up

Regulars

Data Centres 22 Accelerating the Online Shift

In-Depth Analysis 25 Third-party Testing Service

An Engineer’s View

Institution News

Food and Beverage

33 Market Forum

26 The New Imperative

38 On the Move

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. Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123, Republic of South Africa 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: Sanette Badenhorst Circulation: Netta Janse van Rensburg 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.

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Official Publication of

THE SA INSTITUTION OF MECHANICAL ENGINEERING and endorsed by:             

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 South Africa

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VOL 70 May/June 2020

INSTITUTION NEWS

Serving with Pride and Integrity In 2018, SAIMechE National Council decided to advertise for a General Manager position at Head Office, with the view to alleviate some of the load on our stalwart CEO, Vaughan Rimbault, who has overseen the smooth running of SAIMechE since 2008.

e were looking for a dynamic young South African, preferably with a mechanical engineering background, to support the Institution in moving forward into a vibrant future. We were fortunate enough to receive an application from Uncel Mhelembe, an inspiring young engineer from humble beginnings in Tzaneen, Limpopo.

Uncel Mhelembe

Uncel was fortunate enough to meet Gerald Nkhwashu in his hometown when he was a boy. Gerald is a civil engineer, who was working in Limpopo in the early days of our democracy. As we are all aware, there were few role models for engineering in this community at this stage.

Luckily for Uncel, Gerald took him under his wing, sharing the world of engineering which sparked a passion for all things technical. Uncel took to the subject with ease but he was frustrated by any real emphasis on his main area of interest in this civil engineering environment - the engine! And so began his journey into mechanical engineering. Uncel graduated with a BTech in Mechanical Engineering from VUT in 2008 and did not stop there. It is clear that he has a passion for learning and engineering: he holds a GCC (Factories), an MBA from NWU, and is currently enrolled for his PhD in Engineering Management at UJ. He is registered as a Pr Tech Eng and Pr Cert Eng with ECSA. Uncel worked at Eskom Rotek Industries and for WĂ¤rtsilĂ¤ as a mechanical engineer, GMR2(1) before starting his own consulting engineering company in 2015, Rhino Consulting Engineers. Through his company, he held GMR2(1) positions for the Greater Tzaneen municipality, and worked on various

much more than just a pump in a

BOX

complete pumping solutions Email. info@pumptechnology.co.za 6

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www.pumptechnology.co.za VOL 70 May/June 2020

municipal and government projects. While working on these projects, he realised that there’s a poor understanding of the role that mechanical engineers play in our society, with many projects that should require mechanical engineering expertise being awarded to civil engineering groups.

Critical in South Africa

It is with this in mind that Uncel sees the role of SAIMechE as critical in South Africa, in order to elevate the understanding and recognition of the important place that Mechanical Engineering holds in building a vibrant, stable economy. He wisely notes that this systemic change can only be realised through education and increased exposure to engineering from a young age in our society. In Uncel’s words, “One of my objectives is to ensure that SAIMechE becomes the leading source for mechanical engineering associations in Africa. As a centenary Institution, SAIMechE should be the voice of Mechanical Engineers in both the private and public sectors.” “I am humbled to serve SAIMEchE and its members and intend to do so with pride and integrity”

Uncel Mhelemba, Debby Blaine and Vaughan Rimbault

And so, fellow members and engineers, you can see how easy it was for SAIMechE to appoint Uncel Mhelembe to the role of General Manager. Uncel, we are proud of you as a South African, as a mechanical engineer, and especially that you have chosen to join SAIMechE Head Office in this next stage of your career. Thank you and Welcome! We look forward to a bright and sustainable future with you.

SA INSTITUTION OF MECHANICAL ENGINEERING Council 2018 - 2020 Office Bearers President........................................................ Prof D Blaine (Debby) Vice President..........................................H Makwarela (Hangwani) National Treasurer............................... Prof JL van Niekerk (Wikus) Branch Chairpersons Central ................................................................. P Motleka (Portia) Eastern Cape.............................................. G van den Berg (Gideon) KwaZulu-Natal ........................................... Dr J Padayachee (Jared) Mpumalanga Highveld .................................... M Mashele (Mishael) Vaal................................................................. N Swanepoel (Niekie) Western Cape ....................................................Dr G Erfort (Gareth) Portfolios: Procedures..............................................................SZ Hrabar (Steve) Communications and Marketing.....................G Bartholomew (Bart) Professional Development Programme (PDP)................................. ......................................................................MAE Black (Malcolm) Projects and Systems Awards........................HG Bosman (Tertius) Membership .................................C Molomo-Mphephu (Cillia) Diversity and Transformation ..................R Tshitahe (Rudzani) Student and Candidate Affairs.......M Jansen van Rensburg (Marietjie) Chief Executive Officer............................... Vaughan Rimbault National Office Co-ordinator………...........… Carey Evans 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 Wordsview Technologies

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

Babcock Nththuko Engineering Pty Ltd

PPS Insurance Co Limited

Eskom Rotek Industries SOC Ltd

Redheads Engineering Services (Pty) Ltd

Exxaro Resources (Pty) Ltd

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

Festo (Pty)

SA Power Services (Pty) Ltd

Fluor SA (Pty) Ltd

Sasol Technology (Pty) Ltd

Kelvion Systemes (Pty)

Siemens (Pty) Ltd

Hatch Africa (Pty) Ltd

Spirax Sarco (Pty) Ltd

Howden Power (a Division of Howden Africa)

Tenova Mining and Minerals SA

Howden Projects (a Division of James Howden)

Proconics

Thyssenkrupp Engineering (Pty) Ltd Vital Engineering (Pty) Ltd

MBE Minerals (SA) (Pty) Ltd

Weir Warman Africa

Megchem

Thysssenkrupp Engineering (Pty) Ltd

Mod-U-Flow cc Osborn Engineered Products SA (Pty) Ltd

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Vital Engineering (Pty) Ltd Weir Warman Africa

VOL 70 May/June 2020

COVER STORY

Delivering the Goods “At first glance, our pump range appears the same as many others on the market, but it can do so much more,” asserts Chris Munnick, CEO of Carl Hamm PPS South Africa.

“

First, we are one of the very few companies able to assist mines in offering solutions many African mining companies are looking for – the technology to pump ‘run of mine’ underground water at high pressures with less downtime and maintenance than normally associated with most multistage pumps. “Secondly, we pride ourselves on going the extra mile to arrive at cost-effective and efficient solutions for the turnkey abstraction of water, whether on a virgin mine, or that of a closed or flooded mine. And it’s all due to the agreement Carl Hamm concluded to distribute Duchting pumps,” says Chris.

The market has asked for this product for a long time. And now we can deliver it Carl Hamm PPS South Africa, is a subsidiary of the privately-owned fourth generation family business in Germany, and thus brings to bear all the international expertise, underpinned by wide local experience when tackling any project.

Special characteristics

What differentiates the Duchting range from its competitors is the rotational speed, clearances and robust design. Over 2 000 units have been sold across the globe from the USA and Canada, to China, the Philippines, Germany, Poland and of course, South Africa. Chris concludes, “The pumps have a guaranteed efficiency of

over 80 % and vastly reduced maintenance and downtime, making them ideal for any mine.” Clients have enjoyed unprecedented success with these pumps, whether standard or customised, for example: • a high pressure HPXM 50X3 pumping 720m3 per hour was supplied to a coal mine in Germany and is still in operation • a HPXM 250X6 pump installed in a copper mine in Poland ran for 49 000 hours without a service

Multistage pump Type HPXL Technical data

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• a HXPU 200X13 high pressure pump was adapted to the needs of a coal mine in China and pumps 500m3 per hour at 93 bar. Carl Hamm PPS South Africa Tel: (010) 900-2005 Email: chris@carl-hamm.co.za

Fields of application

• Main water drainage in mining • Drainage and mine weather cooling in mining • Pressure boosting systems in industrial processes • Water supply and water treatment plants

Materials

Available in almost any metal from cast iron to Super Duplex stainless steel, the materials are carefully selected depending on the application, the pumped medium and the combinations of materials adapted to the respective conditions of use.

• Condensate production • Mineral industry • Oil and gas applications

Multistage pump types Type HPXU & HPXM Technical data

Quality assurance To ensure highest quality, every pump is tested and certified on our test bed according to international standards. We are able to provide extensive testing besides the performance tests. This includes tests like sound pressure, hydrostatic and vibration tests as well as string test of complete pump units.

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VOL 70 May/June 2020

FLEXIBLE SOLUTION

Robot Loading System Elevate was launched in September last year and is a robot loading system, with a large storage capacity, which takes up a small amount of floor space and is highly flexible. Subsequently, Cellro has sold ten of these systems.

Real-life experience

efore it developed Elevate, Cellro had already had success with Xcelerate, a flexible automation solution. Xcelerate offers customers flexibility when automating small to medium-sized series. However, it seemed that there was also an increasing demand for a loading system with a larger storage capacity. This was particularly true of machining companies which make their own products. That’s when work started on Elevate.

From ‘traylift’ to total solution

The traylift was a predecessor to Elevate. It could be linked to a robot cell and offered larger storage capacity. However, the traylift could not be used as a stand-alone system. With Elevate, Cellro has developed a robot loading system with an integrated traylift. Production can continue uninterrupted thanks to the large storage area next to the machine.

Products with different dimensions can be processed one after the other without the need for manual intervention Greater storage capacity also often means a wider range of products can be processed automatically. This gave customers a need for more insight into and an overview of their production. Cellro achieved this by successfully integrating additional features into the Elevate software.

Countless possibilities

Elevate is equipped with a large robot which makes even pallet handling an option. Clients can also choose a different robot instead, as it is separate from the Elevate unit itself. This means clients can take their pick of pallets and clamps. This also makes it possible to load a pallet with a given product. Last but not least: Elevate can be linked to two machines at once, either when first set up or later on. This makes it a future-proof automation solution.

Clients love the fact that this closed system produces without interruption and can be loaded and unloaded while production is taking place. Because two workflows can run simultaneously, the production process never has to be paused. The first company to buy Elevate uses the machine’s large storage capacity to avoid machine downtime. Imminkhuizen, which supplies machine components, could previously only set up a new batch once the previous run had finished. Elevate allows them to schedule everything in advance. Grippers and clamps can be changed automatically (thanks to the Fixture Exchange feature), meaning products with different dimensions can be processed one after the other without the need for manual intervention. Another major benefit is the software whereby human error is carefully and entirely filtered out of the process. If there’s a mistake, the customer can immediately see what’s wrong and where the error lies. Flowserve, the latest company to begin using Elevate, is using it for a multi-task machine, combined with the Collet Exchange feature. They run small batches with components that vary greatly between batches when making their own products.

The future

If required, Elevate users can expand the robot loading system with a variety of extra options. For example, a monitoring station, a pallet docking station, or a chest of additional pallets or clamps can be added simply. Cellro also expects new clients with complex production planning to increasingly look to Elevate to meet their needs. The possibilities offered by Elevate, together with its user-friendly control system, mean that the production process is as controlled as it is stress-free. Cellro Automation www.cellro.com

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VOL 70 May/June 2020

CONDITION MONITORING

Controlling Maintenance Costs A marine condition monitoring kit is helping a leading ship operator to manage costs and prevent equipment failure across its fleet.

Condition monitoring data collecting on bridge

condition-based monitoring program, devised for the marine industry by SKF, enables ship operators to control costs and avoid damaging equipment breakdown.

One operator, Capital Ship Management Corp. (Capital), has been investigating condition monitoring strategies since 2006, in order to reduce the maintenance costs and minimise unexpected machinery and equipment breakdown. Together with

Use the handheld device to collect vibration data from critical machinery including cargo pumps, engine room fans, compressors, purifiers and electric motors

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SKF, Capital came up with an effective strategy by utilising a new handheld device, launched recently by SKF; the SKF Quick Collect. The company has implemented the solution across a fleet of 30 vessels, with a plan to extend the programme for the whole fleet of 56 vessels. SKF helped the company to determine which onboard machines should be regularly monitored. SKFâ&#x20AC;&#x2122;s equipment supports ship operators such as Capital to improve the reliability of operations. Onboard engineers use the handheld device to collect vibration data from critical machinery including

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CONDITION MONITORING

cargo pumps, engine room fans, compressors, purifiers and electric motors.

Dramatic reduction in costs

George Ioannidis, Technical Fleet Director at Capital says, “This portable vibration measuring instrument helps us to access quick and reliable results for immediate action and reduces the cost of repairs dramatically. Furthermore, the onboard engineers using this vibration device can now collect vibration data from all critical and non-critical machinery including cargo pumps, engine room fans, compressors, purifiers, electric motors etc, and present detailed vibrations reports to class surveyors during periodical machinery survey (CMS).”

STEAM, TURB

The device is small, portable and offers a fast, convenient way to monitor the condition of critical machinery. The quick, accurate vibration data analysis and its ease of use, makes it a powerful diagnostic tool, not only for all chief engineers but also for office technical superintendents.

Untrained users

It provides vibration data in real time, allowing engineers to carry out maintenance and replace components immediately if required. The device collects velocity, acceleration enveloping and temperature data and connects with mobile apps such as QuickCollect and ProCollect, accessed via a tablet or smartphone. It’s easy-to-understand interface means that even a untrained user can understand the principle of operation and validate results of the vibration data measurements. The system can be customised for different marine customers, depending on their specific needs. Vibration data can be viewed in real-time through the app or downloaded and reviewed using Analysis and Reporting Manager (ARM) software on any accessible PC. Data can also be uploaded to the cloud, allowing SKF’s onshore vibration analysts to make a more detailed assessment and prepare a report if needed. “By giving operators access to data that helps them prioritize maintenance work, our solutions directly support them in preventing unexpected failures and reducing operating costs,” Petros Petritis, SKF Marine sales manager concludes. SKF, Tel: 011 821-3500, www.skf.com

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AFRICA

Renewable Energy Projects About 70% of utility-scale renewable energy projects undertaken under the Renewable Energy Independent Power Producer Procurement (REIPPP) programme in South Africa to date have seen the involvement of engineering, design, and advisory company Aurecon, according to Paul Nel, Energy Lead for Africa.

he company is currently in the process of rebranding as Zutari, after officially announcing the separation of the African business from the Aurecon Group, effective from 1 January 2020. With a strong engineering presence in both Cape Town and Pretoria, the energy division is divided into four business lines, namely generation, transmission and distribution, industrial energy solutions, and power system studies. This ensures fully-integrated solutions for its diverse customer base, which includes international and local project developers, institutional clients such as Zambian electricity utility Zesco, and local government clients such as the City of Cape Town.

Paul Nel

“We are currently looking at supporting some clients with bifacial photovoltaic (PV) technologies on their projects,” Paul reveals.

Africa, in particular, requires robust and durable solutions, which often means that clients prefer triedand-tested technology rather than the latest cuttingedge innovations

Aurecon has also been actively supporting some of its energy clients with advanced data analytics, cutting-edge drone-based construction monitoring and complex, bespoke business decision support solutions.

Interconnector studies

“I believe we currently offer some clients unique, digitally-advanced solutions that no one else in our space is doing. We are also actively looking at ways to increase our digital offering, helping our clients to remain relevant in this fast-changing digital world.”

In addition, Aurecon is involved with regional initiatives such as the Southern African Power Pool (SAPP) and, to a certain extent, the East African Power Pool (EAPP), where the main focus is on large interconnector projects. At present, it is undertaking projects in South Africa, Uganda, Zambia, Malawi, Kenya, Mozambique, Madagascar, Ghana, Tanzania, and Nigeria. Apart from the large interconnector studies, the focus here is mainly hydroelectric and solar power, with some clients looking at wind energy in East Africa, for example. “We have really been involved across the board in terms of renewable energy projects in Africa, including hydro power. We have deep insight into what it takes to connect to the grid at the utility-scale level, but also have specific experience in smaller industrial-scale solar power projects specifically for industry. Here hybrid solutions often provide the best energy mix, especially as battery-storage technology has not yet become cost-competitive with more traditional solutions,” Paul explains.

Maturing market

Africa, in particular, requires robust and durable solutions, which often means that clients prefer tried-and-tested technology rather than the latest cutting-edge innovations. Nevertheless, Aurecon remains up-to-date with the latest research and development (R&D) in order to assist the market as it matures. This has resulted in a steady advance from fixed-access solar energy to single-access tracking.

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Unabated

Paul points out that the need for both power and water on the continent is growing unabated, especially due to increasing urbanisation and, to some extent, industrialisation across Africa, underpinned by the new needs brought on by the Covid-19 pandemic. This has allowed Aurecon to achieve significant traction in the energy market. “We are always keen to get involved with the difficult problems knowing that, through this, we not only bring tangible relief, but make a significant contribution to the socioeconomic development of Africa. We have strong institutional experience across the continent, but specifically in South Africa, that can assist our country in getting back on track in terms of its electricity needs,” Paul stresses. The main challenge facing South Africa is its fossil fuel-based energy mix that is heavily dependent on the mining industry for supplying coal and employment opportunities. “We are very dependent on the government to free up the power generation sector.”

Nuclear power

Transitioning from coal-based power to renewable energy is a long and complex journey, as witnessed by the government’s ongoing efforts to separate the transmission, distribution and generation business units of electricity utility Eskom.

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AFRICA

“This unbundling is a prerequisite for the freeing up of the electricity market. Eskom’s inevitable reorganisation will be a slow process. What we are ultimately hoping for is an independent system operator mandated to trade power between both private and public entities. This will also free up significant investment opportunities for the private sector,” Paul highlights.

This unbundling is a prerequisite for the freeing up of the electricity market. Eskom’s inevitable reorganisation will be a slow process In terms of nuclear power, it is vital that options are considered to extend Koeberg’s operating life in order to ensure stability of the national grid, especially as this is the only base-load generation capacity in the entire Western Cape. New technology such as Pebble Bed Modular Reactors would likely still have a long development lead-time. Traditional nuclear generation solutions also remain very expensive and complex to develop, and hence Paul believes additional nuclear power will not be considered an option for South Africa’s energy mix in the foreseeable future. Aurecon, www.aurecongroup.com

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AUTOMATION

Robots in the time of Covid-19 The contagion of Covid-19 has swept through the lives of people across the globe, disrupted all industries and brought the world’s economy to a grinding halt.

s the world moves towards a different tomorrow, future-orientated solutions won’t merely be an option for industries but an absolute necessity. Robotics and automation technology are already playing a pivotal role in the health sector but they’re about to extend further into other industries faster than anyone could have predicted. “The automotive industry has always been closely tied to robotics, and this is unlikely to change,” says Kurt Rosenberg, Managing Director of Yaskawa Southern Africa. “The fast-moving consumer goods (FMCG) and food markets, however, should see an increase and acceptance in the usage of robots and automation technologies. This is largely due to the ‘contact’ element, as health and safety officers will be even more concerned about cleanliness, sanitisation and hygiene in manufacturing processes, handling and distribution of goods, and factories.”

Futureproof

Considering Covid-19 can survive on certain surfaces, measures will need to be put in place to futureproof businesses from any potential outbreaks. And this is where robotics could come in to reduce contact and cross-contamination.” While many industries have instituted stringent hygiene standards and practices for operations, they are also acutely aware of the human element. All it takes is one lapse and the risk of infection is catastrophic. There have already been several high-profile instances where essential services, such as hospitals and factories, have had to temporarily shut their doors because their staff have been infected by the virus.

Mechatronics

Back in the seventies, Yaskawa proposed the innovative concept of an unmanned factory termed “Mechatronics”. Since then, the concept has evolved into i³-Mechatronics, featuring further advancements and implementations of automation through

All it takes is one lapse and the risk of infection is catastrophic

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AUTOMATION the management of digital data. Whether it’s partial or full automation, there are flexible solutions that allow for smart integration, real-time visualisation of systems and industrial evolution through technological innovation.

place of humans in the workplace, hence the reluctance to embrace technology. Andrew Crackett, National Sales Manager at Yaskawa Southern Africa, believes it’s actually affording more opportunities to both organisations and employees.

Not only do these solutions increase overall productivity and systems processes, but there’s also the ability to improve standards and quality of both the manufacturing plant and products.

“We’ve implemented several projects at labour-intensive organisations to streamline operations,” says Andrew. “Instead of seeing a reduction in staff, we’ve actually witnessed the employees reassigned to other areas or new positions.

Considering the current restrictions on the number of employees allowed back at work and the need for social distancing, the industries that embraced i³-Mechatronics are better prepared to deal with the pandemic’s side effects.

“By freeing up resources, there’s the possibility to upskill and redeploy, while still improving the overall process and positively influencing the organisation. Robots will still need quality assurance, operators, and support staff, as an example.”

From the stability and reliability of streamlined production (despite fewer employees at their disposal) to rigorous health and safety standards, a robotised workforce is capable of business as usual even in unusual times.

While the havoc caused by Covid-19 cannot be understated, it has also pushed industries to think towards the future and plan better. A robotised workforce might not seem like something out of a sci-fi film anymore, but a necessary requisite for any business to survive in the face of disaster.

Kurt believes a robot-powered workforce is the way of the future, both locally and internationally. While he’s seen a significant uptake in robotic technology in South Africa, there are positive signs it’ll grow in the years to come as businesses make provision for these types of advancements.

Yaskawa Southern Africa Andrew Cracket, Email: andrew@yaskawa.za.com

Streamlining

At the same time, there’s a fear that robots will take the

A robotised workforce is capable of business as usual even in unusual times

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HAZARDOUS ENVIRONMENTS

High-risk Koeberg Clean-up Averda South Africa’s Specialised Industrial Cleaning (SIC) team recorded what is believed to be a world first by completing a high-risk clean-up of two tanks at Koeberg Nuclear Power Station at the end of last year.

Caution

The SIC team spent weeks preparing for the job to plan out in the finest detail, including a week of safety training before they travelled from Mossel Bay to the Koeberg Nuclear Plant. This training had to be in-line with Koeberg’s stringent safety procedures and the Averda teams core focus was keeping radioactive contamination as low as possible. This high degree of caution was not only to prevent exposure to any radioactive materials or surfaces, but especially because the tanks were still in place alongside the reactors.

Not a trace SIC team - Dwayne Dalton, Brent Arends & Mark Golden

Once all the preparations were completed, the threeday cleaning process could begin. The key was to remove all the remaining particles that could be radioactive from the inside of the tank.

There is no record of any other project in which the inside of these tanks have been high-pressure hydro washed to remove radioactive particles and contamination “To do this, the team started by suspending a 360° high-pressure nozzle into the tank for 12 hours. Only the following day did team members enter in specialise bubble suits to continue this process with hand-held high-pressure nozzles,” Johan explains.

he refuelling water storage (PTR) tanks have been in use to store contaminated radioactive water for some 40 years and needed to be thoroughly cleaned before they were demolished and disposed of, as being due for replacement. “This is a phenomenal achievement by our team from Mossel Bay that services our industrial clients in the region,” says Johan van den Berg, MD of Averda South Africa. “It was a tough assignment in one of the most hazardous environments one could imagine, and our team managed to exceed the client’s expectations.” The project was undertaken under contract from Lesedi Nuclear Services and required the Averda team to thoroughly clean two stainless steel tanks that stand 20m high and 12m wide. They are integral to the nuclear power station’s running, and the radioactive water it has stored could easily have contaminated the structure. According to Lesedi, there is no record of any other project in which the inside of these tanks have been high-pressure hydro washed to remove radioactive particles and contamination.

“We could not have been happier with the results, as was Koeberg. The radiation in the tanks before we started was quite high, but when we were done there wasn’t a trace of any remaining radioactive particles.” Understandably, the safety of all staff was the first priority throughout the project which is standard practice for Averda’s SIC team that services major industrial clients throughout South Africa.

Risky

Averda Mossel Bay branch co-ordinator Mark Golden says that although the possibility of being exposed to radioactive material is risky, many other industrial tanks contain residual gases that are far more volatile. “This is something that’s not visible, so you have to trust your monitors and your training because if the exposure gets too high you have to evacuate immediately.” Johan concludes by saying that with this successful, high-risk project successfully under their belt, the company is confident it has the expertise to take on increasingly complex industrial cleaning projects. Averda www.averda.co.za

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TRACE In is a glo antio leading party ri

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nternational, Inc. obally recognized bribery business organization and provider of third isk management solutions.

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DATA CENTRES

Accelerating the Online Shift The global digital evolution has just been put into overdrive by Covid-19 as locked-down nations are forced to accelerate the shift online, driving a massive spike in data needs. Microsoft Teams has reached 44 million daily users and Zoom users exploded to 200 million in March from a 10 million previous maximum.

atthew Renshaw, Chief Operating Officer of pan-African construction solutions company Profica, says that as businesses and even entire economies play rapid catch-up, the current pandemic challenge is throwing the need for local infrastructure to provide rapid, high-availability data centre services in Africa into sharp relief. “Countries across the African continent now have to leapfrog when it comes to evolving technologies and we will continue to see rapid growth in data-hungry new technologies, including the accelerated roll-out of Broadband, Artificial Intelligence, Cloud, 5G and the Internet of Things,” says Matthew.

Consulting, site selection, development and project management, technology workload migration, and disposition of facilities “As businesses continue to harness new technologies, they need to have the right supporting infrastructure in place. The ability to rapidly adapt and implement, as well as operate and secure business-critical data enables businesses to survive shocks to the economy, with the data centre at the core.” Profica has geared up with specialist partners, CBRE and their Data Centres team based in Europe, to increase expert project delivery services for data centres in Africa. Profica’s senior managers have

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Matthew Renshaw, Chief Operating Officer of Profica

experience in delivering ICT and data centre projects for major brands including Vodacom, Cisco, Goldman Sachs, Barclays, Ericsson and Google. “Even before Covid-19, data centres had been identified as the next real growth opportunity across our continent. They are a critical part of the infrastructure required to grow knowledge economies. Setting up robust, future-proof infrastructure requires specialist expertise from the outset and we are well positioned to deliver across Africa,” Matthew adds.

Untapped markets

“Even with economic growth severely constrained, several data centres have already been constructed, which should continue in key regional hubs.” The demand for cloud services will drive further data centre expansion across Africa, with spending predicted to grow to R11.53 billion in 2022 in the view of the Industrial Development Corporation (IDC) in South Africa. According to Jan Hnizdo, MD of Teraco, South Africa leads the continent with 59 data centres, followed by Nigeria and Kenya with 10 each.

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DATA CENTRES

“We expect to see strong demand for hosting capacity in data centres across the continent. Key hubs, including South Africa, Nigeria and Kenya, are well positioned to be regional growth centres, but investors need clear guidance in these economies that can function very differently from Western markets,” says Matthew. Providers of connectivity and cloud solutions are stepping up to facilitate growth. Subsea cable owner and IP-MPLS network operator Seacom will double the traffic-carrying capacity of its subsea cable systems in 2020, reaching 3TB. Facebook will be implementing its own Africa cable system, Simba, and Google’s Equiano cable will connect Africa with Europe.

The colocation model, where a datacentre provider hosts several enterprise and even hyperscale clients, is set to dominate as companies turn to data centre operators to manage the complex IT infrastructure, connectivity and increased data processing required by new technologies in a proprietary facility, rather than building their own enterprise facilities, according to Matthew. “Colocating makes financial sense, as well as facilitating scalability.

The Converged Data Centre development model

Now in its fifteenth year, Profica’s many years of Advisory and Project Management experience in African markets, combined with CBREs specialist data centre experience, enables the company to add value across the full lifecycle of a data centre development project, including consulting, site selection, development and project management, technology workload migration, and disposition of facilities. Profica supports CBRE in offering a Converged Data Centre model across Africa, which includes the integrated offering of technology and facilities management as well as advisory services. Already an established provider, CBRE delivers technology services to over 30 enterprise, colocation and hyperscale clients and provides facilities management services to over 800 data centres worldwide. CBRE’s Global Workplace Solutions business now manages data centre technology, physical infrastructure and data centre facilities. The technology scope of services within CBRE’s data centre solutions group spans vendor-agnostic strategic consulting, such as cloud migration strategy and planning, data centre planning and fit-out, technical implementation and support, hardware maintenance, data destruction and asset recycling. “Our converged model provides a way to tie business-critical IT and mission-critical facilities together within one value-stream-based funding model,” adds Jim Harding, President of CBRE Global Workplace Solutions (GWS). “This will ultimately help our clients be more competitive and achieve their digital transformation priorities.”

A need to co-locate

Mobile network operators and local companies have dominated the African datacentre market to date. Now, global hyper-scale cloud providers like Amazon, Microsoft Azure, Oracle and Google are challenging the status quo as they need more Africa-based data centres to grow their offerings on the continent.

“The colocation data centre market in Africa will see growth driven by the need for cloud services and the need to provide storage, data and networking to many more users. For Africa, the planning of data centres needs to consider flexibility and modular options to flex with the changing environments.”

The colocation data centre market in Africa will see growth driven by the need for cloud services and the need to provide storage, data and networking to many more users The Digital Economy Report 2019 from Unctad shows that 80% of colocation data centres are in developed countries, while Africa and Latin America together account for less than five percent. According to 451 Research, Africa is currently only served by about 150 colocation datacentres, leaving major scope for more. Matthew believes that building data centres is a critical part of Africa’s digital transformation, now accelerated by the global pandemic. “Continued investment in critical data centre services will ensure that we can continue to function in the virtual world and work to turn our economies around. In Africa, as with the rest of the world, nothing has a greater potential to transform societies than technology. Together with CBRE, we are committed to being part of this.” Profica www.profica.com

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Your boutique business destination Surrounded by lush gardens in the hub of Johannesburgâ&#x20AC;&#x2122;s northern suburbs, The Peartree in Craighall Park caters for groups of fifteen through to 100 guests in three well-appointed and equipped business suites. Breakfast meetings, working lunches, indoor or outdoor dining, half-day and full-day packages including all welcome refreshments, teas and lunches are offered in Standard, Gold and Platinum packages. Secure parking, Wi-fi, lockable space, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.

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IN-DEPTH ANALYSIS

Third-party Testing Service A significant investment in its two testing laboratories has not only allowed Pratley to guarantee the quality and performance of its world-class products, and constantly develop new products, but also to offer a thirdparty analytical service to industry.

ratley Analytical is an autonomous microanalytical division within the company. It is differentiated from most other analytical laboratories, which run large sample sets through standard machinery, by its capability to carry out more in-depth investigative-type analysis, mainly of specialised geological samples, for example.

Nuclear industry

In addition, it focuses on metallurgical analysis. However, its extensive range of equipment, up-todate sample database and the latest software gives it the flexibility to analyse virtually any samples, Pratley CEO Kim Pratley points out.

This is also a specific requirement in the food and beverage and animal feed industries, which need the assurance of invariant samples.

Database

The inorganic chemistry laboratory has two scanning electron microscopes, with one set-up mainly for imaging and the other for analysis, in conjunction with an Energy Dispersive Detector (EDS). Here the wavelengths of X-rays from specific points on a sample can be identified as particular elements. A third machine, an Electron Super Probe, is used to carry out more-intensive analysis, especially where elements lighter than carbon are involved, based on a Wave Dispersive System (WDS). Pratley Analytical also boasts a comprehensive optical microscopy section with six optical microscopes that use both reflected and transmitted light to determine aspects of crystallography such as birefringence. These high-end optical microscopes are also fitted with camera attachments. Powder-form samples, on the other hand, are analysed using an X-ray diffraction machine that compares the crystallography to a comprehensive database.

Extensive range of equipment, up-to-date sample database and the latest software gives it the flexibility to analyse virtually any samples

In addition to third-party work for mining and geological exploration companies, Pratley Analytical provides an in-house service for its own R&D division, as well as providing the necessary Certificates of Analysis (COAs) required for the zeolite it supplies to the nuclear industry, for example.

An Inductively Coupled Plasma machine can examine dissolved or aqueous samples, especially where minute quantities such as parts per billion are required to be detected. The sample is fed through a flame to produce an optical spectrum that is subsequently analysed for the entire periodic table. On the other hand, an atomic absorption spectrometer can isolate one element at a time.

Global expert

The division has numerous other capabilities like core splitting, magnetic separation, density separation, and sample preparation. â&#x20AC;&#x153;Our extensive equipment and highly trained scientific staff provide us with a significant analytical capability,â&#x20AC;? notes Kim. The division is also involved in quality assurance and analysing raw materials, and is headed up by Allan Arnold, a global expert in X-ray microanalysis. While the demand for third-party work has dropped off due to a decline in exploration activity in the mining industry, Pratley reveals that its internal use of the division is ramping up significantly, particularly in its pursuit of innovative new products and market segments. Pratley, Sales Tel: (011) 955 2190 Email: sales@pratley.co.za www.pratley.com

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FOOD AND BEVERAGE

The New Imperative The world has an opportunity to reboot itself into a healthier, more sustainable and equitable position post-Covid-19.

very facet of our human existence is affected, perhaps not directly by this particular coronavirus but, certainly, by the resultant lockdown of the global economy. While I cannot comment on other industries, I can say beyond a shadow of a doubt that the food and beverage manufacturing sectors have to change,” says Roy Henderson, CEO of Green Cell Technologies. “The current way in which the majority of our food and beverage is produced is detrimental to humans, to our animal kingdom and to the planet as a whole. Many of our processes in play today were designed at the advent of the industrial revolution. They use only a fraction of the available nutrition we essentially need to function optimally, are expensive to operate and generate vast amounts of waste. Good nutrition has always been the key to good health and productivity, and it is needed today more than ever. In fact, almost 2 500 years ago, Hippocrates said, “Let food be thy medicine and medicine be thy food.” Two thousand five hundred years later, some are beginning to rediscover the benefits of we are what we eat.

The mass availability of affordable, nutritionally balanced food is going to become ever critical for governments as well as businesses, which to date have been content with focusing on profit Before the onset of Covid-19, we had already seen the beginning of a shift to more whole food-based diets. I predict there will now be an exponential increase in that transition, particularly in light of the extensive evidence on how whole foods help in the management of metabolic syndromes such as diabetes, heart disease and obesity (lifestyle diseases). “These are largely preventable conditions, which we knowingly and often willingly fuel with poor nutrition, and whose presence in humans also increases the mortality rate of Covid-19,” Roy adds. Manufacturing whole foods in bulk for everyone to take advantage of the health benefits is, therefore, now the mission.

Wholesale behavioural change

Indeed, the rapid spread of Covid-19 has truly highlighted the importance for good quality ‘healthy’ foods and influenced behaviour in a matter of days in a way that long-term marketing campaigns would have spent months and millions on doing. Reported by many a news broadcast all over the

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Roy Henderson, CEO of Green Cell Technologies

world is the requirement for frontline responders, for example, to have optimal nutrition to keep them going through the relentless hours of saving lives. Not discounting the incredible work, they are doing, nor their needs, optimal nutrition should be available to everyone. “This is why there is an obligation for the food and beverage manufacturing sector - which is the key to our long-term health, to change how it processes foods and beverages. We should not wait for the next crisis. It is already on the horizon,” Roy asserts. In fact, the mass availability of affordable, nutritionally balanced food is going to become ever critical for governments as well as businesses, which to date have been content with focusing on profit.

Perspective

Already 9 million people die from starvation a year, according to theThe Food and Agriculture Organization of the United Nations (FAO). That didn’t spur anyone to action. Neither did the fact that in 2015, more than half the world’s then population lived on less than $2.50 per day. The lockdowns as a result of Covid-19 will, however, exacerbate this situation, with many who had lifted themselves out of extreme poverty (defined as living on less than $1,90 by the World Bank), falling below the line again.

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FOOD AND BEVERAGE And, because Covid-19 is non-discriminatory, it means that for the first time, the haves are understanding the fragility of our ecosystem and the interconnectivity and interdependence of our markets. This fact is also propelling global consciousness, which I hope will translate into conscious capitalism. What is needed, is the commitment from the manufacturers to be part of the solution. Not perpetuating the problem with foods and beverages that continue to negate nutrition because their current methods are too expensive to harvest all the available goodness from the source material. If the threat of a progressively sick world population and continued economic declines are not enough to provoke this change, consider that consumers themselves are becoming more and more savvy about labels and what goes into the products they ingest. Parallel to discovering the benefits of whole foods, they are asking for their foods to be made so they can access as much health-boosting nutrition as possible. Notwithstanding their own health requirements, they are also desirous of their foods and beverages to be made in a way that takes the health of the planet into account. It is no use that they are healthy when their environment may kill them. Factor in that enforced lockdowns have also provoked a change in retail behavior, which is likely to influence how foods are made, too. There is a good prospect of less lengthy supply and distribution chains, a resurgence of support for local growers, and a requirement for more natural ways of preserving food products, whether they are in supermarkets or delivered by drone due to the continued uptake of online shopping and progression in technology.

Conscious capitalism

New processing methods, already in existence, have proven that it is possible to process the whole plant - fruit, vegetable, organic matter (and even meat and fish). They are able to harvest almost all of the available plant actives (the molecules that give the plant its specific benefits) therefore boosting available nutrition while vastly reducing waste to landfill, and energy consumption in the manufacturing process. “These systems are also highly cost effective, making it entirely possible for manufacturers and processors to still be commercially profitable. However, with better price points at a manufacturing level, more people would be able to access what is required to keep them healthy, better able to fight surprise attacks like coronaviruses, moving to a preventative health state rather than a reactive one, and all the while keeping people working and economies growing. It really could be that simple,” says Roy.

ment on scale these new but existing technologies. These technologies can easily process most whole food and beverage matter with little to no waste and allow us to generate new products, as well as mimic some old ones with good returns.”

Nutrients

At present, inefficient technologies are used to peel, skin, discard, overcook and often destroy much of the nutrients in the foodstuffs we eat. Not to mention the inordinate amount of waste that is generated, which tends to contain the seeds and skins that house the majority of the nutrients we need. This includes the processing of convenience foods, canned and/or dried goods etc. The entire manufacturing system is antiquated and hugely expensive to build, install and maintain. This is all adding to the cost of the end product, which will become increasingly out of reach the more we enter into an economic recession, and even depression. So, rather than facing a future where the poor have nothing left to eat but the rich, why don’t we consider producing nourishing foods and beverages in a manner where they can be afforded by all, but not at the expense of taste and flavor that are already enjoyed?

Continue to negate nutrition because their current methods are too expensive to harvest all the available goodness from the source material “Sounds utopian and naïve? Maybe, but then so was abolishing slavery once. Maybe all it takes is the capitalist will to drive a more altruistic agenda where everyone benefits, including them.”

Health

Advanced processing techniques that; do not use chemicals or harmful heat to produce foods or beverages, and that can extract the nutrients and fibre out of what is currently left behind from traditional methods, which can then be added back into food and beverage, will therefore be instrumental in determining the health of our post Covid-19 world. This is something I have written about many times before, but it has largely fallen on the deaf ears. I sincerely hope everyone is listening now. Green Cell Technologies www.greencelltechnologies.com

“In this new paradigm, there is scope for everyone to benefit. What is necessary, then, is the individual, political and capitalist will, to impleTHE SOUTH AFRICAN MECHANICAL ENGINEER

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REMOTE WITNESS TESTING

A Pioneering Step

n an innovative ‘first’ to keep a customer’s mining project in the Democratic Republic of Congo (DRC) on schedule despite the impact of Covid-19, Zest WEG successfully conducted a remote witness test of Medium Voltage (MV) Variable Speed Drives (VSDs) in WEG’s Brazil factory. “These are extraordinary times, and require extraordinary measures,” says David Spohr, business development executive for high-voltage equipment at South African-based Zest WEG. “With the restrictions on international travel, we had to think creatively about how to complete this final step in the manufacturing process, the witnessed Factory Acceptance Test (FAT), before the equipment could be shipped to the DRC site.”

Under normal circumstances, these tests would require the customer to travel to Brazil and spend a week at the factory witnessing and signing off a range of detailed test and equipment requirement Under normal circumstances, these tests would require the customer to travel to Brazil and spend a week at the factory witnessing and signing off a range of detailed test and equipment requirements. This order comprised two 7MW 3300V WEG MVW01 VSDs for the ball and SAG mill drive application and two 1,2MW 3300V WEG MVW01 VSDs for the HPGR mill application. Both applications required non-standard features, namely ‘frozen charge protection’ software on the ball and SAG mill application and a ‘master & follower’ configuration on the HPGR mill application. A view of the testing facilities at WEG Brazil

David Spohr, business development executive

Participatory

“It was essential that we did not delay the customer’s project, so we arranged to conduct the witness test using web-based communication software,” says David. “This allowed the participation of Zest WEG experts, the engineering contractor and the end-user, all from the safety of their homes in Johannesburg while communicating with five testing technicians in the WEG factory in Brazil.” Using a high-definition camera and web-based communication software, the factory technicians were able to walk the contractor and end-user through each element of the FAT, with clear and real-time visual images of the test results and equipment on the factory floor. The tests continued for three days, beginning at 13h00 and ending at 19h00 to account for time zone differences. Testing covered three key areas – PLC communication software integration, full functional testing and full load testing.

Way of the future

“As with any other witnessed FAT, the customer was provided with a comprehensive results report by WEG. This enabled the customer to check, in exactly the same way, that the remote FAT results were within the required tolerances.” David notes that this pioneering step is likely to influence the way that these tests are conducted in future. “It has shown that the testing can be carried out to the same standards, but with significant savings in time and cost,” he concludes. Zest WEG Group www.zestweg.com

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3D AUTOMATED PAINT DEFECT DETECTION SYSTEM

Finer than a Grain of Salt One of the key technologies introduced in 2019 is an advanced Paint Defect Detection System in the Ford Motor Company’s Silverton assembly plant’s vast 12 000m2 Paint Shop, which is able to detect even the smallest paint imperfections. This fully automated and computerised system scans the paintwork of every vehicle body, and replaces the manual inspection process employed previously.

“

The launch of the paint defect detection system was a major milestone for our Silverton plant, as it significantly ramped up the quality of our paint shop, and complemented our major investment in 2018 to completely automate our painting process with 62 robots,” says Ockert Berry, VP Operations at Ford Motor Company of Southern Africa (FMCSA).

Over 3 000 images are captured in 15 seconds for every vehicle body produced, which are stitched together for a full 3D image that is digitally compared to a perfect computer model “We used an established paint inspection system employed by Ford’s leading plants in the US and in Europe, but went a step further by incorporating a tailgate scanner for the Ranger pickup, which was a first for a Ford plant globally,” Ockert states. “The new system resulted in significant gains in final quality and improved customer satisfaction for all of our locally-assembled Ranger and Everest models.”

Fully-automated

The paint defect detection system is a fully-automated process that uses a specially-developed light tunnel equipped with 21 high-resolution cameras. It relies on a three-dimensional imaging system that applies

varying degrees and angles of light while performing microscopic scans of each painted vehicle surface to detect any imperfections that occurred during the painting process. Over 3 000 images are captured in 15 seconds for every vehicle body produced, which are stitched together for a full 3D image that is digitally compared to a perfect computer model. The 3D rendering highlights dirt particles or surface imperfections by size (finer than a grain of salt) and its precise location. These are then attended to by skilled production operators along one of two manicure lines before final inspection and buy-off, after which the body can proceed to the assembly line.

Quality database

The paint inspection technology is fully integrated into Ford’s global production quality database for its manufacturing operations that is accessible from anywhere in the world via the company’s secure intranet. It links the images taken and the imperfections detected with the vehicle identification number (VIN) for full traceability and quality assessments. Furthermore, the system enables constant monitoring and feedback on real-time data based on the number of defects by colour, model, body panel so that corrective actions can be implemented immediately to address any quality concerns in the paint process – ultimately contributing to the highest level of paint quality for Ranger and Everest models produced in South Africa. Ford Motor Company of Southern Africa Duduzile Nxele Tel: (012) 842-2337 dnxele@ford.com www.corporate.ford. com

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TRIBOLOGY

Locked Down but not Locked Up The SA Institute of Tribology has been fairly quiet for a couple of months with regard to interaction with the public.

owever we have not been inactive. Membership has been diligently pursued by Isabel, keeping lists up to date and chasing members for their annual fees. We are very grateful for your support and ask if at all possible to settle the accounts to assist us in keeping our head above water. Isabel maintains the website and facebook and also finishes and sends out the newsletter. Berice has been clearing and tidying files, sending out statements, organising VAT and age analysis and interim trial balances. She is adept at the Pastel programme and keeps the books impeccably.

Meanwhile let us know if you are interested and would like to attend, it could be easier for delegates from the neighbouring countries who would save on travel and accommodation

Gill works with the committee on training courses, general email communication, liaison with Berice and Isabel, budgets, finances and SARS, keeping records, and early work on the Bid Committee for the 2025 WTC in Cape Town and anything else that has to be done, like learning Zoom.

On-line courses

However the main development is the discussion and implementation of the five day Lubrication Engineering course to be held on-line. This takes quite a bit of organising with the presenters learning the system, a moderator to keep everything together, and the students. It is planned to take about 20 students in one class. They will be informed as to what they need on their side such as a private quiet work place, assurance of no disturbance by your company, laptop or PC with microphone and webcam and sufficient internet speed for video and enough data for the week. While we are preparing ahead, please meanwhile let us know if you are interested and would like to attend, it could be easier for delegates from the neighbouring countries who would save on travel and accommodation. If interested, we can then keep you informed as to progress and probable dates.

Smaller group

As the lockdown lifts we will also be offering the usual live courses, but kept to a smaller group approved by current regulations. Although the Annual Awards Dinner will not be held this year, it is important to at least have the AGM and this will be planned on-line shortly. All members will be informed. And while you are raking up the autumn leaves, try some Leaf Art, as in my daughter Natashaâ&#x20AC;&#x2122;s garden. Gill Fuller, SAIT secretary

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SAFETY

Effective Traffic Management Plans Traffic management planning has come under the spotlight recently as requirements for Proximity Systems (PDS) and effective risk management interventions become enforceable under the provisions of the Mine Health and Safety Chapter 8 MHSA Act 29 of 1996. Most effective

Least effective Nico Pienaar of Aspasa

Traffic management objectives

ccording to Nico Pienaar of surface mining industry association Aspasa, the provisions require positive interventions, risk assessments and meticulous record-keeping in order to remain compliant. Smaller-scale surface mining operations with limited access to resources, or skills, may be particularly prone to underestimate requirements and should therefore work with the association to become compliant.

Change behaviour of staff, contractors and customers in order to implement the required systems which takes resources and time Nico points out that no matter the size or scale of an operation, it remains the responsibility of the employer to take reasonably practicable measures to ensure that pedestrians are prevented from being injured as a result of collision between trackless mobile machines and pedestrians.

Industrywide requirement

As a result, the mine needs to undertake a physical assessment to look at each scenario critically, identify and assess the risks, make provision for ‘the impossible’ and identify what measures can be implemented. “Traffic management is required wherever there is a hazard (something that can cause harm). Unwanted events are usually a consequence of a hazard and risk is the chance of something happening that will have an impact on objectives. “Chance = exposure x likelihood x consequence.

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Wherever there is a risk, controls should be put in place like a barrier that either prevents or mitigates an unwanted event. “A control therefore can only be a human act, an object (engineered device), a technical system or a combination of these. Traffic management deals with the safe movement of traffic and therefore also requires that historical data from Aspasa’s TMM Risk Evaluation reports, MOSH risk analysis and other information be incorporated to complete the mines’ own findings,” Nico advises.

Ongoing intervention

He adds that the compilation of a comprehensive traffic management plan is a difficult and ongoing task that is fraught with challenges, not least of which is the requirement to change behaviour of staff, contractors and customers in order to implement the required systems which takes resources and time. Thereafter the challenge is to ensure continued compliance with systems extended to satellite industries which requires the full commitment of the management team. “This also extends to those who deliver and collect goods and people to and from the site. “Although it is an intensive undertaking, it is a requirement by law and is well worth the time and effort wherever lives and the safety of humans are concerned. Although they should be common-sense and simple, such plans do require the commitment and effort of everyone on the mine in order to succeed,” Nico concludes. Aspasa, Nico Pienaar, Tel: (011) 791 3327 Email: nico@aspasa.co.za, www.aspasa.co.za

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MARKET FORUM

Expanded water treatment solutions Aquamarine Water Solutions, a wholly South African company and independent business unit within the Murray & Roberts stable, introduced its expanded water treatment solutions offering in late 2019. The company’s mission of empowering Africa with technology-driven water solutions is intended to help overcome water scarcity on the continent and simultaneously provide quality water tailored to customers’ specific requirements. To achieve this, the company has partnered with local and multinational technology partners who specialise in water related solutions. This allows Aquamarine to ensure quality in all its offerings; proffer expert advice to customers with regards to component application use; repair and service equipment when required; and uphold the technology owners’ warranties. The company’s complete water solutions offering includes made-to-order and standardised solutions for brackish and seawater treatment. This encompasses the manufacture and installation of containerised and skid mounted water treatment

plants, the provision of chemicals (reverse osmosis, cooling and boiler); componentry; operation and maintenance of plants, as well as risk-dependent finance for any of its projects. “This offering, when combined with the benefits of our partnerships, puts us on a trajectory to provide greater value for our customers,” says Aquamarine Water Solutions Head, Clive Govender. Aquamarine Water Solutions Clive Govender Tel: (011) 456-1000 Email: clive.govender@murrob.com www.aquamarinewater.co.za

Keeping the water flowing Critical pumps in the provision of water and sanitation services, as well as pumps used in the generation of electricity continue to be fully supported during the nationwide Covid-19 lock down period.

“During this time of crisis, we will do everything in our power to support our water utilities and municipalities water infrastructure to ensure uninterrupted supply of clean water to all communities.

Major supplier, KSB Pumps and Valves company spokesman, David Jones, regional sales manager for sub-Saharan Africa, says the company supplies largescale pumps for the distribution of potable water to the entire southern African region.

“The same applies to sanitation services where wastewater and sewerage handling is equally important to fight diseases and infection. Our workmen, technicians and engineers are on round-the-clock standby to ensure that pumps in these services run smoothly.” David adds that KSB Pumps and Valves has also played a crucial role in retrofitting and rejuvenating old pumps and steam valves in Eskom’s power station fleet in order to keep the country’s lights burning. Along with its modern equipment in newer power stations, the company’s full support and vast expertise will be critical to ensure uninterrupted power during the shutdown. KSB Pumps and Valves Annett Kriel Tel: (011) 876-5600 Email: Annett.Kriel@ksb.com, www.ksbpumps.co.za

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MARKET FORUM

Stabilise and support: Energy security can grow African economies Aggreko recently signed a contract with Resolute at the Syama gold mining complex in southern Mali. The goal is to reduce carbon emissions and improve the overall site efficiency. Aggreko will be operating and maintaining a 40MW thermal plant and a 10MW battery storage system with 20MW of solar power planned for 2023. This hybrid solution is set to reduce the mining complex’s power costs by 40% with an anticipated carbon emission reduction of 20% when the renewable power sources kick in. Aggreko works closely with organisations to develop solutions that not only resolve energy security challenges but provide them with reliable resources in times of economic complexities. Using data, insights and innovative technologies, the company has worked with multiple organisations and industries to shore up their energy investments and provide them with vital stability. According to the IEA, energy efficiency goes beyond just the macro economy. The micro economic benefits extend into savings due to reduced pressure John Lewis, Managing Director, Aggreko Africa on importing energy reserves or supplies; the cost plaguing the South African power utility, there is a need to is then knocked on to the customer (individual and comaddress energy security across multiple layers which each pany) which increases spending power and capacity; and plays a role in supporting the economy. savings that can translate into further improvements of Agrekko, Tel: (011) 357-8900, www.aggreko.com existing infrastructure. To break the cycle that is currently

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THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 70 May/June 2020

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Dealership rights South African-based condition monitoring specialists, WearCheck, are proud to announce a partnership with Swedish condition monitoring instrument manufacturers, SPM, allowing WearCheck to sell and support their world-class products. The full SPM range features portable condition monitoring products, online systems, maintenance tools, technologies

and expertise, all using techniques that help customers to achieve the highest possible uptime of critical assets – an approach which dovetails perfectly with that of WearCheck. WearCheck technicians have been trained to use, apply and install the SPM equipment, which performs many reliability solutions techniques, including vibration measurement and analysis, balancing, orbit analysis and laser shaft alignment, bearing and pulse checking, lubrication assessment and root cause analysis. The company’s reliability solutions manager, Philip Schutte, believes the partnership is set to yield many benefits, and that it enhances even further the two companies’ shared vision of maximising the planning horizon for maintenance and repairs. WearCheck Tel: (031) 700-5460 Email: marketing@wearcheck. co.za www.wearcheck.co.za

WearCheck staffers, Philip Schutte (reliability solutions manager) (second from left) and Annemie Willer (RS senior sales technician) (fourth from left), visited SPM’s head office in Sweden recently to seal the deal between the two companies

Latest Addition The Verder Group, a global leader in advanced industrial and niche market pump solutions, is pleased to announce the latest addition in the Group’s Verderflex range of peristaltic tube pumps, the Rapide 5000.

or a pump that does not need a costly, external air supply.

The Rapide 5000 has been developed to offer simple, reliable and cost-effective pumping solutions for industrial applications. The design combines the flexibility of the Vantage 5000 pump head with the simplicity of a single or three-phase powered industrial gearmotor.

The new Verderflex Rapide 5000 is ideal as a stand-alone single or double head pump or integrated into a system. This lubricant-free peristaltic pump can run dry without pump damage as, with the tube’s powerful recovery, it has excellent dry priming and viscous product pumping capabilities. The pump is especially suitable to dose and transfer abrasive and corrosive liquids such as chemical additives, inks, paints and off gassing liquids.

The innovative pump head has been field-proven on many successful installations of the more sophisticated, programmable Vantage 5000 dosing pump. Verderflex’s engineers have developed the Rapide 5000 peristaltic pump for users who require a simpler pump design with no local controls,

Verder Pumps South Africa Kirstin Adam Email: kirstin.adam@verder.co.za www.verderliquids.com/za

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DREDGING DUTIES Its growing reputation for prompt and cost effective dredging in the mining sector has extended the work of Integrated Pump Rental into tackling sewage settlement ponds.

“The design of our system, and the way it channels water flow to agitate the settled material, ensures that there is no chance of damaging the pond liner,” he concludes.

A recent contract at a wastewater treatment plant is part of a strong flow of repeat business from South Africa’s platinum mines, according to Ruaan Venter, rental development manager at Integrated Pump Rental. This particular plant was operated by the mine, but also served the local municipality and nearby communities.

Integrated Pump Rental Tel: (011) 894-2906 admin@pumprental.co.za www.pumprental.co.za

“Using our specialised SlurrySucker dredging equipment, we could quickly dredge the sewage pond before there was any danger of overflow,” says Ruaah. “Regular monitoring and dredging of these facilities allows them to effectively settle the sewage flowing in, and keep the system operating well.” He notes that the SlurrySucker uses a pump with an open-vane, non-clogging impeller, an important innovation in these applications as there are still solid objects and sanitary products that could block a normal pump.

Pulp-and-paper plant When a pulp and paper producer required inspection and maintenance of its fire water system, it turned to rope access specialist Skyriders to provide a quick and cost-effective solution. Skyriders’ experience in the petrochemical and power generation industries stood it in good stead with this flagship project. “Our experience and track record with hazardous and

chemical environments made it a natural extension for us to continue work in the pulp and paper industry,” Skyriders Marketing Manager Mike Zinn comments. For example, the company was recently involved with a deluge system for a major petrochemical producer, which is a water mist system based on open spray heads attached to a piping system, connected to a water supply by valves. The pulp and paper producer opted for rope access as this provided the safest and quickest access of its manufacturing facility for the mandatory inspection of its fire water system, which involved examining all of nozzles and hoses. Traditional scaffolding, on the other hand, is both time-consuming and costly to erect. Extra time for proper dismantling also has to be factored in upon completion of the project. Mike Zinn Marketing Manager Tel: (011) 312 1418 Email: mike@ropeaccess.co.za www.ropeaccess.co.za

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Complete vacuum process Hudaco Group company, Berntel, is introducing several new product ranges through the Bearings International (BI) branch network. These include Ober, an Italian designer and manufacturer of portable pneumatic tools, motors, automated machinery, and systems for drilling, tapping, threading and screwing, including power screwdrivers with electronic torque control; compressors and dryers from German manufacturer BOGE; and smart vacuum solutions from Piab. In addition, Berntel represents a range of well-known brands,

such as JELPC pneumatics, Piab vacuum components, JORC Industrial condensate drain management, VMECA water-free units, and Belef actuation. The main applications are food and beverage, automotive, general industry, sugar, pulp and paper, OEMs, machine builders, and agriculture, Berntel General Manager Neil Champion explains. The complete solutions available focus on the efficient generation of clean, dry compressed air to condensate drain management, pneumatic, vacuum, process, and industrial components, and designing and programming control systems with PLC integration. â&#x20AC;&#x153;What is critical for customers to understand is that Berntel focuses on solutions specifically for vacuum process and industrial automation. It is a nicely-mixed product range that offers a complete package. We have strived to make a simply and user-friendly basket for a range of requirements and applications,â&#x20AC;? Neil concludes. BI Contact Tel: (011) 899-0000 Fax: 087 057 6122 Email: info@bearings.co.za www.bearings.co.za

Printing PPE Drive and automation technology leader SEW-Eurodrive (Pty) Ltd. has joined a nationwide campaign to use 3D printing technology to produce much-needed face masks and shields for healthcare workers and first responders. The initiative was organised by 3D printing solutions provider Additive Manufacturing Solutions (AMS), with MD Bernhard Vogt calling on all companies and individuals equipped with such technology to join the campaign. By mid-April, the initiative had produced an astonishing 15 000 face shields to meet the needs of private healthcare providers such as Netcare and the Department of Health.

SEW-Eurodrive, which has a state-of-the-art 3D printer in its design department, responded to the rallying cry, and an engineer is printing masks from the safety of his home. The project is being overseen by the design and engineering departments. Sew Eurodrive (Pty) Ltd Jana Klut Tel: (011) 248-7000 Email: jklut@sew.co.za www.sew.co.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

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MARKET FORUM

On the Move Walter Mxabangu Ntuli

Wendy Buffa-Pace

Walter Mxabangu Ntuli has been appointed Aquamarine Water Solution’s Sales Engineer: Public Sector

Now a Reality Aimed at OEMs looking to add mobility to their autonomous or collaborative robots, NSK has developed an innovative direct-drive wheel unit specifically designed for use in quiet environments, such as hospitals, hotels, offices and libraries. Robots fitted with the new wheel unit can efficiently carry and move loads up to 100kg without disturbing people. With digital trends such as AI (artificial intelligence) and ML (machine learn-

Atlas Copco has appointed Wendy Buffa-Pace as managing director to the board of directors

ing) beginning to show genuine promise in real world applications, efforts are ramping up to develop mobile robots and humanoid robot hardware that can perform useful tasks in close proximity to people. The major obstacle with systems like conventional AGVs (autonomous guided vehicles) used in factories and warehouses, is the noise they make. In contrast, the NSK direct-drive wheel unit is much quieter, facilitating use in public spaces and non-manufacturing environments.

Settings such as service sector businesses and public facilities require robots that operate quietly to avoid impeding conversations and disturbing people from their tasks. The quiet nature of NSK´s wheel unit can be attributed to its gearless structure (direct-drive motor), which leverages the technology behind the company´s Megatorque Motor to eliminate the operating noise generated by typical gearboxes. Geraldene Govender, (011) 458-3600 Email: nsk-sa@nsk.com

Dependable Infrastructure “BMG specialists play an important role in upgrading ageing water and wastewater facilities and designing new drive systems, to ensure a dependable infrastructure,” explains Kelly Mac Iver, Gears Business Unit Manager, BMG ElectroMechanical Division. “The selection of robust equipment, which can endure continuous operation under severe conditions is critical. Every drive package selected must match the application perfectly, to ensure energy-efficiency, low running costs, minimum downtime and extended service life of the system.

Gears Business Unit Manager BMG ElectroMechanical Division Kelly Mac Iver Mobile: 082-453-7347 Tel: (011) 620-1615 Email: KellyM@bmgworld.net

“Care for the environment is also a priority and for this reason, we select environmentally-friendly drive solutions that help minimise emissions. “It is also important to prevent unnecessary breakdowns, which is why reliability is our main focus when designing the drive systems for new and upgraded facilities. All BMG components are precisely matched to each other and to application requirements, to ensure high productivity, smooth operation and long service-life. “Apart from the supply of new drive systems, the company’s broad branch network offers original spares and advanced workshop resources that ensure all repairs to drive components meet pristine OEM standards,” Kelly concludes.

THE SOUTH AFRICAN MECHANICAL ENGINEER

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Jehiel E Lawrence Xylem South Africa has appointed Jehiel E Lawrence as its new Sales Director for Southern Africa

High security welded mesh

Pallisade

Gates

Gate Automation

Razor wire and more ....

What is High Security Weld Mesh HIGH Security Weld Mesh is wire fused and welded at a Horizontal distance of 76.2mm and a vertical distance of 12.7mm also known as 35B/3510 where 3 denotes 3”(distance between vertical wires), 5 denotes 0.5” (distance between horizontal wires), and B or 10 denotes gauge of wire

Salient Features •

Difficult to Climb: The spaces between the Horizontal wires are too narrow for fingers to have grip

•

Impregnable: Extremely difficult to cut with a hand cutter as the beak of a wire cutter will not be able to penetrate the horizontal wires

•

Excellent Replacement option to Solid Wall as:

1. More economical than a solid wall 2. Faster to install than a solid wall 3. CCTV Camera has a clear view •

Further upgrade possible with electric security system

•

Anti-corrosive & low maintenance

Standards •

Manufactured according to BS EN 10016-2

•

Wire Sizes in accordance with BS EN 10218-2

•

Tolerance on Mesh Size in accordance wiht EN 10223-7

•

Tolerance on Panel Size in accordance with EN 10223-4

•

Welding Strength in accordance with BS EN 1461

•

Zinc Coating in accordance with EN 10245-1

•

Anti Corrosion in accordance with BS En 3900 E4/F4

Tensile Strength •

Wire has a tensile strenght of min 550 MPA

MARK: 083 454 6488

Email: mark@palifence.co.za

www.palifence.co.za THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 70 May/June 2020

SA Mechanical Engineer May/June 2020

Articles inside

Finer than a Grain of Salt

On the Move

The New Imperative

Effective Traffic Management Plans

Market Forum

Locked Down but not Locked Up

A Pioneering Step

Third-party Testing Service

Controlling Maintenance Costs

Delivering the Goods

Accelerating the Online Shift

Renewable Energy Projects

Robots in the time of Covid-19

High-risk Koeberg Clean-up

Robot Loading System

Institution News