SA Machanical Engineer October 2012

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62

October 2012

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AN ENGINEER’S VIEW

Qualifications and the Phase to Professional Competence Chris Reay Chairman of the Working Committee: Communications (SA Institution of Mechanical Engineering)

I often follow the debate on the profiles, experiences, expectations and opinions of the issues concerning the Baby Boomers (born 1940 to 1960), The Generation Xs (1960 to 1975-ish), and the Generation Ys (post 1976).

P

robably the most significant item that is relevant to all these age groups is that of lifestyle. Each age group tends to indulge in the criticism of the previous one laying blame for all the problems that beset their current lifestyles. Characteristics such as social responsibilities, work ethic, corporate practice, family stability, wealth profile and continuity of employment are significant items.

Corporate value systems have changed with the evolution of bottom line items that go beyond profit.

Awareness of the environment, ecology and health systems have emerged strongly where the impacts of these are able to be managed with technology development.

Graduate has claimed that such learning has never been applied in their subsequent careers?

In engineering education training and practice, it is not uncommon to witness those who question the effectiveness of present-day curricula which in real terms have not differed significantly from those of earlier generations. Obviously the tools that facilitate learning have changed with modern information technology developments such as computers, software and digital configuration. How often has one heard the comments questioning the inclusion of certain academic basics into programmes where the graduate has claimed that such learning has never been applied in their subsequent careers? In engineering curricula this may be a truism but the challenge is that due to the “connectedness” of science and technology, where does one omit such content?

Remain intact

The great thing about an engineering curriculum is that it addresses the challenge of tackling those aspects of life that do not radically change: the laws of nature and science remain intact, the fundamentals still exist, the approach to problem solving and the need to develop empirical competence are still the foundations of the Engineer’s world. They are the

toolbox for future applications. What does matter thereafter is the training and practice of how to use them to build the environment we purport to do better than any other profession.

What age group is the right mentorship group? Are the retired or semi-retired the right dispensers of experiential skills and advice? Has this thinking now emerged for the reason that each generation of Engineers from the baby boomer era was both supervised and mentored by the next level in the system as a matter of course where it was not called “official mentoring” but de facto on the job development in the process of evolving the next skills layer?

There was clear period of world practice in infrastructure development with the emergence of industry, production and modern supply chain logistics. Large projects covering all the technologies were common: energy development, transport, communications and service industries emerged that had decades of continuity that encouraged sequential training and development of practical skills.

Short supply

We must question why we now have an era where this has reduced significantly and it is evident that internationally well experienced skills in the lower, active age groups are in very short supply.

From a human development perspective, the period over which a candidate Engineer needs to develop sufficient competencies to be recognised as a professional will not have changed. Gladwell’s theory on the 10,000 hour rule probably applies where any person claiming expertise will have spent 10,000 hours odd developing that expertise.

So the candidacy phase which is set as 3 years minimum is rarely met, and the statistics show that 5 years is the norm. If you work that out, it is about 10,000 hours.

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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October 2012

Bearing Man Group Tel: (011) 620-1500, Fax: (011) 620-1775, Website: wwww.bmgworld.net

VOLUME 62

Contents Cover Story 8

High Efficiency Motors

Monthly Column 11 Prominent Professionals

Power Transmission Opinion 15 Soapbox

Computers in Engineering All rights reserved. No editorial matter published in “SA Mechanical Engineer” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

Pipes, Pumps & Valves 33 Joining Forces 36 Seize the Day

Exhibitions 38 INDUTEC 2013

Regulars

12 Laser Alignment

Copyright

NUMBER 10

17 Labour Productivity - Hidden Treasure

3 6 35 39 40

An Engineer’s View Institution News SAIT SAINT Market Forum

Business 19 All Together Now!

Developing Skills 21 Infrastructure Demand

CESA 23 Excellence Awards

POWER GENERATION TODAY 25 ‘Rediscovering Hydropower’ 30 Power Generation News The monthly circulation is 4 242

Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123, Republic of South Africa Tel: (011) 781-1401, Fax: (011) 781-1403 Managing Editor Susan Custers Editor Kowie Hamman Circulation Catherine Macdiva Advertising Mark Bennett DTP Zinobia Docrat / Donovan Vadivalu Subscriptions Please email us at accounts@promech.co.za if you wish to subscribe to “SA Mechanical Engineer” at R405,00 (excl postage and VAT) per year; R1 020,00 per year for Africa/Overseas.

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

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

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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October 2012

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THE SA INSTITUTION OF MECHANICAL ENGINEERING

New SAIMechE Workshops for 2013 Total productive maintenance

Council 2012 - 2014 Office Bearers

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

Branch Chairpersons

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

Portfolios:

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

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

Continuous flow processes

Implementing Continuous Flow develops Engineers to look at their current Manufacturing processes differently. The course provides detailed Methodology, how to change the organization to a Continuous Flow Organization, leading to reduced Wastes, reduced Inventories and dramatically improved Customer Service.

Also introducing workshops on: 'XSOH[ 0DWHULDOV 7DQNV Reintroducing the following workshops: 3UDFWLFDO 5LVN $VVHVVPHQW 6WDLQOHVV 6WHHO &RUURVLRQ &RQWURO 7KH (QJLQHHU DV 0DQDJHU GD\V

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PO Box 511, Bruma, 2026 Tel: (011) 615-5660, Fax: (011) 388-5356 Email: info@saimeche.org.za Website: www.saimeche.org.za Membership: Central, Eastern Cape, Mpumalanga, Highveld & KZN: membership@saimeche.org.za Membership: Western Cape: saimeche.wc@vodamail.co.za

Company Affiliates Alstom Power Service SA

RSD a division of DCD-Dorbyl

Babcock Africa Limited

S.A.M.E Water

Bateman Engineered Technologies

Sasol Technologies

Bosch Projects

SEW Eurodrive

Fluor SA

Siemens

GEA Air-cooled Systems

SNC-Lavalin SA

Hansen Transmissions SA

Spicer Axle SA

Hatch Africa

Spirax Sarco SA

Howden Power

Technical Systems

Howden Projects

Thyssenkrupp Engineering

Industrial Water Cooling

Transvaal Pressed Nuts & Bolts

MBE Minerals (SA) (Pty) Ltd (previously KHD Humboldt Wedag SA)

Total Productive Maintenance (TPM) is a systematic approach to understanding the functions of equipment, the equipment's relationship to product quality and the likely causes and frequency of failure of the critical equipment components.

TPM prevents quality defects and breakdowns, eliminates the need for equipment adjustments, and makes the work easier and safer for equipment operators. TPM is aimed at maximizing the effectiveness of the organisation’s equipment through the optimisation of Equipment Availability, Performances, Efficiency and Product Quality.

To view calendar of 2013 events, visit www.saimeche. org.za or contact Linda Robinson or Carey Evans on (031) 764-7136 to procure a list of scheduled events.

Western Cape Branch Dinner and Dance Friday 9 November 2012 7pm for 7:30pm

Ultra-Flow Engineering Services

Megchem Eng & Drafting Services

Vital Engineering

Mod-U-Flow

Weir Minerals Africa

Osborn Engineered Products SA

Winder Controls

3 Course meal with complementary table wine R200 per person or R2000 per table Cash bar available Contact Bev on email: saimeche.wc@vodamail.co.za

Rotek Engineering

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October 2012

THE SA INSTITUTION OF MECHANICAL ENGINEERING

SAIMechE John Orr Lecture 2012

By Dr Bernard Fanaroff, Project Director: Square Kilometer Array South Africa

SAIMechE hosts the prestigious John Orr Memorial Lecture each year to commemorate the achievements of Professor John Orr (1870 – 1954) in engineering education in South Africa.

The history of this prestigious lecture dates back to 1961 when the first lecture was initiated to honour Professor Orr. This year the John Orr Lecture will be delivered

by Dr Bernard Fanaroff.

D

r Fanaroff studied physics at the University of the Witwatersrand and was awarded a PhD in Radio Astronomy from Cambridge University. He taught at the University of the Witwatersrand and then worked as a union organiser for nineteen years.

He has served South Africa in many official roles: Deputy Director General in the Office of President Nelson Mandela Head of the Office for the Reconstruction and Development Programme Deputy Director General of the Department of Safety and Security Chair of the Integrated Justice System Board Chair of the Steering Committee for Border Control.

Dr Fanaroff is presently the Project Director of SKA South Africa.

The lecture will be held at Wits University on 27 November 2012, starting at 18h00. The lecture will be streamed live via video web streaming and may be available at other centres (to be confirmed): Full information will be available on the SAIMechE website - www.saimeche.org.za, then go to Calendar, and see above event listings, or contact Anisa at our National office on (011) 615-5660.

About John Orr:

John Orr was born in 1870 in Lancshire and in 1887 entered Glasgow University where he graduated

BSc in Mechanical and Electrical Engineering. He received further technical education at Coatbridge Mining College and the Royal Technical College, Glasgow. In 1893 he was awarded a Whitworth Medal and Exhibition, tenable at the Royal College of Science, London. He gained further practical experience in Scotland and England before coming to South Africa in 1897.

Initially he was attached to the School of Mines of the South African College in Cape Town (which later became Cape Town University), but a year later went to the Kimberly Branch of the School of Mines as the Professor of Mechanical and Electrical Engineering. He retained his professorship when the School Dr Bernard Fanaroff was transferred to Johannesburg in 1903 as the Transvaal Technical Institute. After several changes of name, this organisation became the University of the Witwatersrand in 1922, and Orr’s chair became the de Beer’s Chair of Mechanical Engineering.

In 1952 he resigned to organise mechanical education at the Witwatersrand Technical College, where he remained until he retired in 1945. He was awarded the honorary LLD by the University in 1936. A Mechanical Engineering Chair and a wing of the Mechanical Engineering Laboratory at the University of the Witwatersrand are named after him.

He was a man of wide interests. He was President of the forerunner of the present South African Institution of Mechanical Engineering in 1908/ 09, President of the South African Association for the Advancement of Science in 1917, he helped to establish the South African Standards Institution in 1907, and was awarded an OBE in 1919, the Silver Jubilee Medal in 1935, and the Coronation Medal in 1937. He also directed technical training for the army and industry during World War 11.

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COVER STORY

High Efficiency Motors

Ray Williers, BMG technical manager, is doing a rotor test on BMG’s new range of Synergy IE2 electric motors

BMG Drives has extended its range of electric motors with the introduction of its premium specification Synergy series. This new generation product range incorporates high level specifications and features.

“E

team including electric motor designers, engineers and quality managers, to develop BMG’s flagship range of Synergy series, high performance, superior efficiency and rugged duty electric motors.

“These new Motoline Synergy IE2 motors set the benchmark in arduous duty, premium efficiency motors.”

Develop a premium efficiency IE2 motor using superior materials, with a matched construction configuration, to provide a platform for subsequent efficiency improvements Optimised

“BMG – Bearing Man Group - is an entirely South African company, with products, services and response attitudes that are critically focused on assisting local manufacturers to be globally competitive and profitable.

In the design of the Synergy series motors, every component, together with pristine manufacturing methods, has been optimised for ultimate performance and reliability. Quality control of the manufacturing processes and components, as well as the testing of finished motors, is managed in the manufacturing facilities by an SABS trained engineer.

“The company has mobilised its highly experienced

The design team’s goals were to develop a premium

Graeme Neilson, general manager, BMG’s electric motors division

8

lectric motors consume two thirds of the world’s electricity, yet the vast majority of these motors are not optimised to consume the minimum energy and deliver maximum reliability,” says Graeme Neilson, general manager, BMG’s electric motors division. “Low cost construction of motors, at the expense of quality and features is often a manufacturer’s primary target. This approach ignores the total cost of ownership and frequently results in motors which fail to perform in an efficient and reliable way.

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COVER STORY

efficiency IE2 motor using superior materials, with a matched construction configuration, to provide a platform for subsequent efficiency improvements, such as IE3 standards as these technologies reach commercial viability.

The tooling and manufacturing methods were scrutinised and improved to eliminate common ‘below the skin’ manufacturing defects which are undetectable without special equipment, but which nevertheless effect efficiency, performance and reliability.

Housing design

The class leading quality of these motors is characterised by a premium housing design which reflects the high standard of the internal design of the Synergy series.

The result is that BMG’s Synergy series, which is SABS certified, encompasses the latest technology in electric motor design. This translates into production efficiency advantages for the South African manufacturer.

An important performance feature of the Synergy range is that the motors are most efficient when running at 50%, 75% or 100% of full load, where energy savings of up to 3% can be achieved. Energy savings of up to 30% can be achieved by ensuring that all other mating components, like the gearbox and couplings are energy efficient and correctly fitted.

Important advantages

Apart from energy saving – a critical issue facing this country – high efficiency motors have important advantages over standard electric motors. These benefits include longer service life, suitability for voltage variation applications, reduced temperature rise and minimal maintenance requirements.

BMG’s IE2 electric motors have new features which include an IP66 rating for the motor enclosure for enhanced protection against dust and water, Class H insulation for safe operation in high temperature applications and an oversized terminal box for easy access to the cables. These motors, which are SPM ready, have a Class B temperature rise and a removable gland plate, from frame size 132.

Energy savings of up to 30% can be achieved by ensuring that all other mating components, like the gearbox and couplings are energy efficient and correctly fitted The bearings are lubricated with high temperature grease for reliable performance. An added advantage is all components are interchangeable with IE1 motors.

Other motors in the BMG Drives include cast iron and aluminium motors, as well as pad mounted motors for fans, poop pump motors and HV motors from 260 kW to 4 mW. A wide range of vibrator motors is also available.

Support

BMG Drives is uniquely positioned to meet the exact gear drive and motor requirements of contractors, designers and the end-user in diverse industries.

A team of technicians, with extensive experience, offers a technical advisory and support service and a substantial stockholding is held at regional centres for quick and efficient delivery throughout the entire Southern African region.

Graeme Neilson, Electric Motors, BMG Drives, Bearing Man Group, Tel: (011) 620-1500, Fax: (011) 620-1775, Email: graemen@bmgworld.net, Website: wwww.bmgworld.net

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MONTHLY COLUMN

Prominent Professionals Johnny Coetzee, Head of Engineering, AngloAmerican Thermal Coal

award for the civil design, with the latest award being the Department of Mineral Resources’ safety flag award for the year 2010/11, the highest and most prestigious award given to a mine with an excellent safety record.

Academic School

Future – a concept, a dream or a wish

Welkom Gymnasium High School.

Graduate studies

From a mining perspective, safety has always been a huge challenge. My dream, which is in fact steadily becoming a reality, would be to operate a mining machine underground, particularly under difficult mining conditions, from the safety of a control room above the ground.

National Diploma for Technicians (Mechanical)

Post-Graduate

Government certificate of competency.

Professional Bodies

ECSA – registered as professional certificated Johnny Coetzee engineer.

Projects

Career Path

Most challenging

First employer

Started at Anglo Gold in Welkom as an engineer in training.

Growth path

Worked as Section Engineer at President Brand Gold Mine, different shafts until 1996. Then transferred to Anglo American’s coal division at Goedehoop Colliery as Section Engineer.

Soon became an Assistant Engineering Manager before a promotion to Engineering Manager at Kriel Colliery. After two years got involved until 2005 as Engineering Manager to build Anglo American’s new coal mine, Isibonelo. Then became Head of Engineering in charge of all Eskom dedicated mines. Two years ago, became the Head of Engineering for Anglo American Thermal Coal.

Present employer and position

Head of Engineering, Anglo American Thermal Coal.

Most rewarding

The Isibonelo project, mainly because it was my first greenfield project with its own unique challenges. Apart from unique technical challenges, it was a great experience to work with a large team covering all engineering disciplines.

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

Engineering in general is running out of engineers with experience and practical skills. The gap between older experienced engineers and the young generation now emerging is too big.

Achievements A project

The Isibonelo project was a particular personal milestone in my career. We started this open pit mine as a greenfield project. This included the integration of people and equipment from Sasol’s Syferfontein Opencast Mine, as well as building the infrastructure, opencast crushing plant and conveyor systems and finally commissioning the mine. This involved design work which had to be facilitated and implemented to get the operation going. My team’s main success with this project was to complete it on time and within budget and more importantly, safely.

Any awards

The Zondagsfontein project. The shaft sinking and equipping was a particular challenge, especially when we were exceeding the project programme. Underground mining machines, for example, were lowered down with a mobile crane because there were time constraints the conventional way. We had to engineer solutions around this problem.

The Isibonelo mine’s modular bunker design received a national

How would you mend this?

We need to fill this gap in getting structured processes in place through which young engineers can be trained and equipped to become professionals. This can be achieved through coaches and mentors. After all, people are your biggest asset and we’ve got to take them through a structured process to achieve success.

Message to young engineers

Work hard and when entering a specific direction in engineering, pick a mentor to assist you through a structured plan of where you want to be with your career as a professional.

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POWER TRANSMISSION

Laser Alignment Aligning the shafts in a drive train installation has traditionally been undertaken in a number of ‘oldschool’ ways using a straight-edge with feeler gauges or different dial indicator methods like reverse dial or rim-and-face methods. Today there is laser alignment. To hear more, “SA Mechanical Engineer” visits Christo van der Walt, managing director of Engineering Dynamics in Pretoria, specialists in laser alignment and vibration monitoring solutions.

The trend

“End-users are increasingly demanding proof of specific and certified tolerances in terms of alignment which can, frankly, only be achieved with laser technology and its built-in documentation and reporting features,” Christo says. “The importance of proper shaft alignment has come to the fore because maintenance engineers have become more aware of the costly damage that misalignment brings about in reducing bearing life significantly often resulting in premature failure.

Christo van der Walt, Engineering Dynamics

“Thus we’re now focussing on all aspects of machine alignment, not only shaft alignment during instal-

Turbine alignment

lation, but also on bore alignment inside large engines and gearboxes, especially the rebuilds and refurbishments,” adds Christo. “Our equipment can also be used to check the spindle direction on machine tools ”

Engineers have become more aware of the costly damage that misalignment brings about in reducing bearing life significantly often resulting in premature failure Fine tolerances

Engineering Dynamics is the South African distributor for Easy-Laser, a Swedish portable laser alignment system which comes in a wide range of models for specific applications such as shaft, bore and turbine alignment. “In the past it was acceptable to do alignment to within a tenth of a millimetre, but with lasers we work to a thousandth of a millimetre,” explains Christo.

“Most of the time live adjustments can be made with the result showing graphically on a colour screen immediately, saving precious installation time and reducing machine downtime dramatically.”

Soft foot

However, alignment of a drive train starts even further back. “Many make the mistake of not even looking at the pre-alignment requirements and then they battle endlessly to align the machinery,” says Christo. “Pre-alignment checks highlight factors like ‘soft foot’, a condition where, as you’d get with a wobbly table when one leg is shorter than the others, one of the machine’s feet is not flat on the base which causes machine distortion.

Most of the time live adjustments can be made with the result showing graphically on a colour screen immediately

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THE SOUTH AFRICAN MECHANICAL ENGINEER

“Soft foot will cause distortion and stress on the machine’s frame which can result in severe machine

VOL 62 October 2012

POWER TRANSMISSION

damage,” he adds. “ In some cases there will be a measurable rocking of the machine, known as gross soft foot which is easy to discover and correct with shims. However, smaller distortion problems can only be detected with a laser alignment system, yet can go on to cause worsening alignment problems that lead to machine failure.

Propeller Drivetrain

Combination of factors

“Soft foot can be measured and diagnosed, but is usually caused by a combination of various factors such as a warped, bent frame or base plate or an uneven, damaged foundation,” explains Christo. “Other factors are broken or bent machine feet, loose bolts or too many shims under a machine foot in an attempt to align the machine.”

Soft foot is a frequently overlooked condition which makes alignment of two shafts almost impossible.

“For this reason it is important to make soft foot checks an essential part of the pre-alignment process,’ says Christo. “These checks not only require a good laser alignment system, but the system should also be able to diagnose soft foot, not just measure it. Any of our shaft alignment systems can be used for this purpose.”

Graphically showing results of alignment measurements

Smaller distortion problems can only be detected with a laser alignment system, yet can go on to cause worsening alignment problems that lead to machine failure

Bore alignment

The Easy-Laser system’s flexibility makes it a piece of cake to adapt the same instrument to measure the bore alignment in diesel engines. “Simply by using one of the installed applications on the display unit and special fixtures for its detectors, the system can also be used to measure the linearity of the bores for the crankshaft in an engine block,” explains Christo.

The system can measure the vertical and horizontal linearity of the bearing pockets before the client starts machining the bores as well as after the machining process. In the past there wasn’t really a quick and accurate way to check that the pockets were 100% in line. Clients had to make do by measuring using optical methods which require skilled operators. Now laser technology makes it possible to check the linearity of a whole row of pockets very quickly and with high accuracy.

In every toolkit

“In our experience this feature is growing in popularity fast among engine refurbishing companies because they can now document and show a client how much the crank direction was out previously compared with the new end result. This is important to negate any claims against the rebuilder should a bearing fail and to possibly shift the attention Aligning a pump installation

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POWER TRANSMISSION

Line bore engine

Pulley alignment

System should also be able to diagnose soft foot, not just measure it to the company that did the final assembly of the engine,” says Christo. “Marine engineers use the same principle to align the drive/propulsion system in ships. In the past this was carried out by using the piano-wire method to align the engine, a long drive shaft passing through several mountings and the propeller. Laser simplifies this long tedious task to a straightforward, quick operation.

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“Mechanical components like bearings and gears are designed for normal operating loads and therefore any additional external forces such as those created by misalignment, will reduce the life expectancy of these components,” Christo says in conclusion.

“Laser alignment equipment should be part and parcel of any service technician’s toolkit today.”

Christo van der Walt, Engineering Dynamics, Tel: (012) 991-3168, Email: christo@edprevent.com

VOL 62 October 2012

OPINION

Soapbox On his rounds, Kowie Hamman, our Editor, is conducting an informal survey on the lighter side of engineering.

We follow up from last month with two pertinent questions.

Does your spouse understand exactly what you really do?

Tom Esterhuizen of Tom Esterhuizen & Associates

My wife knows exactly what we do, in fact she’s at reception, our office manager.

Where is your favourite holiday place in South Africa? (why?)

Chris Coetzee of Resonant Solutions

Gouritz Mouth. It’s one of areas in South Africa where you can literally leave your wallet outside for a week and it won’t be taken. There you drive past a farm entrance where they leave pumpkins in a basket at the gate and you simply take one and leave the money in the basket, they trust everyone will do that.

Rudolph Beer of Martin Engineering

Everywhere in SA, because it’s a beautiful country.

Chris Coetzee of Resonant Solutions

I don’t think she really understands, but that’s not her fault, it’s mine. I particularly don’t take work home, but there is an up and a downside to this.

Rudolph Beer of Martin Engineering No.

Willem Sullivan of Hansen

No, because I am a man and tend to not talk enough according to her. But she understands the high level work I do, not the nitty-gritty stuff.

Greg Perry of SEW

Yes, she has a good idea.

Brian Volk of PHC Projects

She understands what an Engineer does but is not really aware of the specifics.

Phildy Schlotz of DRA

Yes, my wife is an architect and understands projects very well, especially the construction environment.

Thalefang Mtombeni of Schaeffler

I am single, no partner…

Izak van Niekerk of Bell Equipment

Yes, but I don’t understand what she really does, she’s an architect, but in IT...!

Willem Sullivan of Hansen

George, it is too pretty for words.

Brian Volk of PHC Projects

Current favourite place is Umhlanga as it is a place where I can just relax and not have to rush around.

Phildy Schlotz of DRA

Several places. We started touring recently and that got me hooked on exploring new and different places all the time.

Thalefang Mtombeni of Schaeffler

I’m absolutely gaga about Durban. The people and the vibe there is just amazing. It may not be as scenic as Cape Town or as vibrant as Joburg, but I just love going there because it’s just one big ‘jol’ where everyone is relaxed and wouldn’t care of you go to the mall in your shorts and flip-flops.

Izak van Niekerk of Bell Equipment

Cape Town, not only in SA, but in the world!

Cape Town has everything from beautiful people to nature, the best food and wine and a relaxed vibe like you’re on permanent holiday! I like holidays...

Tom Esterhuizen of Tom Esterhuizen & Associates

Where I grew up, in the Lowveld. However, I also favour Cape Town, that’s why we moved here two decades ago.

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COMPUTERS IN ENGINEERING

Labour Productivity – Hidden Treasure A new comprehensive factory management system designed from the shopfloor up to improve functions from quoting to despatch with particular emphasis on labour productivity, has hit the market. John White of BizmanTools Productivity kicks off by speaking to “SA Mechanical Engineer” about labour productivity.

“A

sk any group of line managers involved in production, if their company has a written disciplinary policy and you can be sure that the vast majority, if not all, will respond in the affirmative! Many will also make use of dedicated HR departments and/or external consultants.

Now ask the same group, how many of them use written labour performance standards in the management of their operations and you will probably find that fewer than 10% say they do.

A large portion of the wage bill is simply thrown away every month Disciplinary issues generally have limited financial impact on a business because they tend to affect a minority of staff for short periods of time. However, productivity issues tend to affect the majority of staff all the time and consequently have a large and continuous financial impact.

I’ve been measuring labour productivity in South Africa since 1985 and from experience I can tell you that in the absence of objective management, you can expect productivity levels ranging from 20% to 60%. In other words, a large portion of the wage bill is simply thrown away every month.

This lost production represents a massive hidden treasure just waiting to be recovered.

Short term gains

The mystery to me is that while we all know that South African businesses need to become more competitive both locally and internationally, the recovery of this treasure is seldom a top priority and sometimes is ignored completely. My theory is that we have come to expect management of the shop floor to be constantly problematic with line management having to “police” the shop floor continuously in order to get things done.

How many times do frustrated managers huddle together to berate the poor productivity of their workers and long to find “Attila the Hun” to be their next line supervisor in the hope that a strong man (or woman) will improve things in the factory? The problem is; even if you find somebody to sort things out, unless the solution becomes entrenched in a system belonging to the business, the productivity gains may disappear when your “strong” man moves on.”

Endless reports

Two issues must be addressed before the employer can implement a successful productivity improvement programme. The first is knowing exactly what is expected from staff, and the second is a record-keeping system to associate work done with individuals and/or groups. Explains John, “Traditionally, you solve the first issue by developing production standards from time studies either yourself or using external consultants. The second issue tends to be problematic; the last thing you want to do is turn your workforce into clerical staff writing endless reports instead of producing your products and services. And I have personal experience of these issues.”

John is an engineer by training and spent more than 25 years running a variety of production operations here and in the UK from food packaging to marine and industrial heat exchangers and furniture, to name

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COMPUTERS IN ENGINEERING

a few. He then became a computer programmer in self-defence in order to make the tools he needed to get things done. Since then, he has concentrated on writing business applications for the last 20 years.

Frustrated managers long to find “Attila the Hun” to be their next line supervisor in the hope that a strong man (or woman) will improve things in the factory?

More than productivity

From the get-go

“It’s a law of physics and fact of life that if you pay attention to something it will change. So with this in mind, BMT - Productivity is designed to allow managers to get started right away by "paying attention" to productivity in their business whether work standards already exist or not. Existing standards will be confirmed and new ones will be developed as you go. Data collection is reduced to an absolute minimum and does not involve worker time sheets; you simply need to establish “who did what”. The result is real productivity management up and running within weeks instead of many months, years or never” says John.

BMT-Productivity has evolved into a complete factory management solution. In addition to the core productivity system, the programme offers advanced quoting and re-quoting for standard production and jobbing environments with full automation of the bill of materials, plus materials management,

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production scheduling, finished goods management and it even has a dispatch management section to control the loading of trucks and monitor PODs. The program features a “Work In Progress” control panel designed to allow management to view the progress of all jobs in the factory in real time as production data is entered, with “drill down” for details as required.

“The whole ethos of BMT-Productivity is to get more done with less effort and so I took great care when designing the quoting system to combine quoting power and flexibility with ease of use and speed,” says John. “By providing software tools to make every aspect of work easier and more fun, it is only natural that people become more productive.”

By integrating quoting with the management of everything that follows such as raw material purchasing, stock control, works instructions, labour productivity, finished goods control and dispatch, employers can sharpen up their business like never before. “Our software gives all the objective information needed to improve productivity across the board and close the reality gap between what you would like to do and what you actually do,” John concludes.

Bizman Tools, John White, Tel: 084 622 7410, Email: john@bizmantools.com, www.bizmantools.com

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BUSINESS

All Together Now! A collaborative environment could effectively deal with the two most common disputes between the sales and financial departments that often require the intervention of a third senior manager. In the first dispute, your sales person has spent weeks negotiating the conclusion of a large deal only to find the customer’s account has been placed on hold due to non-payment. In the second, the financial department blames sales for not passing on the information that the customer had hit a rough patch.

R

estricting access to one person or department at a time and severely limiting the number of available actions in the name of standardisation will do more to drive the customer to your competitor than your competitor could ever do. Welcome to Business Process Management (BPM).

The collaborating team is greater than the sum of all its parts Collaborative

With BPM a variety of people or departments – such as sales, CRM, technical, accounts, marketing – could quite feasibly require simultaneous access to the account in order to fulfil one of the countless actions required when handling such an account.

There is growing recognition that the more complex types of business processes – such as employee management, customer management, and claims management to name a few – require an altogether different form of management practice. Indeed, Forrester Research says that today’s approach to business processes must support shifts in regulations, customer expectations, and worker demands that require a more ad hoc and collaborative management approach.

Research houses and business analysts have settled on naming this practice ‘adaptive case management’ which Gartner describes as capturing the backwards-and-forwards nature of human interaction to reach a specific outcome.

There are considerable returns to be had from addressing your unpredictable business processes with case management. Going back to the example of managing a customer account, few companies would be able to access a complete view of a customer

account at any given time. This is because portions of the case have been distributed throughout the company – such as sales, accounts and service – and remain isolated from each other. However, if the company draws all these portions into a central view, management will immediately see significant improvements in operational transparency, case insight and business intelligence. In turn, the ability to immediately view the case – whether it be a general overview or a detailed statement – means management can monitor activities effectively and step in to address any risks far more rapidly.

Case management

What’s more, the central repository enables the various departments working on the case to collaborate simultaneously and effortlessly. Driving human interaction has an enormous ability to positively affect business outcomes, particularly when this collaboration is multi-disciplinary or encompassing of the various departments that previously operated in isolation.

The salesperson picks another customer to target based on the account status, the finance department is able to capitalise on the insights gained into the customer’s health by the sales department in its regular engagements with that client and, even traditionally possessive employees, soon come to realise that the collaborating team is greater than the sum of all its parts.

Tim Stanley, Tel:(011) 513-3414 Email: Tim.Stanley@global360.com, www.Global360.com

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DEVELOPING SKILLS

Infrastructure Demand South Africa is not training enough engineers, artisans and technicians to deliver the long-awaited R845-billion government infrastructure projects in the pipeline.

T

his is the conclusion of the 2012 Infrastructure Sector Research Survey, carried out by executive search firm, Landelahni Business Leaders Amrop SA. “Across the world, crucial infrastructure schemes are competing for a dwindling skills pool amid fears that the skills shortage could delay projects in major markets,” says Landelahni CEO, Sandra Burmeister.

“Driven largely by China and India, construction is expected to grow globally by 67% over the next eight years.

Sandra Burmeister

Artisans

In 2006, South Africa produced a total of 3 222 artisans across all trades.

In 2010, this number rose dramatically to 11 778. “This is testimony to what government and business can accomplish by working together with a focused outcome,” says Sandra.

“The National Programme for Artisan Development (NAD) aims for another 50 000 artisans by 2015. Based on current figures, this is a high target.

“We must guard against a focus on quantity of certifications over quality. The pass rate needs to go well beyond its current level of 45%. Moreover, the focus needs to be on four-year, rather than one-year certifications.

“Only then will we make a significant impact in securing our artisan skills base for the future.”

“Meanwhile SA’s major construction companies are looking northwards to win a share of the huge infrastructure projects being rolled out across the African continent.

“The SA government’s ambitious infrastructure drive

is intended to jump start growth,” says Sandra. “The Medium-Term Expenditure Framework (MTEF) has set aside R845-billion for public sector infrastructure projects with a further R3,2-trillion infrastructure projects under consideration up to 2020.

A huge scale

“So far, around 25% of these are being financed and implemented. This means a R250-billion spend per year, about R100-billion more than the average spent over the past five years, including the FIFA World Cup.” Growth in sub-Saharan Africa is expected to be about 14% higher than that in South Africa. On the African continent $20-billion in infrastructure projects are already underway.

According to the 2012 KMPG Global Construction Survey, “new infrastructure projects are expected to be on a huge scale, so size and global reach will matter. With scale comes complexity as global players navigate tough political, commercial, regulatory and governance environments.”

Public sector capacity

In government, engineering skills have reached a new low, with a recent Consulting Engineers SA (CESA) report estimating that there are only 1 800 engineers across government (excluding state-owned entities) and more than 1 000 engineering posts are vacant.

The National Treasury reports that in 2010/11 government spent only 68% of its total capital budget. “Ramping up government capacity to implement R3,2-trillion of mega-projects is an enormous challenge and is likely to result in an increase of public-private partnerships,” says Sandra.

“We are already relying on international partners to bring expertise not available locally, as we see with Gautrain, the building of new coal-fired power stations, nuclear energy initiatives and the drive for alternative energy.”

“We simply do not have the right kinds of skills to meet the specific demands of huge new infrastructure projects,” says Sandra. “We continue to face the dichotomy of high unemployment among the unskilled and semi-skilled, and high vacancy rates for the highly skilled.

Engineering graduates

Of the 600 000 candidates who wrote schoolleaving examinations in 2009, only 22% passed maths higher grade and only 7% passed physical science higher grade. In the same year, only 28% of students in public higher education institutions were enrolled for programmes in science, engineering and technology.

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Total graduations (degrees and diplomas) across all engineering disciplines between 1998 and 2010 numbered 70 475, at a 13,8% pass rate. Of this total, 29 280 engineers graduated with degrees from universities, an average of 2 252 per year.

“There was an upward trend for black and female engineering graduates which is positive,” says Sandra. “However, the average university pass rate is 16%, far below the international average of 25%.”

Same situation as China, where only about 10% of the vast number of graduate engineers is considered globally employable Infrastructure-specific graduates

In the case of infrastructure specific studies, in 2010 electrical engineering university graduates numbered 899, followed by civil engineering at 847, and mechanical engineering at 766.

“Last year the Engineering Council of SA (ECSA) launched a national initiative to tackle the chronic shortages of engineering skills, in line with government’s somewhat ambitious plan to develop 30 000 engineers by 2014,” says Sandra. “This initiative remains severely hampered by the low maths / science pass rates at school level and the low graduation rate of engineering students.

“We should guard against getting into the same situation as China, where only about 10% of the vast number of graduate engineers is considered globally employable. Instead we need to focus on producing high quality engineers who can meet market demand in specific areas, and not lower standards to drive numbers that look good on paper.”

Professional engineers

ECSA data shows that, in 2010, there was a limited pool of 14 700 professional engineers registered across all disciplines, with many of these aging out of the market. “Gender remains an issue,” says Sandra, “with fewer than 3% female professional engineers.”

The number of candidate engineers is relatively robust at 5 600. However, according to ECSA, the conversion rate to professional engineers is low because lean organisations are not committing resources to the required three-to-four years of on-the-job mentoring.

“There is growing global demand for specialist engineering skills to deliver on new mega-projects,” says Sandra. “With this comes increased demand for professionals in risk management, information technology professionals able to support business and systems efficiencies, and executives capable of leading across multiple geographies and cultures.”

Remuneration

Remuneration packages will continue to spiral for those with specialised skills demanded by the market. Skills premiums for certain core business activities will continue to rise.

“A significant increase in investment in the development of graduates, young professionals and mid-tier professionals will help to balance supply and demand, and in the long run will be more cost effective.

“That means executive incentives should be aligned to increasing skills across the business, and not only to boosting bottom-line profits,” Sandra adds.

Global resourcing strategies

“Global resourcing strategies are essential to enable delivery of infrastructure investment in the face of increased mobility of scarce skills.

“Leaders of the future must be able to manage large businesses, projects and stakeholders across multiple geographies and cultures. Businesses will need to be able to offer both the breadth and depth of services – design, build, finance and operate,” Sandra concludes.

Landelahni, Sandra Burmeister, Tel: (011) 750-9536, Web: www.landelahni.co.za Contact Mark Bennett on Tel: (011) 781-1401 Email: samecheng@promech.co.za Website: www.promech.co.za to book your space!

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CESA

Award recipients at the CESA Aon Engineering Excellence Awards held at Vodacom World

Excellence Awards Consulting Engineers South Africaâ&#x20AC;&#x2122;s (CESA) Engineering Excellence Awards held at Vodacom World in Midrand on 15 August recognised innovation, quality, outstanding workmanship and professionalism in the industry.

T

he category of Engineering Excellence with a value greater than R250 million was won

by HHO Africa for the Upgrading of Koeberg Interchange for the Department of Transport and Public Works Provincial Government of the Western Cape with BKS receiving a commendation for the Upgrading of the Ben Schoeman Freeway for the South African National Roads Agency.

The category of Engineering Excellence with a value between R50million and R250 million was

won by BKS for the Safety Rehabilitation of Klein Maricopoort Dam for the Department of Water Affairs. The JW Waste Water Partnership comprising Knight PiĂŠsold Consulting, Zitholele Consulting, PD Naidoo & Associates and the WSP Group received a commendation for the Northern Waste Water Treatment Works, Sludge Drying Bed for Johannesburg Water.

The category of Engineering Excellence with a value less than R50 million, was won by Aurecon for the Meulwater Water Treatment Works for the Drakenstein Municipality. Goba received a commendation for the Brakspruit Bridge Project for Transnet Freight Rail.

In the category of Best International Project, Vela VKE Consulting Engineers was announced the winner for the Baia de Luanda - Luanda Waterfront Development with Bosch Projects receiving a commendation for the Ubombo Sugar Mill in Swaziland for Illovo Sugar.

Young Engineer of the Year for 2012 is Imraan Mahomed from BKS. CESA, Graham Pirie, Tel: (011) 463-2022, Email: gspirie@cesa.co.za, Web: www.cesa.co.za

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BLUE IS THE NEW GREEN

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POWER GENERATION

POWER

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

T O D A Y

‘Rediscovering’ Hydropower

Advertising: Mark Bennett Circulation: Catherine Macdiva DTP: Zinobia Docrat/ Donovan Vadivalu Disclaimer PROMECH Publishing does not take responsibility for the opinions expressed by individuals.

Copyright

TICKER TAPE

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

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

Channeling water flow for power generation

Of all the technologies available for green electricity generation, hydropower has been exploited the least in South Africa, not only because it requires specific topographical conditions, but also because generally the potential of this technology has not been fully explored by many.

Y

et, some of the smaller hydropower electricity generation installations in South Africa date back decades, long before anyone even thought of looking at alternative sources for energy.

Great potential

“The Hartebeespoortdam, for instance, has a hydropower station which was installed in the twenties, decommissioned in the sixties

NamPower could be ‘fast-tracking’ to 2016 its Erongo coal-fired project, located about 10 km east of Arandis, which is midway between Swakopmund and Usakos.

Namibia reportedly requires new baseload capacity by 2016 to avoid possible severe power outages.

WBHO is focusing on longer-term gas related infrastructure opportunities in Mozambique which could potentially include the construction of a new gas-fired power station in Mozambique for Eskom. Natural

and is now being considered for refurbishment,” says Wim Jonker Klunne, senior researcher, renewable energy at the CSIR Built Environment when “SA Mechanical Engineer” speaks to him about a hydropower research project he’s currently carrying out.

“Another example is the very first system in South Africa which was a 300 kW station on the slopes of Table Mountain, inaugurated in 1895.

gas has increased importance as an attractive source of power generation on the Mozambique government’s agenda since the discovery of a major gas field off the country’s eastern coast.

High-quality LED’s offer opportunities and solutions to the energy crisis, climate change, resource scarcity, safety in cities and productivity in offices. Efficient lighting could save Africa up to $10bn according to Philip’s internal market research figures.

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POWER GENERATION

development is becoming a challenge due to environmental and socio-economic concerns, and more recently its vulnerability to changing climates and hence water availability in the main water bodies, micro hydropower development continues to be an attractive resource especially in remote parts of Africa.” This is due to the fact that microhydro installations tend to use only part of the available water in rivers, making them less vulnerable to changes in water quantities due to climate change.

Exposing technology

Wim has compiled a database, housed on a special website, to promote the technology by giving it more public exposure. “The large knowledge base on technical aspects of microhydro in general does suggest a proper understanding of the technology,” he says. “However, the relatively small number of small and micro hydropower projects implemented in Africa suggests barriers, other than the technology, are still persistent.

Wim Jonker Klunne, senior researcher, renewable energy at the CSIR Built Environment

“There is enormous exploitable hydropower potential on the African continent, yet we have one of the lowest hydropower utilisation rates in the world,” Wim adds. “While large-scale hydropower

“Basic technical information on existing hydrostations is available, but it’s not complete nor consistent over the different information sources,” Wim adds. “This lack of information severely hampers the possibility of learning from past experience and is a barrier to the large uptake of small and micro level hydro.

There is enormous exploitable hydropower potential on the African continent, yet we have one of the lowest hydropower utilisation rates in the world

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“We have to make an unofficial generic distinction though between large hydro and small hydro,” he explains. “The most generally accepted definition for small hydro is around 10 MW of installed capacity, but recently some international donors seem to use a maximum capacity of 15 MW when referring to small hydro. Within the range of small hydro, the distinction can be made between mini hydro, often limited to an installed capacity of maximum 1 MW, micro hydro which is below 300 kW, and pico hydro which is below 20, 10 or 5 kW, each with its own specific technical characteristics.”

Africa

Many countries in Africa have a rich history of small scale hydropower, but over time large A hydropower unit in numbers of these stations have fallen in disrepair. Some because the national grid reached their location but others because of lack of maintenance or pure neglect.

“Recent initiatives have attempted to revive the hydropower sector in a number of countries in Africa, either through international development agencies or through private sector led initiatives,” says Wim. “This includes countries in Central Africa like Rwanda, East Africa’s Kenya and Tanzania as well as Malawi, Mozambique and Zimbabwe in Southern Africa where new initiatives are focusing on implementing small scale hydropower projects.”

Barriers

TICKER TAPE

The challenges facing micro hydropower exploitation in general are many, most of them to do with the general barriers for the uptake of renewable energy and independent power producers. “These generic barriers can be summarised into a lack of clear-cut policy on renewable energy and associated requisite budgetary allocations to create

Swaziland

Recent initiatives have attempted to revive the hydropower sector in a number of countries in Africa an enabling environment for mobilising resources and encouraging private sector investment,” says Wim. “Also, there’s an absence of lost-cost, longterm financing models to provide renewables to customers at affordable prices while ensuring that the industry remains sustainable.”

Specifically for micro hydro, large scale implementation is hindered by: Lack of access to appropriate technologies in the mini, micro and pico hydro categories which, because of small heads and high volumes or very high heads and low volumes, pose special technical challenges.

Lack of infrastructure for manufacturing, installation and operation. Most African countries do not have the facility to manufacture even the

The Energy Division of WEC Projects is implementing South Africa’s first biogas-to-power plant at a municipal wastewater treatment works. Biogas can be used to fuel gas engine generators at treatment works and provide a percentage of the electricity these plants use for operation.

Cheap solar energy from photovoltaic cells will be at grid parity with Eskom by 2015. PV energy is set to be cheaper than Eskom’s coal-generated electricity by 2017.

PV energy is created by panels using solar radiation.

Murray and Roberts has positioned itself to provide operation, maintenance and efficiency enhancement services to the power sector. It has been difficult for Eskom to keep up with the maintenance programme for its coal-fired power stations because of the shutdown periods and low supply-demand margins. M&R is starting to grow its engineering capacity again in areas outside of its involvement in the existing contracts of Medupi and Kusile.

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most rudimentary turbines or parts that might be critical in maintaining the schemes.

Lack of local capacity to design and develop small hydropower schemes for areas sometimes considered too remote. Generally, most African countries lack the ability to undertake feasibility studies or detailed ones including detailed design and costing of the schemes even for small hydro sites.

Several initiatives are currently ongoing on the continent aimed at installing a large number of microhydro schemes to serve rural populations.

Although quite a lot of information is available on the technical aspects of these projects, little has been published on implementation models.

Very clearly the inclusion of entrepreneurs or private sector developers could benefit the sustainability of the systems

A hydropower station in Lesotho

The way forward

“Judging from the analysis of a number of the current initiatives, it is very clear that microhydro developments need to be embedded in a national programme for capacity building and industrial development to foster a new industry to emerge,” Wim elaborates. “Particular attention needs to be given to governance issues as experience shows that linkages with ongoing economic activities will ensure proper management of the system.

“Very clearly the inclusion of entrepreneurs or private sector developers could benefit the sustainability of the systems, although mostly a requirement is that developments feed into the national grid as this ensures a steady income stream for the enterprise.”

Feeding the grid

Hydropower on a farm near Sabie

TICKER TAPE

Several African countries have established renewable energy feed-in tariffs which do support the establishment of small scale hydropower linked to the electricity grid. “Local stakeholders such as the private sector, financial sector and government entities need to be made aware of the opportunities for the technology,” concludes Wim. “Coordinated efforts need to be initiated to get this technology thriving again.”

Comprehensive technical information and a discussion forum on all forms of hydropower technology is available on two websites created specifically to disseminate and exchange information on hydropower systems and developments in Africa in general.

Wim Jonker Klunne, CSIR, Tel: (012) 841-3993, Email: wklunne@csir.co.za, www.microhydropower.net and www.hydro4africa.net

Saudi Arabian power and water group has confirmed that the 50MW Bokpoort concentrated solar power project, proposed for the Northern Cape, will be its first investment in Africa. The Greenfield Bokpoort development is one of several REIPP projects being supported by the state-owned IDC. The targeted financial closure date for Bokpoort is the end of 2012, with the developers having set the third quarter of 2015 as the commercial operation date.

It is estimated that the most simple of green wave tech-

nology can bring about savings of up to 10% in time, fuel and carbon emissions, if South African business embraced green wave technology. A green wave is an intentionally induced phenomenon in which a series of traffic lights are co-ordinated to allow continuous traffic flow over several intersections in one main direction.

Indian power company KEC International and Siemens have signed power distribution system improvement contracts with Kenya worth $12.6 million. Kenya Power says this will help steer their strategic plan to increase access to electricity to 50% of Kenyans by 2020.

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POWER GENERATION NEWS

Spraywater Control Valves PSV Mitech’s Globe Control valves for attemporator spraywater control have been operating successfully at a power station for over seven years with zero defects. The valve bodies were designed to ANSI 1500# with butt weld ends. The trims were a combination design with the ZZ trim at the bottom for the low-flow high-pressure drop startup condition, and a cavitation control trim at the top to handle the high-flow low-pressure drop running conditions. The tri-linear characteristic increased the operating range ability to over 100:1.

The valves are designed to operate with an electric actuator, and they have a standard type bonnet with stainless steel grafoil gaskets.

Stop-Start systems SKF announced that their rotor positioning bearing has qualified into the SKF BeyondZero Portfolio because it is an integral component of Stop-Start systems for micro-hybrid vehicles. In dense urban traffic, StopStart can reduce fuel consumption and CO2 emissions up to 15%.

Based on an annual mileage of 14 500km, this solution saves 75kg CO2 per vehicle per year.

Stop-Start turns off a vehicle’s engine when the vehicle stops at a red light or slows down in congested traffic situations, then restarts the engine quickly and silently when power is needed.

The SKF Rotor Positioning Bearing consists of a high performance mag-

netic ring clamped to a highspeed, high-temperature bearing. Together they produce a powerful, accurate, repeatable and durable magnetic field.

The strong magnetic impulses produced by the SKF rotor positioning bearing provide the starteralternator control system with the rotor ’s exact angular position, and enable the system to stop and start the engine quickly and quietly.

SKF South Africa, Samantha Joubert, Tel: 011 821 3500 Fax: 011 821 3501, Email: samantha.joubert@skf.com Web: www.skf.co.za

Co-generation

Psv Mitech, Greg Walker, Tel: 0860 778 778, E-mail: gregoryw@mitech.co.za Web: www.mitech.co.za A WEG 30 MVA 13869 to 2313.8 kV mobile substation solution distributed locally through Zest Energy, a Zest WEG Group Company

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POWER GENERATION NEWS Most Promising Technologies Concentrated Solar Power (CSP) on its own is probably the most promising of large-scale renewable energy technologies in South Africa, says Kadri Nassiep, CEO of the South African National Energy Development Institute (SANEDI)

He says it is too early to quote success stories but that for SANEDI, "the opportunity lies in positioning South Africa as a pioneer in this field, possibly leading to further innovative solutions.

Such was the case with dry cooling for Eskom power stations that were

CSP has the potential to be incorporated into South Africa's coalfired plants. According to Kadri there is a definite opportunity to consider steam augmentation of a coal-fired power plant using CSP. He explains, "With the reduction in coal consumption there is the added benefit of reducing overall plant costs due to shared components. The use of CSP extends to other aspects of electricity production including supporting the cooling cycle of the water used in power production."

CSP will allow South Africa to continue using coal in the case of steam augmentation plants. He continues, "This will benefit the coal mining industry in terms of jobs retained or created.

CSP's promise lies not only in the size and reliability of plants, but also in the capacity to store heat and use this heat during off-sun periods of the day.

located in water scarce regions."

Kadri adds, "CSP has a role, not only on its own, as has been seen in the Rebid programme, but also as a means of extending the life of the coal-fired plants that could be built in South Africa in the future. The localisation of components will, however, be critical in ensuring the technology thrives, as job creation and economic growth are at the top of the list of priorities for the green economy to succeed."

South African National Energy Development Institute, Kadri Nassiep,Tel: (010) 201-4700, Fax: (010) 201-4820, Web: www.sanedi.org.za

Kadri Nassiep

CSP may well be the closest to a base load power plant that renewable energies can provide for, without the costs becoming uneconomically high."

With a worldwide focus on saving energy and harnessing the heat produced by operating equipment, Zest Energy is having a great deal of success in integrating a biogas power source with the overall process to improve efficiencies and reduce production costs.

While effectively recycling the energy inherent in production processes, this approach also reduces harmful emissions such as methane and cuts down power overheads.

“We’re also introducing tri-generation to our customers, which involves generating electrical power, harnessing the heat produced by the operation of the mechanical equipment to optimise the process and further using the heat produced to provide cooling through the use of equipment such as absorption chillers,” says Zest Energy managing director, Coenraad Vrey.

“In this emerging area of our business we draw on our Spanish technology partner and generator set manufacturer, Guascor, for whom Zest Energy is the local distributor, as

well as WEG expertise and the expertise of the other companies in the Zest WEG Group.

This means that we offer one point of contact to give our customers access to a complete power generation offering.”

Principal contractor WEC Projects has awarded Zest Energy a contract to complete the cogeneration and electrical integration solution as part of Johannesburg Water’s first municipal waste water biogas to power plant with heat recovery. The project is currently being executed at the Northern Waste Water Treatment Works (WWTW), after which it will continue at Driefontein WWTW. In total at both project sites, five containerised Guascor SFGLD240 biogas generators will be installed and commissioned. Zest Energy has drawn in expertise from other companies in the Zest WEG Group for this project, including EnI Electrical and Shaw Controls.

Zest Weg Group, Jamie Wilson, Tel : (011) 723-6000, Email : jamiew@zest.co.za, Web: www.zest.co.za

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SAMHYDRAULIK, which is one of the leaders in the field of hydraulic transmission, has been operating for over 25 years in the international market, offering a complete range of orbital hydraulic motors and power steering units, axial pumps and motors for medium and high pressure ranges, all characterised by excellent performances.

SAMHYDRAULIK employs 120 people who operate inside a very modern and efficient plant that spans over 6 000 square metres to assure a high standard and flexible production capacity.

The latest computer technology is used for both design and production, combined with strict quality control procedures during all production phases, which translates into innovative, reliable and functional products that meet the various needs of the market.

Its ISO 9001 certification, held since 1994, is the result of a qualityorientated philosophy on which SAMHYDRAULIK has always based its operation.

A H 3214 Axiom Jan11 indd 1

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

THE SOUTH AFRICAN MECHANICAL ENGINEER 62 62October 2012 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL VOL May 2012

2011/03/14 10:58:12 AM

PIPES, PUMPS & VALVES

Joining Forces “United we stand, divided we fall,” is a common phrase used around the world to encourage people to join hands in achieving an objective which is in everyone’s interest. As competitive as individual businesses are, so can a united representative body bring benefits to all. This is what business clustering, or industrial clustering, is all about.

T

he case in question here is local valve manufacturing companies in South Africa, represented by Vamcosa, the Valve & Actuator Manufacturers Cluster of South Africa.

“SA Mechanical Engineer” speaks to champions of the cluster, Ross Hunter and Mark Wilson, to find out more. “Over fifty percent of the local valve manufacturers have so far joined Vamcosa to unite as a group,” Ross explains. “We felt we no longer had a vehicle in Savama, the South African Valve & Actuator Manufacturers Association, as many importers have joined them over the years, directly clashing with our objectives as local manufacturers.”

Ross Hunter, Vamcosa champion

“After many consultations with the dti (department of trade & industry) we concluded that forming an industry cluster would be the answer because the dti prefers dealing with group representation rather than with each individual company,” adds Mark Wilson. The dti has been promoting clustering for many years now, not only in a geographical sense as per the original definition of clustering, but also in terms of clustering types of industries together.

Clustering is very different from an association in that there has to be a fair amount of trust between the different manufacturers Clustering

“Our prime role as local valve and actuator manufacturers is to get the products we manufacture designated,” Ross explains. “The cluster is a subsidiary of the SA Capital Equipment Council and open to all local valve manufacturers who are truly 100% local manufacturers in terms of the body’s evaluation process. Clustering is very different from an association in that there has to be a fair amount of trust between the different manufacturers because certain company information has to be shared with everyone.”

At this stage, after two year’s ground work, Vamcosa has expanded to much more than just the designation process. Ross elaborates, “We’re involved in BEE transformation initiatives for members, export marketing, creating standards for the industry and all sorts of other things which are of a common in interest to all member companies. Under Savama,

Mark Wilson, Vamcosa champion

for instance, it wasn’t in everyone’s interest to lobby for an SABS mark on all products because then the imported products would be negatively affected.

We can now, through Vamcosa, push something like this forward much more effectively in order to control imports.”

Not rebels

Ross stresses that forming the cluster was not a case of a splinter group of rebels wanting their own way, but rather a method of protecting local manufacture and allied industries. “As companies which manufacture the entire product locally we, for example, directly support the distressed local foundry industry,” he explains. “Jobs and skills are protected in both the valve manufacturing and the foundry industry, in spite of our industry not modernising due to the lack of dwindling volumes as a result of imports.”

THE SOUTH AFRICAN MECHANICAL ENGINEER

AM

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PIPES, PUMPS & VALVES

“The main advantage of a cluster, compared with an association, is the fact that there aren’t office bearers who do all the work while everyone else sits back,” Mark adds. “Although we are the designated two spokesmen, everybody is actively involved making the organisation much more pro-active than an association usually is.

Huge amount of trust

“Mark and I were made the champions because of our common passion to get this initiative off the ground in order to save the industry from fading into oblivion,” says Ross. “Similarly, members of the cluster must all have a passion for their businesses, their future growth, skills development, job creation and supporting other local industries.

“There is a definite ‘culture’ requirement for clustering,” adds Ross. “In approaching certain companies, for instance, we might very well find that they don’t quite fit the culture of clustering, mainly because of the huge amount of trust which is required. We have a very strict code of ethics in our constitution otherwise just one rotten apple can destroy the whole barrel.”

Members of the cluster must all have a passion for their businesses, their future growth, skills development, job creation and supporting other local industries Ethical code

Admitting a new member to the cluster, therefore, involves a strict evaluation process initially. “When we look at potential new members, we evaluate them in terms of their manufacturing process and the amount of local content to ensure they are genuine local manufacturers,” says Ross. “Even just importing castings, for example, disqualifies a company immediately. We then vote on the company’s ethical and moral standing and then admit them or not. Similarly an existing member’s participation in the cluster can be suspended by a vote if the company no longer complies with the code of ethics.”

A typical example of the benefits of working in a cluster is the active export marketing initiative Vamcosa is currently working on. “Another strong emphasis is on getting standards in place for the industry,” Ross says in conclusion. “We have already established technical working groups with Eskom and plan to do so with other corporate end-users like Sasol, PetroSa, Transnet and the water boards. We’re talking genuine local manufacture by companies who have a proven code of ethics and a strong interest in preserving and growing the valve and allied industries on home soil.”

Ross Hunter, Vamcosa, Tel: (011) 882-8030, Email: rossh@rgrtech.co.za

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THE SA INSTITUTE OF TRIBOLOGY

Back to Basics Lubricant technology is advancing in leaps and bounds, essentially driven by the need to conserve energy.

Therefore nanotribology, biotribology, engineered surfaces, surface texturing, green tribology are all topics of great interest in the R&D field. Numerous international publications and seminars are being held on these issues. Statements are being made that the friction losses in a vehicle can be reduced by 61% within the next 15 to 25 years. These are big savings, and result in BIG energy (CO 2) savings.

T John Fitton

hese were the major issues that were being discussed at the International Joint Tribology Conference that was held recently and are the cutting edge that will hit us in the future.

However, from a Southern African perspective there are a number of more important and bigger issues that can be understood and implemented that will save energy, increase machine life and reduce overall costs. The most common question that I hear is “what is the price of the lubricant”, this should rather be turned around to “what is the cost of lubrication?” This is subtle, but significant.

An oil is no longer an oil More expensive lubricants on a cost per litre basis may result in reduced energy consumption due to lower internal friction, better stability and lower heat generation. This has been shown in a recent South African study that proved a significant 3 to 6 % energy saving in a gearbox, by moving from a mineral to a PAO based industrial gear oil. There is unfortunately a large caveat here, being that not all claims made by the oil marketers are true in ALL circumstances, and the machine operating environment (temperatures, loads, environmental condition and service periods) MUST be taken into account when choosing the correct lubricant for the application.

Price vs cost

Conducting lubrication surveys and root cause analyses are critical in understanding the cost

of lubrication for an industrial plant or piece of equipment. Reductions in lubrication breakdown and stoppages can have a significant saving on the bottom line and it could be as simple as improving the cleanliness levels of the lubrication fluids, or ensuring that the lubrication schedules are appropriately set and adhered to.

The product quality and specifications clearly need to match the operating environment as well as the machine manufacturer’s requirements. As the newer technology is being introduced these issues are becoming more and more critical and an oil is no longer an oil. Care should always be employed on the part of the end consumer that they are using the correct lubricants in the correct application or machine, and that it is of the correct quality and specification as is required by the equipment manufacturer. Just because “we have always used a specific lubricant in this application” does not mean that it is still applicable with newer or harder working machines, with higher loads, shorter residence times, higher ambient temperatures and smaller sumps. The use of non-compliant lubricants may affect machine warranties, machine life and energy consumption.

The bottom line is that energy savings can be made and overall costs reduced, by getting back to basics.

Understanding the cost of lubrication, rather than the lubricant spend is a step in the right direction and small increases in the lubricant price will reduce the cost of lubrication over time.

John Fitton The SA Institute of Tribology Committee Member SAIT, Gill Fuller, Tel: (011) 802-5145/6, Email: secretary@sait.org.za, www.sait.org.za

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Seize the Day Mines in Africa have limited resources in terms of reliable local service companies, so they often latch onto South African companies who happen to be on site with necessary skills and equipment to help out with engineering problems beyond the scope of the work they’re there to do in the first place.

of the projects they’re now doing all over Africa.

“It all started when we installed a new Swagelining slurry pipeline at a mine near Kolwezi over a year ago,” he says. “Mine management was so happy with the service they got from us that they asked us to do a couple of other small jobs since we had the people and equipment on site. This rapidly escalated into bigger projects and today we have over 100 people employed at Rare Congo, our affiliate company at Kolwezi.

Extending services

Wally van Coller

T

his happened to Rare, fluid conveyance specialists based in Midvaal between Alberton and Vereeniging, when the company sent a team to a mine in the Democratic Republic of the Congo (DRC) to install a pipeline.

“SA Mechanical Engineer” speaks to operations director at Rare, Wally van Coller, about some

It always starts with a new pipeline installation or the rehabilitation of an old pipeline and then progresses to other engineering work

“Naturally, these projects are more than just pipes and pipelines,” adds Wally. “Besides partnering with a local company who does the civil work, we had to tap from our in-house experience or employ people who could do the work required. For example, we’ve just completed a large ore-pass 500 metres underground for this open cast copper mine which also has an underground shaft. Although this was outside the scope of our usual work, we simply employed people who could design and install the civils, wear linings and conveyor systems to complete the job in seven months, a third of the time a previous contractor took to build an ore pass.”

A similar evolution has taken place in Zambia to bring about the establishment of Rare Zambia.

“Ghana and Botswana have joined the list as well to complement a number of current projects in South Africa,” says Wally. “It always starts with a new pipeline installation or the rehabilitation of an old pipeline and then progresses to other engineering work. So much so that we’ve re-aligned the company to Rare Projects and no longer do the manufacturing of pipe products as we used to in the past.”

Diamonds

A good example of this flexibility is the building of a diamond washing plant which involved concrete sumps with PPL tanks to collect effluent near the source and pump it above ground to a neutralizing pit. From there the neutralized affluent gets pumped into an HDPE evaporation pond. All the pipelines for this project were also installed by Rare. The company also offered the mine a long-term solution to semi automate the diamond washing process which they hope to install in the near future.

Pipe liners

Swagelining can be used on all types of applications where corrosion and abrasion impacts dramatically on pipe life

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THE SOUTH AFRICAN MECHANICAL ENGINEER

New pipeline work, installed above or below surface, as well as pipe rehabilitation, is mostly undertaken with Swagelining technology, a method of lining steel pipe with a HDPE liner to extend pipe life far beyond steel pipe’s normal life expectancy, especially in the case of slurries. “We have the sole right in Africa to this British technology,” says Wally. “Originally it was developed to rehabilitate leaking cast iron

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PIPES, PUMPS & VALVES

The Swagelinings technology to rehabilitate old pipelines

gas piping in England. Today we use Swagelining on all types of applications where corrosion and abrasion impacts dramatically on pipe life.”

The traditional method of rehabilitating a pipeline is to dig it up and replace, which incurs a major expense and is extremely difficult in the case of old pipe which may now run under built-up areas.

“Depending on the condition of the pipeline we can either use the Swagelining process or the CIPP (cured in place pipe) process to re-line the inside of the pipe to extend the pipeline life another lifetime,” explains Wally. The Swagelining process applies tight fit or interference fit HDPE liner inside the pipe in situ to protect it from further corrosion while cathodic protection will protect the outside. This lining with its lower friction improves flow which in turn reduces the power requirement from the pumping side.

The large ore-pass 500 metres underground

we provide all the technology and support to maintain and manage such systems into the future.”

Wally van Coller, Rare, Tel: (011) 906-8000 Email: wally@Rare.co.za, Website: www.Rare.co.za

On all types of applications where corrosion and abrasion impacts dramatically on pipe life Maintenance

“We’ve just completed a 900mm diameter concrete sewerage pipeline in Port Elizabeth but CIPP technology can also be used to fix leaking steel, asbestos and fibreglass water pipelines,” Wally adds. “The CIPP process is mainly for larger diameter pipe and consists of a process where a ‘sock’ of special needle punched polyester material soaked with tailor-made resins is pulled through the pipe, followed by either hot water or steam to cure the resin in the sock to form a new liner.” These liners can also structurally restore the original pipe.

All these technologies are brought to customers through a total cost of ownership scheme which Rare calls the Xtender management programme.

“Our business model is unique in that we not only supply all the equipment needed to get water from the dam to the end-user, but we’ve introduced several technologies to rehabilitate systems cost effectively,” Wally says in conclusion. “In addition THE SOUTH AFRICAN MECHANICAL ENGINEER

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EXHIBITIONS

INDUTEC 2013 Exhibition Management Services (EMS) has announced the launch of a European-style trade event based on research they have been conducting for the last three years.

D

esigned as an umbrella event for African industrialists, the South African Industry and Technology Fair, or INDUTEC for short, consists of 10 compatible, co-located title events targeting different sectors of industry. INDUTEC will take place from 14 to 16 May 2013 at Gallagher Convention Centre in Johannesburg.

Based on four of EMS’s already successful

and long-established industrial shows, INDUTEC 2013 will be adding six more industry focus sectors to its line-up. Three of these have attracted the attention and support of one of Germany’s largest trade fair organisers.

“Hannover Fair International, a subsidiary of Deutsche Messe, is supporting Intermac Africa, Manutec Africa, and Smart Automation Africa as suitable platforms for their international clients to access the South African market,” says Gotz Dormann, the company’s Managing Director.

Ten sectors

The 10 sectors profiled at INDUTEC are: Pumps Valves and Pipes Africa Watertec Africa Petro.t.ex Africa Intermac Africa (Industrial Technology, Machinery and Engineering Supplies) Manutec Africa (Manufacturing Technologies) Smart Automation Africa Afriplast Expo (International Plastics Industry) Energex Africa Industrial GreenTec Africa Empowertec Africa (Small Business Opportunities Showcase)

Hannover Fair organisers support new SA Industry and Technology Fair “By running Pumps Valves and Pipes, Watertec Africa, Petro.t.ex Africa and Energex Africa together in one venue in 2011 we proved that trade fair exhibitors and conference-goers in South Africa undoubtedly benefit from the critical mass and synergy generated by this co-location,” says John Thomson, Managing Director of EMS. “INDUTEC 2013 will be boosted by government initiatives such as the new R5,75-billion Manufacturing Competitive Enhancement Programme,” adds John. “It will also see benefits from the recently announced National Development Plan (NDP) which aims to improve manufacturing capability across all industrial and manufacturing sectors.

Serean Thomson, Tel: (011) 783-7250 Email: marketing@exhibitionsafrica.com Website: www.exhibitionsafrica.com

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SA INSTITUTE FOR NON-DESTRUCTIVE TESTING

Highest Qualification “A Non Destructive Testing (NDT) Level 3 Qualification and Certification is the highest qualification achievable in NDT, according to International Standards such as ISO 9712, and a very good starting point for a career as an NDT Professional”.

W

hile NDT Level 1 personnel focus on the actual testing and related inspection processes, the Level 2 focus more on the understanding and interpreting of International standards, as well as the evaluation of indications found, relative to the applicable codes. The Level 3, on the other hand, is responsible for the entire inspection process, the application of resources as well as the related infrastructure, including all quality-related issues and documentation.

Practitioners / tradesmen, technicians/ technologists and engineers have different levels of competency and skills, as required by the increasing level of responsibility during the design, manufacturing, or maintenance phases of engineering projects. Simi-

larly, each level of NDT qualification requires a specific set of knowledge and skill which is related to the increasing responsibilities ascribed to each qualification level by the applicable International Standards which governs the training and certification of NDT individuHarold Jansen als. Therefore, qualified and certified Level 2 individuals, with adequate experience, are preferred when considering prospective Level 3 candidates.

To this extent, the training of Level 3 NDT Professionals is not limited to classroom training, but knowledge and experience gained through research, studying, involvement and investigations in the related NDT method/technique, is compulsory.

Tertiary qualifications in either engineering or applicable scientific fields are recommended as a prerequisite for attending a Level 3 Workshop, due to the course being equivalent to a NQF Level 7 qualification (Four year Bachelor’s degree). Individuals intending to venture into the Level 3 domain must be highly knowledgeable, analytical, solution driven, dedicated, self-motivated, principled and hardworking.

From 2013, the SAIW will offer a Workshop to be presented in 4 Modules scheduled for the first weeks in August, September, October and November; with the examination to be performed during the first week in December. These changes have been implemented to provide more candidates with the opportunity to further develop and contribute to the growing global NDT market Harold Jansen, Tel: (011) 298-2107, Email: jansenh@saiw.co.za

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MARKET FORUM

First for dewatering pumps

Sorting results for diamonds

Sulzer Pumps has launched the next generation of dewatering pumps, developed for harsh conditions in the construction and mining industries. Available in two series, one for drainage (the XJ pump) and one for sludge (the XJS pump), the ABS submersible dewatering pump range is the world's toughest and smartest dewatering pump.

Apart from offering stable operation, long life and high portability, the ABS submersible dewatering pump range is packed with electronic intelligence called AquaTronic and AquaPlug.

These two features save energy, reduce wear and allow pump condition to be checked without disassembly.

The result is a pump made for the real world, with major benefits that include: correct motor rotation, motor protection, rapid assessment of operation/fault history, no control panels required and reduced energy consumption and wear.

The AquaTronic unit integrates electronic intelligence into the pump, while the AquaPlug control and monitoring module integrates it into the power supply.

Thanks to the AquaTronic unit, pumping with the ABS submersible dewatering pump range starts immediately with full capacity and runs consistently.

The direction of impeller rotation is always correct, as the AquaTronic unit electronically compensates for incorrect phase order. This is a first for dewatering pumps. In addition, the unit prevents unnecessary servicing.

With its USB link and a connected PC, pump diagnostics can be carried out rapidly and easily, without disassembly.

AquaPlug provides a range of control and monitoring functions, including automatic stop/start, optional level control, alarms and service indication.

Although the pump can be run continuously, AquaPlug can also be used to stop it when snoring. By stopping at dry running and starting automatically at a specified level, energy use can be optimized and wear can be reduced.

Sulzer Pumps, Jonas Enevold, Tel: 011 820 6000, Fax: 011 820 6200 E-mail: jonas.enevold@sulzer.com, Web: www.sulzer.com

40

CommodasUltrasort, the mining division of Tomra Sorting Solutions, has shown that diamond sorting with its X-Ray Transmission (XRT) belt sorter produces outstanding results. A pilot study between March and August 2011 on one of the world’s largest diamond mines, where CommodasUltrasort took a prototype XRT belt sorter and fed material with various throughputs and of various size ranges, produced a total recovery of between 98% and 100%.

The pilot was requested by the mine as they were seeking a new recovery method for large diamonds prior to tertiary crushing.

The advantage of XRT technology, as opposed to XRL, is that it sorts on an atomic density rather than according

to physical characteristics or properties such as relative density and luminescence. As the luminescence properties are not always consistent in diamonds, a technology was required that would recognise all diamonds regardless of their physical properties.

XRT is able to see the atomic make-up of each particle going through the detection zone of the machine. Therefore, a diamond, which consists of covalently bonded atoms forming so-called ‘diamond molecules’, appears in a distinct light-grey x-ray image.

CommodasUltrasort, Lütke von Ketelhodt, Tel: (087) 941-3840, Email: ketelhodt@commodas-ultrasort.com Web: www.commodas-ultrasort.com

The right connection “Our coupling footprint covers all industry segments,” says Voith Turbo South Africa Product Manager - Shaft to Shaft & Falk Couplings, Varma Parag. “Any industry, irrespective of its nature, is constantly striving to maximise productivity and minimise downtime”, continues Varma.

“To this end, industry has to find a balance between performance and savings on energy and maintenance but maximum performance simply remains non-negotiable because it directly affects productivity. The longer equipment can operate trouble and maintenance-free, the lower the total cost of ownership. With these factors top of mind, we supply a

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62 October 2012

quality range of, off-the-shelf couplings, as well as customised coupling solutions with the right capabilities designed to reduce wear and maintenance stoppages, increase service life and ultimately save money”.

The coupling range from Voith Turbo, includes Voith’s unique resilient and membrane coupling ranges, which are well complemented by Falk Gear, Grid and the Wrapflex elastomer coupling.

Voith Turbo, Varma Parag, Tel: (011) 418-4000, Fax: (011) 418-4081 Email: varma.parag@voith.com, Web: www.rsa.voithturbo.com

MARKET FORUM

Precision Cutting of Complex Materials

AquaJet Director, Preeshan Naidoo

Johannesburg-based Multi Alloys specialises in the supply and distribution of special grades of various corrosion resistant materials, which include duplex and super-duplex grades of high alloy 904L and 310 stainless steel, in addition to alloy grades of nickel, copper and titanium.

found that water jetting cutting is more efficient than the industry standard thermal cutting process, which often results in contamination or spatter on the back of the pieces being cut. This ultimately causes damage to the plate, while resulting in higher costs and prolonged turnaround times,â&#x20AC;? he says.

Multi Alloys managing member Ken Perel points out that the company specialises in the supply of corrosion resistant bars and plates, which are used to extend the lifespan of machinery and prevent premature failures of components in various industrial applications. When required, the products are cut into precisely specified sizes and dimensions by Aquajet Profiles, which makes use of the powerful cutting force of water and garnet sand to create a unique cutting tool known as a jet.

Aquajet director Preeshan Naidoo adds, â&#x20AC;&#x153;An additional benefit of water jetting is that it is considered to be the most environmentally-friendly form of industrial cutting. This is due to the fact that the jets produce no hazardous waste or emissions, and require a minimal amount of water, which is also fully-recyclable.

Whatâ&#x20AC;&#x2122;s more, the garnet abrasive is a non-toxic natural substance that can also be recycled for repeated use, ultimately ensuring compliance with more stringent environmental laws.â&#x20AC;?

â&#x20AC;&#x153;Multi Alloys has been an Aquajet customer for the past eight years, as the unique water jet cutting process allows us to achieve close tolerances without any machining. We have also

AquaJet, Preeshan Naidoo, Tel: (011) 908 5550, Fax: (011) 908 5551 (PDLO LQIR#DTXDMHWSURÂżOHV FR ]D :HE ZZZ DTXDMHWSURÂżOHV FR ]D

patterns to control the racquets using only a playerâ&#x20AC;&#x2122;s mind.

Bridging the Gap

CogniGame â&#x20AC;&#x201C; controlling automation components by the power of thought

It is becoming easier to comprehend the factory of the future with recent brain-computer interface (BCI), voice command and image recognition technology from Festo.

The company created a buzz at this yearâ&#x20AC;&#x2122;s Hannover Trade Fair when it showcased its rendition of a famous 1970s table tennis videogame, which, with a modern twist, uses carefully rehearsed thought

BCI technology measures voltage fluctuations on the surface of the userâ&#x20AC;&#x2122;s head â&#x20AC;&#x201C; as with electroencephalography (EEG) via a series of electrodes. This creates a communication channel between the brain and the hardware without any need for interaction from the user via voice or input devices.

Festo worked closely with CogniWare to develop this software solution that uses thoughts and biosignals to create instructions.

The concepts found in the CogniGame have practical implications in the modern factory by facilitating faster communication between humans and machines. In the factory of tomorrow, not all work sequences will be automated, so new operating sequences and concepts are needed to enable better communication, whether using joysticks, voice input and other interfaces.

Festo, Tracey Swart, Tel: 08600 FESTO (33786), Web: www.festo.com

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MARKET FORUM

FLTR Chris Heunes, Lester Fine & Klint Bawden with 27 Grindex Bravo 700 37KW 50HZ pump units developed to handle any highwear applications

+LJK ZHDU $SSOLFDWLRQV Known for their reliability, durability and dependability, Grindex pumps are popular in mining and construction industries for use in demanding applications. “Thanks to the motor protection relay in the control panels, the pumps can run unsupervised for longer periods,” says Klint Bawden, Grindex product manager.

Grindex's Bravo slurry pumps are designed for pumping slurry and other fluids with high concentrations of abrasives, like sand and stones, delivering between 30l/s and 140l/s. Typical applications

include dredging, cleaning of settling ponds, coal and ore slurries, bentonite, coal washing water, steel works, quarries, mines and many other industries.

As pumping slurry is one of the most demanding applications for any pump, parts require maintenance and repair costs are high. In many cases, frequent pump failures lead to costly production downtime. Also, excess sediment buildup in a sump cost time and money to remove.

problems by developing the slurry pumps that can handle any high-wear applications with an effective solution to the rising costs of slurry handling: “The robust, hard-working pumps lower operating and maintenance costs and offer excellent value in terms of initial investment,” concludes Klint.

Voith Turbo. Klint Bawden.

Tel: +27 11 418 4000, Email: klint.bawden@voith.com Web: www.rsa.voithturbo.com

Grindex has focused on solving these

Pump Repairs

a spray booth and drying chamber for Belzona protective coatings.

Director Flip van Heerden explains that the Secunda operation had expanded into three new markets over the past year: new pump sales, the repair of flame-proof pumps for the mines, and Belzona protective coatings.

He adds that a much larger facility had been necessary to accommodate new machinery that included equipment to handle rotating machines up to 10 tons.

“Our test bay allows us to accurately measure pump performance and to supply the customer with a performance curve that shows precisely how that pump is performing. If the test curve is not up to OEM specification, we specify exactly what needs to be done and how much it will cost to get the pump back to spec.”

Mechanical seals manufacturer Aesseal has formed a separate company, Aespump, to manage rotating equipment repairs in the Secunda area.

42

Aesspump has occupied its own building with newly-built test bay, new machinery and dedicated clean-room facilities for flameproof pump repairs. There is also

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Aesseal (Pty) Ltd, Rob Waites, Tel: (011) 466-6500, Fax: (011) 466-6588 E-mail: rwaites@aesseal.co.za, Web: www.aesseal.co.za

MARKET FORUM

Raise Your Glass environment is never compromised.

“Having made large investments in our winery and cellar, we use the most modern winemaking equipment and technology available in the industry,” says Marius Botha, production manager at Darling Cellars.

One of the winemaker’s greatest concerns is to protect the wine Atlas Copco’s Marius Botha in front of his filling machine. The from oxidation making NG27 handles a capacity of 6 000 bottles ph on the bottling line a dependable supply of nitrogen crucial A winery on the Cape West Coast, Dar- for pre- and after-bottling processes. ling Cellars, recently invested in Atlas Marius explains, “Wine is blanketed Copco’s nitrogen technology, leading with nitrogen during the maturation to significant improvements in their process and we use nitrogen to purge bottling process, while ensuring that oxygen from the bottles before filling with their commitment to quality and the wine. Nitrogen is also used to remove

excess wine during the levelling process.

Previously, we made use of nitrogen gas cylinders which were expensive and could only handle volumes of 150 litres per minute. Now the dedicated nitrogen generator from Atlas Copco meets all our nitrogen requirements, easily handling a capacity of 6 000 bottles per hour, on a bottling line of four million bottles per annum.”

The superior technology of Atlas Copco’s Pressure Swing Adsorption (PSA) NG27 nitrogen generator ensures delivery of correct pressure and a quality flow of nitrogen to the filler at 99.8% purity at full capacity, which is, according to Marius, higher than the standard bottling requirement level of 99.5% for anaerobic processes.

Atlas Copco, Charl Ackerman, Tel: (011) 821-9113, Fax: (011) 25- 9847 Email: charl.ackerman@za.atlascopco.com, Web: www.atlascopco.co.za

Affordable, but Not Inferior DCD Protected Mobility has acquired the Springbuck Armoured Personnel Carrier (APC) range from Drakensberg Truck Manufacturers and has begun marketing these home-grown vehicles alongside its existing range of sustainable products for the defence and security sectors.

“We’re very excited to have expanded our existing product range to include a vehicle that has such potential on the African continent, particularly in terms of emerging markets,” DCD Protected Mobility general manager, Andrew Mears, says.

“The Springbuck APC has been designed for ease of operation, maintenance and repair, harnessing internationally available drive-line components for assured performance and availability of parts.”

The vehicle, which derives its name from

h d the antelope, known for its toughness and sure-footed dexterity, has been designed around the ergonomics of the driver and crew, specifically for the African market.

Andrew describes it as “affordable, but not inferior”, making it ideal for a broad spectrum of security applications.

The permanent 4x4 Springbuck APC features a powerful MWM 6 litre engine and carries a driver and ten personnel.

With B6 ballistic protection upgradeable to B7, the all-steel armoured v-shaped

hull is designed to withstand a TM57 landmine under the hull, or two under any wheel. The standard configuration can be easily adapted to suit various applications, including an ambulance, cash-in transit, riot control or tactical patrol vehicle and, with the addition of turret-mounted weaponry, the vehicle can also be effectively used in combat.

Dcd Protected Mobility, Andrew Mears, Tel : (011) 914-1400, Email : andrew@dcd.co.za

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All Aware Becker Mining S o u t h A f r i c a ’s latest patented tri-technology Collision Avoidance System (the CAS-400 series) with four proximity warning zones, has been designed to overcome the limitations of existing systems and can even bring the mine vehicle to a complete ‘STOP’, should this be necessary

“CAS (Collision Avoidance System) is a very necessary safety system on the mines, particularly underground, because in this harsh environment, it is impossible for a vehicle operator to always be fully aware of other miners and vehicles in his immediate proximity,” says Edwin Bauer, Becker Mining South Africa.

Becker collision and personnel avoidance systems consist of personnel and vehicle tags and the machine-mounted devices which detect them. Higher end

tags warn personnel of an approaching vehicle. These products may be utilised as a simple stand-alone or complete system and can be deployed using a phased approach, to minimise a huge initial capital outlay.

The new CAS-400 series receiver provides first in its class audible voice annunciation (customisable in different languages - on request) and visual warning proportional to the position of the threat. An onboard buffer enables authorised personnel to download daily

movement details, either physically, or via a wireless network, like a leaky feeder system.

Miners are cautioned by a transceiver tag (Personnel Avoidance System or PAS) when they come close to any vehicle, by means of a flashing light and buzzer on a cap lamp. The number of flashes, which is limited to five, indicates the number of vehicles in a miner’s vicinity.

The detecting range can be set according to specific requirements. The combination of this system provides a warning where miners are warned of machines, machines are warned of personnel and machines are warned of other machines.

A further advantage of Becker’s new multiple technology approach is that mines now have the flexibility of being able to monitor both slow and fast moving equipment on surface and underground with one system.

An important feature of Becker’s safety systems is they are designed to facilitate future upgrades.

Becker Mining South Africa, Edwin Bauer, Tel: (011) 801-5900, Email: info@za.becker-mining.com, Web: www.za.becker-mining.com

No Loose Ends CCTV with remote monitoring can also help organisations to identify employees who are not adhering to policies and procedures, in real-time, so that corrective action can be taken quickly. It is also possible to monitor when staff arrive and leave, so that time sheets can be verified, along with numerous other applications.

Larger organisations today are often geographically distributed across the country, with sites that are outside of major hubs and towns.CCTV solutions with remote monitoring capabilities can be used to monitor multiple distributed sites without the need for a constant physical presence.

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While remote monitoring solutions are not new, bandwidth has traditionally been an inhibiting factor, hindering organisations from taking advantage of the benefits of CCTV with remote monitoring. While bandwidth is now cheaper and more affordable than ever, video footage can still consume large amounts of data throughput. With this in mind it is important to look for a solution that offers compression tech-

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nology which reduces video streams to improve throughput speeds and lessen bandwidth usage.

It is also important that remote monitoring sites be able to view footage in real-time.

Because of bandwidth limitations, it is vital that CCTV and remote monitoring solutions are also able to support ultralow bandwidths, to allow remote sites to access live content at low bitrates, while also enabling users to access the high resolution footage should this be necessary.

Even in organisations with a single branch, it is not possible to watch all areas at all times, so using CCTV cameras as a performance monitoring and management tool can provide enormous benefit.

Graphic Image Technologies, Mark Chertkow, Tel: (011) 483-0333, Email: markc@git.co.za

MARKET FORUM

Drilling rig upgrade

DCD Marine was recently awarded the contract to upgrade and repair the Saipem-owned semi-submersible rig, Scarabeo 3.

The Scarabeo 3, a second-generation drilling rig, manufactured in 1975 in Germany was designed and engineered for drilling in the extreme marine conditions found in the North Sea. The bridge, containing the actual drilling rig, is

triangular and rests on three columns, which are in turn each mounted on a hull. This design creates a superior level of stability and was considered extremely futuristic at the time. As testimony to the robust construction of the Scarabeo 3, some of the original pulleys only needed replacement in 2001.

“After 37 years of active service, the Scarabeo 3 was in need of a compre-

Global Trading Agreement RS Components, the world’s largest high service distributor of electronics and maintenance products, has signed a new global trading agreement with SMC, a leader in pneumatics. The agreement will enable RS to provide a more comprehensive product range worldwide, a key element of its overall maintenance strategy,

and to maintain its high standards of product availability for its customers.

It will also enable RS to offer the best possible price and service to its customers for the SMC product range, which includes actuators, connectors and control valves and pressure regulators for pneumatics.

Says Devin Ross, marketing specialist at RS Componemts SA, “ The combination of our high service worldwide distribution capability with SMC’s technological leadership will enable us to better serve our customers’ needs by giving them access to the latest pneumatic control technology. This strengthens our offering in the automation and control market, our primary technology focus for the maintenance sector.”

RS Components, Devin Ross, Tel: (011) 691-9300, Fax: (011) 466-1577 Email: devin.ross@rs-components.com, Web: www.rsonline.co.za

hensive inspection and revamp,” says Dcd Marine General Manager, Gerry Klos.

“All vessels are required to undergo a special survey every five years in order to comply with the necessary marine classification codes. This entails returning the vessel to within a maximum 5% variance from its original state.”

The scope of work for DCD Marine includes the replacement of over 120 tons of steelwork for the deck plates and shell plating; the renewal of sea safety walkways on all three columns and the installation of four new lifeboats and davits.

“DCD Marine is also responsible for the replacement of over two kilometres of pipework on board. This includes the pipes on the sanitary discharge lines below the main deck, the seawater pipes in the engine rooms and the three mud pit rooms, the diverter line piping, and a complete upgrade of the anti-pollution and drainage system.

“Cleaning of void spaces and blasting and corrosion coating will also be done in various areas onboard the rig,” explains Gerry.

DCD Marine, Gerry Klos, Tel: (021) 460-6000 www.dcd.co.za

Index to Advertisers Aesseal

16

Axiom Hydraulics

32

Bearings International BMG

26

Outside Front Cover

Bonfiglioli

28

CMG

18

EMS/Indutec

10

Festo

35

Hansen

14

KDP Services

22

KSB

Outside Back Cover

PPS

11

Pump & Seal Services

34

Retecon

Inside Front Cover

Rodecon

34

SEW

20

Sprag Components Symbiosis Yellotec

4 Inside Back Cover 23, 39

Zest WEG Group

THE SOUTH AFRICAN MECHANICAL ENGINEER

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MARKET FORUM

"Unfair Imports" countervailing initiatives implemented by the government and other parties.

The government plans to review tariff and non tariff barriers to protect local manufacturing as well as designate certain industries of “critical importance” to local manufacture by organs of state and public entities. Bernard also believes the government is assisting with initiatives such as the Manufacturing Competitiveness Enhancement Program (MCEP), which aims to support manufacturing enterprises in upgrading their plant and thereby support the value-add process.

Bernard Maguire of Sassda

The Southern Africa Stainless Steel Development Association held its annual AGM in July this year.

Bernard Maguire, the chairman of Sassda’s board, believes “unfair imports” of finished goods into South Africa have become a serious threat to local manufacturers during the course of the past couple of years. Bernard summed up the

Mark Koerner Mark Koerner has recently been appointed as Philips Lighting General Manager and Solar Africa for Southern Africa.

Bernard said that the past twelve months had been interesting as Chairman of Sassda but believes the appointment of Bill Scurr on the 2nd of April 2012, is a positive step in the right direction.

“Bill's brief is to get Sassda back to basics and in essence that is serving the industry and following the needs of the members,” says Bernard.

Alan Oswald

Sassda, Bernard Maguire, Tel: (011) 883-0119, Web: www.sassda.co.za

Nico Schoeman

A winner again!

Community Service Award. The AEE has a membership of over 16 000 professionals in 89 countries and recognises significant achievements of its US-based and international chapters through the annual Chapter Recognition Awards Program which comprises seven possible awards, of which SAEE won three.

Professor Grobler

For the second year in a row, the Southern African Association for Energy Efficiency (SAEE) has won the US-based Association of Energy Engineers’ (AEE) 2012 Overall Best Chapter Performance Award in the international category, in addition to the Best Website Award, and the Best

46

An elated Prof LJ Grobler, President of the SAEE says, “Apart from receiving international recognition by the AEE, our members and board members have actively worked towards growing the industry at local and international level through standards representation, awareness creation, skills development, and cementing monitoring, verification and control structures.”

SAEE, Yolanda de Lange, Tel: (041) 367-1041, Email: media@saee.org.za, web: www.saee.org.za

THE SOUTH AFRICAN MECHANICAL ENGINEER

VOL 62 October 2012

Alan Oswald has been appointed as Managing Director of Robor Galvanizers and Nico Schoeman has been appointed as Managing Director of Robor Pipe Systems, both divisions of Robor (Pty) Ltd.

Derek Smythe Babcock International Group has appointed Derek Smythe as the new CEO of its Equipment division.

Ian Maclean Engineering firm, Parsons Brinckerhoff, has appointed Ian Maclean as Managing Director for its Southern African operations.

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uncommon opportunities

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THE SOUTH AFRICAN MECHANICAL ENGINEER

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