SA Mechanical Engineer Nov/Dec 2015

S MECHANICAL A ENGINEER Nov/Dec 2015

Publication of the South African Institution of Mechanical Engineering, incorporating News of Associate Organisations

IMPROVING WEAR AND CORROSION RESISTANCE REFRIGERATION AND IoT

Torrefied Biomass PelleTs for indusTrial Boilers

Chris Reay

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

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The monthly circulation is 3 947

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2016 Short Term Training Events SPECIALISED SEMINARS

Programmes for these seminars will be available soon Centrifugal Pumps, Systems and Slurry Applications Gauteng

Durban

Cape Town

14-15 Mar 2016

12-13 Sep 2016

16-17 May 2016

Introduction to Adhesives Science Gauteng

Durban

Cape Town

14 April 2016

29 April 2016

23 March 2016

Heat Exchangers Gauteng

Durban

Cape Town

22 June 2016

23 March 2016

6 April 2016

Flame Proofing & Related Protection Methods in Explosive Environments

6

Gauteng

Durban

Cape Town

10 May 2016

15 June 2016

3 May 2016

THE SOUTH AFRICAN MECHANICAL ENGINEER

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STANDARD WORKSHOPS Programmes available

Managing a Coal Fired Fire-Tube Boiler Gauteng

Durban

Cape Town

28 April 2016

13 April 2016

20 April 2016

Engineers Solving Business Problems Gauteng

Durban

Cape Town

28 April 2016

13 April 2016

20 April 2016

Business Process Mapping Gauteng

Durban

Cape Town

10-11 May 2016

24-25 May 2016

7-8 June 2016

Capital Budgeting for Projects Gauteng

Durban

Cape Town

6 July 2016

27 Sep 2016

13 July 20 16

Leadership and Management Principles and Practice Gauteng

Durban

Cape Town

2-3 Nov 2016

10-11 Aug 2016

18-19 May 2016

Overview of Fans and Air Handling Gauteng

Durban

Cape Town

30-31 May 2016

9-10 March 2016

13-14 July 2016

Leadership and Management Roles in Engineering Gauteng

Durban

Cape Town

12-13 Oct 2016

19-20 Oct 2016

5-6 Oct 2016

Root Cause and Failure Mode and Effects Analyses Gauteng

Durban

Cape Town

2-3 Aug 2016

16-17 Aug 2016

6-7 Sept 2016

Machinery Failure Analysis and Prevention Gauteng

Durban

Cape Town

23-25 Feb 2016

To be advised

8-10 March 2016

Pressure Safety Valves Gauteng

Durban

Cape Town

16-18 Feb 2065

To be advised

9-11 Feb 2016

find out if you qualify to #joinourtable at pps.co.za PPS is an authorized Financial Services Provider.

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Your boutique business destination Surrounded by lush gardens in the hub of Johannesburg’s northern suburbs, The Peartree in Craighall Park caters for groups of two through to 100 guests in nine 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, business centre, fibre optic broadband AV, lockable space, and an onsite Hair & Beauty Boutique, all underpinned by highly qualified and helpful staff dedicated to ensuring your event is a success, make The Peartree a destination of choice.

www.thepeartree.co.za e-mail: info@thepeartree.co.za Tel: 011 781 0682 41 St. Albans Ave, Craighall Park

Vaughan Rimbault

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Torrefied biomass pellets

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John Rundle, managing director of Steam Generation Africa

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A mobile steam plant with containerised boilers

Two Cochran 10T Thermax gas fired boilers installed

The first Cyclotherm boiler with a Limpsfield Gas fired burner and auto flame combustion control system in South Africa

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Cochran; 135 Years of World-Beating Energy Solutions Steam Generation are the exclusive southern Africa agents for world-famous British boiler and associated equipment manufacturers, Cochran. Established in 1878, Cochran were actually the original inventors of the revolutionary horizontal firetube boiler. The Thompson-Cochran group later brought modern package boiler technology to South Africa, and as part of Rolls-Royce, Cochran became a leading international boilermaker. Since regaining its independence as a company, Cochran has continued to develop its global business and is now proud to re-enter the South African market in association with respected African heat technology company, Steam Generation.

The new Scottish-South African partnership will supply Cochran’s famous Borderer, Wee Chieftain, Thermax and Coalmaster boilers to the region, supported by expert installation and maintenance services delivered by Cochran’s trusted South African partner, Steam Generation.

Cochran are also a global leader in Heat Recovery Boilers. Operated in conjunction with a wide range of industrial engines and processes, they generate ‘free’ hot water or steam using previously wasted exhaust or process-generated heat. Often paying for themselves in just a few months, Heat Recovery Boilers reduce waste and total energy costs, whilst also cutting overall carbon emissions.

+27 11 695 2500/3 steamgeneration.co.za

Also visit Cochran at: cochran.co.uk FAX +27 11 312 4710

info@steamgeneration.co.za

Energy Solutions Worldwide

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1.

2.

3.

4.

5.

6.

7.

8.

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Furnace Empty Pass Evaporator Superheater Economiser Plugged Ash Hoppers ESP Large Hanging Deposits

Academic

Career Path

Michael Symonds

Commentary

Projects

find out if you qualify to #joinourtable at pps.co.za PPS is an authorized Financial Services Provider.

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Economist, Elsie Snyman, addressing CESA delegates

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A total of 67% of firms reported difficulties in recruiting male engineers and 80% reported problems recruiting female engineers

There is a clear correlation between the level of discounting and competition. As competition started to intensify after 2009, the propensity to discount also started to accelerate. The average discounting rate accelerated in the last two surveys, to 25.8% in December 2014 and 25.2% in the June 2015 survey

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MARTHINUSEN AND COUTTS - LEADERS IN ELECTRIC MOTOR AND POWER GENERATION REPAIR, MAINTENANCE AND SPECIALISED MANUFACTURE.

Large AC / DC Motors Small AC / DC Motors Traction & Flameproof Motors Transformers Power Generation ON SITE SERVICES

CUSTOMISED ELECTRICAL Coralynne & Associates +27 11 422 1949

AND MECHANICAL DESIGN

Marthinusen & Coutts Your Assets. Your Needs. Your Service Partner.

A division of ACTOM (Pty) Ltd Tel: +27 (0)11 607 1700

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www.mandc.co.za

commercial@mandc.co.za

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Reaching your targets: locally and internationally For local companies there is no more sitting on their laurels. International firms are entering our markets stirring up the waters. Globalisation is a fact and, therefore, many engineering firms are in the thick of expanding locally and internationally.

A new annual being published by Promech Publishing will cover:  The concept of clustering whereby like-minded suppliers in the engineering industry get together through export councils to jointly accomplish what cannot be done alone  Plugging holes in the supply chain to ensure security of resources required to manufacture  Interviews with champions in the engineering sector who have expanded their companies exponentially locally and internationally  Case studies of incredible growth stories  Comprehensive information on govt incentives and other monetary assistance in underpinning localisation and forging a path internationally  Examples of how large orders and projects can be tackled by competitor firms who band together  Information on project pipelines, export pavilions, trade delegations, distribution agreements, process guarantees, preferred supplier status and much more.

CLARIFYING CLUSTERS Sybil Rhomberg, MD of the SA Capital Equipment Export Council will clarify: • that clustering is not about collusion but competitive advantage among peers • the role of industry-based export councils as the link between specific industry clusters and various government departments, providing early leads, organising outward-selling and inwardbuying missions • the benefits of a pre-shipment finance system and the multitude of grants, tax breaks etc available to assist companies in getting on the map.

Contact: Helen Bennetts Tel: (011) 781-1401 Cell: 076 751 9228 engworld@promech.co.za

About Promech Publishing Five magazines make up Promech’s stable: • “SA Mechanical Engineer” • “Bulk Handling Today” • “Supply Chain Today” • “Architect & Specificator”, and • “Skills On Site”.

Established in 1993, the company retains its top slot as a reputable and informative publishing house. www.promech.co.za

DISTRIBUTION Local: 12 097 printed copies will be mailed to local senior public officials, mining houses, municipalities, the parastatals, the agricultural sector, trade, energy, consulting, civil, infrastructure, transport and logistics, environmental bodies.

• SACEEC, Vamcoza, SAMPEC, SWH-MANCOSA, SARRSC members (100) Digimag: An exact electronic copy of the annual will be emailed to a well researched list which will target decision-makers in Africa and globally. It will also be on our website: www.promech.co.za for a full year • Mines and mining houses in SADC, Africa and overseas (1741) • Trade Consuls (199)

PRINT ADVERTS Full Colour adverts

Casual Insertion

+1 Page Editorial

+2 Pages Editorial

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18 787

28 181

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11 690

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insertion costs + 20%

Special Positions – by negotiation only

“We don’t believe in waiting for things to be done for us, we go out there and put the programmes in place ourselves with the support of government,” Sybil Rhomberg.

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POWER

GENERATION PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 Email: samecheng@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Editorial Contributors: Liesl Venter and Patricia Holburn Advertising: Colleen Cleary Circulation: Catherine Macdiva DTP: Lindy Fobian/ Jacquelene Nene Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.

Copyright

All rights reserved.

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

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

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Figure 1: Positioning of energy storage technologies

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T O D A Y

Brian Arellano

Jonathan Hawkins

Cleverson Shindi Takiguchi

Flavio Lopes Jr

Figure 2: Storage system acting as energy supply

Figure 2: PV intermittency in a 4.6 MW power plant

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Figure 3: PNM’s installation aerial picture

Solar PV Meter data.

Primary (Net System) Meter data.

Battery Meter data.

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Figure 6: Single-line diagram

Figure 7: System output 0.1 – 10% of PV meter

Figure 8: 100% of PV meter

Figure 9: Magnified view of 1/15/12 smoothing

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Figure 10: Magnified view of 1/16/12 smoothing

Figure 11: Smoothing with irradiance sensor input

Figure 12: Magnified smoothing with irradiance sensor input

Figure 13: Correlation of smoothing model to primary meter

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Figure 14: Ramp rates for 2 sampled days – 40% gain

Figure 15: Ramp rates for 2 sampled days – 60% gain

Figure 16: Ramp rates for 2 sampled days – 80% gain

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Figure 17: Ramp rates for 2 sampled days – 100% gain

Figure 18: Frequency responses for 40 and 100% gains

Figure 19: First iteration - manual shifting – winter schedule

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Figure 20: V1.8 - automated shifting – summer schedule

Figure 21: Peak shaving prior to optimisation - day profile

Figure 22: Peak shaving after optimisation - day profile

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Figure 23: Site meter output in peak shaving

Figure 24: Feeder voltage profile in peak shaving

Figure 26: Arbitrage - battery output vs CAISO price - 2

Figure 25: Arbitrage - Battery Output vs CAISO Price - 1 4/13/12

5/12/13

6/21/13

6/28/13

7/5/13

3/6/12

6/22/13

4/15/12

2/11/13

5/27/13

Classification

Mild

Mild

Mild

Mild

Mild

Mod

Mod

High

High

High

RSDP

32.03

58.82

60.38

65.86

55.22

17.93

60.3

30.48

72.03

63.01

RSDP

30.25

61.23

55.79

63.6

44.68

11.09

57.45

28.81

67.86

60.61

MM Power

32.39

68.78

63.19

69.13

78.21

0

62.78

22.46

76.85

73.14

MM Ramp Rate

41.1

71.21

69.37

72.52

75.76

0.02

64.4

36.54

82.33

73.38

Table 1: SNL PV smoothing analysis outputs

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Mohlaleng_2580_E

Less drive sometimes gets better results Slowing down a pump or fan from 100 to 80% can reduce your motor’s energy use by up to 50%. A VSD, also known as a Variable Speed Drive, is a device that can adjust electricity supply. By controlling the speed of your motors, and matching them closely with the requirements of the system, a VSD can typically cut energy consumption from 20 to 50%. Talk to one of our Energy Advisors today and let us assist you in devising the most effective energy plan for your industrial business.

Call our Eskom Contact Centre and request a call from an Energy Advisor on 08600 37566.

For more information go to www.eskom.co.za/idm

Eskom Holdings SOC Ltd Reg No 2002/015527/30

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Hymie Marnewick

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GEA GRASSO COMPRESSORS AND SCREW PACKAGES Whether it’s in the food industry, chemical industry, in offices or in shipping, they all need refrigeration. GEA Southern & Eastern Africa has the optimal cooling and air conditioning solutions for your requirements. We place particular value on energy efficiency, reliability, cost effectiveness and sustainability.

GEA Southern & Eastern Africa 48 Reedbuck Crescent, Corporate Park South, Midrand 1682, RSA Tel. + 27(0)11 392 7114, Fax. +27(0)11 392 7000 info-sea@gea.com

www.gea.com

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engineering for a better world VOL 65

November/December 2015

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Water savings

Energy savings

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MARKET FORUM

Bryan Anderson

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MARKET FORUM

From left: Fritz Fourie, managing director, Hansen Transmissions, Gavin Pelser, managing director:engineering, BMG, Charles Walters, chief executive officer, Invicta Holdings Limited, Byron Nichles, chief executive officer, BMG and Shaun Dean, chief executive officer, Hansen Industrial Transmissions nv

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MARKET FORUM

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Jaco van Deventer

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MARKET FORUM

Scott Meikle, Carrier South Africa MD

www.promech.co.za * * * * *

S MECHANICAL A ENGINEER

Easy navigation through the site Comprehensive archive Free to users No registration Searchability

Sept 2015

Publication of the South African Institution of Mechanical Engineering, incorporating News of Associate Organisations

IN-FIELD DIAGNOSTIC SERVICE YOUNG ENGINEERS BROUGHT UP TO SPEED

RITZ Pumps South Africa (Pty) Ltd Tel: (011) 397-5616 www.ritzpumps.co.za

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Opportunities identified and challenges dealt with, keeping a long term focus on sustainable business.

November/December 2015

083 643 9480

► EIA Process

► Environmental Risk Assessments

► Geographical Information Systems

► Agricultural Assessment and Advise

► Project Managment

► Wetland and Riparian Services

► Natural Resource Services

► Visual Impact Assessments

► Ecological/Biodiversity Services

► Public Participation Process

► Application Assistance

► Game Ranch Management

► Developement Research, Monitoring and Evaluation

N2 Mnini ECO Duties

Plant rescue

Durban Coal Terminal Site Inspection

Ohlanga Pump station ECO Duties

Freightpak Warehouse Site Audit

Public participation Makhabeleni

Ballito Interchange Botanical survey

Site assessment Sundumbili pipeline

l Tel: (031) 303-2835 l Fax: 086 692 2547 l l Email: info@afzelia.co.za l www.afzelia.co.za l Skills on Site

Septmeber 2012

1