JANUARY - FEBRUARY 2019, Vol. 3, ISSUE NO. 1
Centrifugal Slurry Pump Extending the mechanical seal life
In this issue... Total announces groundbreaking oil discovery in south africa P07
Construction of Kafubu water project in Zambia begins P20
The Unexpected Job Market being created by Renewable Energy P34
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Editor Brenda Kyle editor@pumps-africa.com Writers Elizabeth Mbithe, Harriet Mkhaye Herman K., Liz Changawa Nita Karume, Rashid Mjomba
CONTENTS Corporate News WILO opens new facility in Dubai.....................................................................3 Aspen Pumps acquires Salina SAS...................................................................5
Sales and Marketing Pumps Africa Team rnarketing@pumps-africa.com E. Africa Advertising Executives Mercy Cherop, Walter Baraza S. Africa Advertising Executives Siphiwe Zara, Kelly Moz Graphic Design and Layout Irene Faith Omudho Published By: AROCC Publishers P. O. Box 2922-0020 Nairobi Kenya Tel: +254 772 187334, 790 153505 consultancy@arobia.co.ke, info@arobia. co.ke ***************************** The editor accepts letters and manuscripts for publication from readers all over the world. Include your name and address as a sign of good faith although you may request your name to be withheld from publication. We reserve the right to edit any material submitted. Send your letters to: editor@pumps-africa.com ***************************** DISCLAIMER: AROCC Publishers makes every effort to ensure the accuracy of the contents of
Energy News Hwange Power Station to boost Zimbabwe’s power capacity............................6 South Africa: Total announces ground-breaking oil discovery............................7
Product News Blackhawk launches landfill/remediation models............................................8 Davis & Shirtliff to distribute SMA Solar Technology inverters.......................10 KSB to showcase advanced high-efficiency pumps.........................................12
Events 4th East & Southern Africa Gas & LNG Conference 2019...............................14 Pumps, Valves and Pipes 2019.......................................................................14
Projects Mombasa County awards construction of 2 seawater desalination plants.......16 Stigler Gorge water project nears completion amid concerns.........................18 Construction of Kafubu water project in Zambia begins.................................20
Feature Extending the mechanical seal life of your Centrifugal Slurry Pump...............22
Reports Fear helped avert Day Zero in Cape Town......................................................26 Zimbabwe capital water woes may lead to rationing......................................28
its publications, but no warranty is made as to such accuracy and no responsibility will be borne by the publisher for the consequences of actions based
Interview The Unexpected Job Market being created by Renewable Energy...................34
on information so published. Further, opinions expr essed are not necessarily shared by AROCC Publishers. ***************************** *AROCC Publishers is trading in Kenya
Also See
Industry Tips
Features
Projects
Reports Mining Agriculture Energy
as Arobia Creative Consultancy
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CORPORATE NEWS
Pentair investments in Aqua Membranes Aqua Membranes has developed a patented process to print dimensional polymer shapes directly on flat sheet RO membrane
By Harriet Mkhaye
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entair plc has closed a minority investment in Aqua Membranes, a developer of patented 3D printed spacer technology that enables performance improvement in spiral wound elements used in reverse osmosis (RO) membrane applications, including residential and commercial water filtration.
Founded in 2011, Aqua Membranes has developed a patented process to print dimensional polymer shapes directly on flat sheet RO membrane, which replaces conventional feed mesh. The printed spacer material is fully customizable by application and market.
“Aqua Membranes’ strong portfolio of intellectual property and its developmental track record, combined with Pentair’s technical expertise in water treatment technologies, will allow us to expand our customer offerings in the residential and commercial water treatment arena,” said Phil Rolchigo, Pentair Executive Vice President and Chief Technology Officer.
“We are very excited to have Pentair lead our Series A investment round,” said Craig Beckman, CEO of Aqua Membranes. “Pentair’s technology is a leader when it comes to minimizing water waste from home RO systems.
“This investment aligns with our innovation roadmap and has the potential to provide our customers with more sustainable and lower cost water treatment solutions,” he added.
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This collaboration will enable us to commercialize and further improve the efficiency of this technology that can protect families from contaminated water with a more sustainable product. It’s only the beginning of our potential to develop even more cutting edge products together in the future.”
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CORPORATE NEWS
WILO opens new facility in Dubai The Dubai office serves as a regional platform for countries in the Near and Middle East and in North Africa By Elizabeth Mbithe
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ollowing a year-long construction period, the Wilo Group, one of the leading manufacturers of pumps and pump systems, is celebrating the official opening of its new facility in Jafza (Jebel Ali Free Zone), Dubai. “With the opening of our first office in Dubai in 2008, we laid the groundwork for successful developments in the Near and Middle East. This new building and its functional expansion accounts for the strategic significance of this central location within the region,” says Oliver Hermes, chairman and CEO of Wilo Group. High-level guests from politics and business The opening celebration was attended by prominent individuals, including German ambassador to the United Arab Emirates Peter Fischer and Mohammed Al Muallem, CEO of DP World and Jafza.
“Since the founding of our first office about ten years ago, we have become a major supplier of pumps and pump system solutions in local markets,” said Georg Weber, Chief Technology Officer of the Wilo Group, during his opening remarks. “In the future, we will be able to better and more efficiently serve the needs of our customers and partners in the region by fulfilling local market requirements with tailored products, solutions, and services,” Georg Weber explains further. Dubai – a central hub for the region The Dubai office serves as a regional platform for countries in the Near and Middle East and in North Africa. Oliver Hermes, who is also chairman of the German Near and Middle East Association (NUMOV), emphasises the significance of the Emirate of Dubai: “With this central hub, we
can further expand our bilateral cooperation with partners from the United Arab Emirates and the Near and Middle East in line with our intensified globalisation strategy.” Dubai is one of the world’s leading digital hubs. As such, it offers the Wilo Group an excellent opportunity to strengthen its position as a digital pioneer in the pump industry and to promote the future use of digital products and solutions. In addition to office space, showrooms, and a logistics centre, the Wilo complex, which covers over 8,000 square metres, will also feature dedicated training rooms and its own assembly line. The new Wilo building is among the most energy-efficient buildings in its class in Dubai and was certified in accordance with LEED Gold.
From left to right: Yunjoong Kim (WILO SE), Georg Weber (Chief Technology Officer WILO SE), Mohammed Al Muallem (Chairman of DP World and Jafza), Peter Fischer (German Ambassador to the United Arab Emirates) and Yasser Nagi (Managing Director WILO SE United Arab Emirates) at the opening of the new Wilo representative office in Dubai
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CORPORATE NEWS
Aspen Pumps acquires Salina SAS This acquisition extends Aspen’s global footprint, adding an administrative office in Paris and an operational hub in Normandy cementing Aspen’s market leading position in Europe By Harriet Mkhaye
including Aspen’s full range of condensate removal pumps, Aspen Xtra and Big Foot Systems.
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he global leader in design manufacture and distribution of condensate removal pumps, Aspen Pumps Group, has completed the acquisitions of Salina SAS a leading French distributor of airconditioning and refrigeration ancillaries. This acquisition extends Aspen’s global footprint, adding an administrative office in Paris and an operational hub in Normandy cementing Aspen’s market leading position in Europe. Salina, as Aspen’s distributor in France, has been pivotal in building
Aspen’s position in the market, and the acquisition is a natural development in a close trading relationship that has lasted over 20 years. Salina’s product offering includes many high quality brands,
This investment underpins the commitment of Aspen shareholder 3i Group plc to support Aspen’s global ambitions. Adrian Thompson, Aspen CEO said: “Salina is a great company that has built its market position through a dedication to strong brands, excellent service and customer relationships. We are delighted to welcome the team at Salina to the Aspen family. ” Financial terms have not been disclosed.
Marvelu pump manufacturer: first international debut By Harriet Mkhaye
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arvelu pump manufacturer recently made its first international debut at the Electra Mining Africa event last year. The company is known for its supply of submersible slurry pumps across a wide range of commodities on the African continent since 1996. Some of the common applications for the Marvelu pump include high wall pumping in open pits, pumping during dam and harbor wall construction, pumping from shaft bottoms, flood level control and pumping over extended distances of up to 4 km. The new pump will not only feature the Marvelu twin volute casing technology, but will also be fitted with a forced convection-cooled, oil-filled motor, a non-pressurized
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mechanical seal, over-sized bearings and an extreme heavy duty cable.
rivers and dam dredging and cleaning.
The pump is engineered with the ability to operate in temperatures of up to 90 degrees Celsius and can run dry for extended periods. The subsidiary of Marvelu will operate from a fully equipped facility in Germiston. The facility will consist of a fully equipped workshop, a pump test bay, a warehouse and a service exchange store, as well as the company’s large rental fleet.
In addition to servicing the mining sector in South Africa, the Southern African Development Community region and Central, West and East Africa, the company will be able to support its growing customer base in the industrial and water and wastewater sectors.
Marvelu submersible slurry pumps Africa will offer the full range of submersible pumps. These are used not only in the mining industry, but also in general industrial applications such as steel manufacture, iron-ore and lime factories, wastewater and sewage treatment plants, harbors,
All products are backed by highly skilled and knowledgeable technical personnel with an in-depth understanding of pump applications. The range of products includes the well-known Marvelu submersible pumps, pontoon-mounted pumping solutions, control panels, hoses, couplings and ancillary equipment. submersible slurry pumps.
CORPORATE NEWS
Selwood opens new UK branch The Birmingham facility is part of an ongoing programme which has seen Selwood invest heavily in its pump rental fleet and branches
By Liz Changawa
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elwood has expanded its thriving operation and created new jobs with the opening of a new branch in Birmingham. The branch, Selwood’s 20th pump rental centre, builds on the company’s position as the number one pump rental provider serving the water, utility and construction industries in the UK, and enables additional capacity for it to service major projects in Central England. The Birmingham facility is part of an ongoing programme which has seen Selwood invest heavily in its pump
rental fleet and branches. It is the third new centre in as many years, following branch openings in Aberdeen, and Saltash in Cornwall. The branch opens with immediate vacancies for office staff and mobile engineers. It is expected that there will also be opportunities for future roles including project managers, LGV drivers, pump fitters and technicians. Richard Brown, Managing Director– Pumping Solutions at Selwood said: “The Midlands is a key region for Selwood, and the opening of this
new branch in Birmingham underlines our commitment to the region. “Our teams are proud to have strong partnerships with clients in the area, including Severn Trent Water and many of its contractors, and this new facility will help us nurture and grow those relationships. It also makes Selwood ideally positioned to support the HS2 high-speed railway project and other major programmes across Central England in the coming decades.”
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ENERGY NEWS
Hwange Thermal Power Station expansion to boost Zimbabwe’s power capacity By Nita Karume
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wange Thermal Power Station in Zimbabwe is set for expansion to a tune of US$1.5Bn. The said expansion project will see two more generating units being constructed. Unit 7 and 8 are both projected to generate approximately 300MW of electricity upon completion. Zimbabwe’s President Mnangagwa will be presiding over the ceremony for the expansion later on this week. According to Chinese firm Sino Hydro that has been tasked with undertaking the expansion project, the expected date completion is in approximately 4 years. Zesa Holdings, a local company will also be part
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of the team executing the thermal station’s expansion. According to the firm’s spokesperson Mr Fullard Gwasira, the completion of the project will see creation of up to 2 500 jobs. Among this, 2200 employees will work at the plant while the other 300 work in transmission and distribution. The Hwange Thermal Power Station expansion project comes at a time when Government is luring both local and foreign investors to set up businesses. This is with an aim to create job opportunities as well as development of key infrastructure in the country. According to media reports, firm investment commitments worth over
US $20Bn have been received so far. This is as at December last year. The increased investor interest comes after the government of Zimbabwe amended the Indigenisation and Economic Empowerment Act to allow foreign investors to fully own almost all their projects. The funds received are projected to help The station, which has an installed capacity of 920MW, is currently working well under its potential, generating 310MW as of last week. Moreover, it is also unable to operate flat out at present. This can be attributed to cooling design problems. As such, this, along with maintenance of older boiler generator units should be looked into with the expansion project to ensure smooth operation of the same.
ENERGY NEWS
Total announces ground-breaking oil discovery in south africa This breakthrough is expected to attract major oil companies in exploring the blocks they have already acquired which will subsequently drive major new upstream oil activity offshore. The Block 11B/12B covers an area of 19,000 square kilometers, with water depths ranging from 200 to 1,800 meters, and is operated by Total with a 45% working interest, alongside Qatar Petroleum (25%), CNR international (20%) and Main Street, a South African consortium(10%).
By Herman K.
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he recent gas condensate discovery by Total in South Africa has set the stage for a significant contribution to the nation’s economic development as it will assist in reducing dependency on imports of oil and gas. The discovery on the Brulpadda prospects is located on Block 11B/12B in the Outeniqua Basin, 175kilometers off the southern coast of South Africa. The Brulpadda well encountered 57meters of net gas condensate pay in Lower Cretaceous reservoirs. Following the success of the main objective, the well was deepened to a final depth of 3,633meters and has also been successful in the Brulpadda-deep prospect.
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“We are very pleased to announce the Brulpadda discovery which was drilled in a challenging Deep water environment”, said Kevin McLachlan, Senior Vice President Exploration at Total. “With this discovery, Total has opened a new world-class gas and oil play and is well positioned to test several follow-on prospects on the same block.” Total drilled this exploration well with the latest generation drilling ship and was able to leverage its experience in similar environments, such as the West of Shetland, UK. Following the success of Brulpadda and confirmation of the play potential, Total and its partners plan to acquire 3D seismic this year, followed by up to four exploration wells on this license.
About Total in South Africa Total has been present in South Africa since 1954. The Group is active on the whole oil and gas value chain and directly employs 1,000 people in the country. Upstream, Total has developed oil and gas exploration activities in the Outeniqua basin with operating interests in two blocks, 11B /12B and South Outeniqua. Downstream, Total, which is ranked in the top four petroleum products market companies in South Africa, operates about 550 service stations throughout the country and is present in all other business segments (lubricants, B2B, aviation, LPG, other specialties). It also has interest in the Natref refinery in Sasolburg. Through SunPower affiliate, Total has also been developing solar projects and locally producing photovoltaic panels. Since 2016, its Prieska solar power plant (installed capacity of 75 megawatt-peak), located in the Northern Cape, has been supplying electricity to the equivalent of 70,000 households.
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PRODUCTS
Blackhawk launches landfill/remediation models Blackhawk’s advanced-design Edge Pneumatic Piston Pump™ provides up to 20% more lift than comparably priced air-push pumps, with matching SCFM air consumption and lower all-in purchase prices By Pumps Africa
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he new landfill/remediation pumps from Blackhawk Technology share the same lowcost/high-efficiency DNA – fraternal twins engineered to do more with less, pumping virtually anything flowable with above-ground drive. One is pneumatic, the other electric; both are low-profile and workerfriendly, with TDH depths to 280 feet (85 meters) and controlled flows from 1.2 to 5.0 gpm (4.5 to 19 lpm). Blackhawk’s advanced-design Edge Pneumatic Piston Pump™ provides up to 20% more lift than comparably priced air-push pumps, with matching SCFM air consumption and lower allin purchase prices. Edge’s greater surface clearance and innovative closed secondarycontainment system improve stuffing box efficiency and significantly reduce seal wear. Above-ground drive motor and power means no pneumatic air can enter the well, sump or discharge. No fugitive air means far less bio-fouling, carbonate crystallization and air locks along the discharge line, allowing greater efficiency with longer pump life. Edge Model 101 operates to depths of 280 feet at flows to 2.0 gpm; Model 102 offers flows to 5.0 gpm at depths of 119 feet. Blackhawk’s Apollo-AC Electric Piston Pump™ responds to customer
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requests for a grid-power version of the highly regarded Apollo Solar Piston Pump™ and its simple, linearrod driver. In addition to lower purchase prices and lower amp draws, the low-profile Apollo-AC combines the convenience and consistency of 24/7 grid power with the reliability, low-maintenance and easy installation that define Apollo pumps. Apollo-AC 101 operates to depths of 280 feet at flows to 1.2 gpm; Model 102 offers flows to 3.0 gpm at depths of 120 feet. The 3/8-hp motor runs on virtually any converted AC source. About Blackhawk Blackhawk Technology Company is the originator and the No. 1 manufacturer of above-wellhead, positive-displacement piston pumps – leading-edge technology refined by nearly 30 years of customer-driven improvements. Blackhawk continues to introduce innovative products to the industry’s most comprehensive line of pneumatic, electric and solar piston pumps and pump supplies, all designed to withstand the harshest weather and downhole pumping environments. Founded in 1990, the company originated landfill and groundwater remediation piston pumps now covered by several patents and marks, with others pending. No company offers more real-world pistonpumping experience in landfills, chemical facilities, hydrocarbon
production and remediation sites throughout North and South America, Europe, Asia, Africa and Australia.
PRODUCTS
Xylem launches chemical-free water purification system globally
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ylem, a leading specialist in water technologies, in partnership with H2Ozone has globally launched a chemical-free water purification system which inactivates all pathogenic organisms from water supply, including Legionella, Salmonella, bacteria, E.coli, and the Cryptosporidium oocyst.
medical facilities. HydroInfinity Residential Series treats water to independently verified drinking standards, using unique H2Ozone patented technologies to deliver UV treatment, ozonation and filtration. The fullyintegrated solution is the first of its kind and the only chemical-free water purification system.
The product christened HydroInfinity Residential Series is a complete water treatment and booster system ideal for private and shared water supplies such as schools, offices and
The system works by collecting, purifying, storing and distributing water from a variety of sources including: rainwater, boreholes, surface water, wells and
municipally supplied water. Only the purest water is delivered, with bacteria levels below that of bottled water. HydroInfinity Residential Series uses electric sensors, remote control systems and software that automatically monitors and ensures that no compromised water enters or exists in the system. It also allows 24/7 remote access monitoring and provides full visibility of the pump and tank’s operation and status, as well as offering predictive analysis.
Enerpac introduces cordless model
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igh pressure hydraulic tools specialist Enerpac, part of the Actuant Corporation, has announced the launch of its ZC-Series cordless hydraulic pump, which combines the performance of an electric pump with the portability of a battery pump. The ZC-Series cordless pumps are designed for remote locations without access to power and interior locations where trip hazards, ergonomics or size could cause problems. The cordless pumps are intended for use in industrial applications such as foundation repair,
rail maintenance and concrete post-tensioning. As the cordless pumps are quiet, they can be used in applications where noise and emissions from gaspowered equipment are a concern.
single-acting cylinders, a 4-way, 3-position manual control valve used with double-acting cylinders and a 4-way, 3-position manual control valve with locking and power seat functions. About Enerpac
The ZC-Series has a brushless 1.4 hp motor and 3-stage pump which, the company says, maximises productivity while minimising heat build-up. Power for the pump is supplied by a rechargeable 82V lithium-ion battery. Valve options for single and double acting tools with the ZC-Series pump include a 3-way, 3-position manual control valve used with
Enerpac is a global market leader in high pressure hydraulic tools, controlled force products and solutions for precise positioning of heavy loads. We manufacture products, from the smallest hydraulic cylinder to complete computer-operated lifting and positioning systems. Their focus is to provide their customers with the most extensive line of
products and accessories that maximize force to increase productivity and make work safer and easier to perform. Enerpac products are available worldwide through a network of 1,400 distributor partners. With 28 facilities in 22 countries, they are capable of providing the technical support and the hydraulic expertise needed to support the servicing of standard products, design custom products for unique applications and develop solutions to move some of the largest structures on earth.
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PRODUCTS
DAVIS & SHIRTLIFF to distribute SMA Solar Technology inverters in East Africa Davis & Shirtliff has already sold 70 SMA inverters in the East African market with both partners focusing mainly on the solar off-grid. By Pumps Africa
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avis & Shirtliff, a Kenyan company specializing in the supply of water and energy equipment, has signed a deal with German company SMA Solar Technology, to distribute SMA’s photovoltaic inverters in East Africa. SMA Solar Technology manufactures inverters for photovoltaic installations used to transfer electricity into the grid. Davis & Shirtliff has already sold 70 SMA inverters in the East African market with both partners focusing mainly on the solar off-grid. The company, based in Hesse – Central Germany, has chosen Kenya as its base in East Africa, at a time when the growth of solar market is promising in the continent and renewable energy projects coming up in multiples. It will market its inverters through Davis & Shirtliff. Off-grid electricity distribution system has gained traction with many companies turning to it. “The installation of an off-grid solar system can significantly reduce the electricity bill and therefore the operating costs of manufacturers,” said Phillip Holi, Technical Director of Davis & Shirtliff.
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With the introduction of its photovoltaic inverters, SMA has tapped into the perfect business climate where more companies are investing in the solar off-grid systems. Sub-Saharan Africa has recently been receiving many investment proposals and interests on the growth of the renewable energy sector. The British government announced that it is keen on investing more than US$127m in renewable energy projects to prompt the growth of the sector in subSaharan Africa.
Renewable Energy companies in East Africa have been receiving grants and credit facilities to finance their activities within the region led by Investor group; Inspired Evolution, an investment advisory firm specializing in the energy sector in Africa; Norfund, a Norwegian private equity firm, the Netherlands Development Finance Corporation (FMO), and Swedbank, a bank based in Stockholm, Sweden.
PRODUCTS
Tsurumi to launch new submersible pumps at Bauma 2019 The new submersible pumps can cope with sandy water, groundwater and rainwater. By Pumps Africa
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with sandy water, groundwater and rainwater. The water may also contain stones with grain diameters of up to 12 mm.
The 615 is the new top model of the KTZ series that now comprises 15 models. Thanks to a motor output of 15 kW, the aggregate achieves up to 2800 l/min with discharge heads of almost 40 metres. In contrast, the 415 with the same motor ‘only’ pumps 2000 litres but up to a maximum height of 55 metres.
The pumps are pressure-resistant to a submersion depth of 25 m and have a pressure port with a diameter of four (model 415) and/or six (mode 65) inches on the outside thread. The KTZ series was launched back in the 1980s and is one of the best-selling pumps in the product line. Even the smallest model with a motor output of just 1.5 kW can move 430 l/min up to a height of 21.5 m. Obviously the manufacturer can deliver precisely what the target group requires with the KTZ.
“We are launching this highperformance duo that complements itself;” says product manager Stefan Himmelsbach. Both submersible pumps can cope
The highlights of the series also include the dry running-safe design (motor cooling and oil lubrication), the high wear-resistance (abrasive pumping media) and the fail-safe
apanese pump manufacturer Tsurumi, will present two new pumps, for the first time, at the Bauma 2019 in Munich, Germany. With its innovations KTZ415 and KTZ615, the Japanese company has outdone its series of professional drainage pumps for difficult applications.
feature (electrics). The KTZ is built in Tsurumi’s mega factory in Kyoto that is the world’s largest production site of its kind. This manufacturer supplies a total of 44 series for direct sale via 250 dealers in Germany alone. Many pumps can be leased. Tsurumi will be displaying many other pump models for structural and civil engineering projects in Hall A6 at Stand 338, as well as another innovative that it still under wraps but which will be launched in 2019. Engineering enthusiasts can also look forward to exhibits of cutaway pump models and live wet applications. Tsurumi’s European central office in Düsseldorf will also be celebrating its 35th anniversary during this time: this will also be addressed.
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PRODUCTS
KSB to showcase advanced high-efficiency pumps The Calio S is intended for heating, ventilation and air-conditioning systems and the CalioTherm S for drinking water circulation systems.
By Harriet Mkhaye
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SB Group will showcase for – the first time – its latest generation of high-efficiency circulator pumps of the Calio S and Calio-Therm S type series, at ISH 2019, which takes place from 11-15 March in Frankfurt. The Calio S is used for heating, ventilation and air-conditioning systems while Calio-Therm S is used for drinking water circulation systems. The developers have placed a particular focus on ease of use and compatibility with existing systems and they come in a new look compared to their predecessors. The new look pump has a 230 V power plug in screw-in design and a straight cable entry. With this, connecting the power cable is easy. It also has a vent plug at the front which enables convenient manual venting and deblocking of the pump if required after long standstill periods. Measurements in KSB’s acoustic test facility resulted in noise characteristics below 30 dB(A). This makes the new pumps some of the quietest circulator pumps on the market.
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Operation is straightforward using pushbuttons and a display with symbols. An economical LCD field shows the operating mode, current input power, flow rate and head in alternation.
previous setpoint.
If the Setback Operation function is enabled, the pumps identify minimum heat demand when the fluid temperature sinks continuously. They automatically reduce the setpoint by 30 percent. When heat demand rises again, the pumps revert to their
The pumps are available in standard overall lengths of 130 mm and 180 mm in grey cast iron or stainless steel. All 180 mm pumps are fitted with thermal insulation shells as standard.
For applications requiring heads of up to eight metres, two additional sizes, Calio S 25-80 and Calio S 3080, will be on offer from mid-2019.
Your Success Is Our Priority KSB Pumps and Valves is the leader in the design, manufacture, and application of heavy-duty, centrifugal slurry pumps, Over time, we have grown in both size and expertise to ensure that KSB's products are always at the forefront of slurry technology. By delivering cutting-edge solutions to your industry every day, KSB strives to be the expert of choice in slurry transport. We value our customers and are proud that you choose us to provide your pumps and services.Slurry pumps and parts can be custom engineered with options that include various impeller types to fine tune pump performance for specially tailored slurry pumping needs. These options allow optimum wear life and sustained efficiency - the best in the industry. KSB Pumps and Valves (Pty) Ltd
+27-11-876-5600
www.ksbpump.co.za
> Our technology. Your success. Pumps• Valves• Service
GIW® Minerals
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EVENTS
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ooping in 150+ professionals within gas industry around the world, GAS-ESA 2019 will provide a valuable opportunity for international players to network with the local community and more clearly & exactly grasp the updated information about ESA new gas investment potentials, LNG trade initiatives, financing & local content strategies, projects updates and technology innovations
from industry experts. It is the prior platform to help East & Southern Africa gas authorities and operators solve challenges in gas industry development together with E&P, LNG, pipeline, import terminal and gas to power projects, also a good opportunity for service and technology providers to show their technical competitive edge.
Pumps, Valves and Pipes 2019
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he largest and most comprehensive African trade-show dedicated to the industries involved in the conveyance of liquids, gases & slurries. INDUTEC Africa is proud to present the 11th edition of Pumps, Valves & Pipes Africa. Over 1,200 industry professionals from 16 countries attended the exhibition in 2017 to do business, network and learn. The 2019 edition of PVP will co-locate with African Construction Expo and Totally Concrete Expo providing
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an even bigger platform for exhibitors to promote and showcase their brands. If you are looking to expand your business into Africa, generate new leads, meet new partners and find out about new projects and innovative technologies, then Pumps, Valves & Pipes Africa is the trade show for your business. Dates: 11 – 13 June 2019 Venue: Gallagher Convention Centre, Johannesburg, South
Africa
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PROJECTS
Mombasa County awards construction of two seawater desalination plants Two companies, Almar Water Solutions and Aqua Swiss, were finally selected to build the desalination plants By Herman K. The construction of two seawater desalination plants in Kenya’s coastal county of Mombasa is finally set to begin, after the county authority awarded Almar Water Solutions and Aqua Swiss the construction contracts. The two Spain and Swiss based companies were finally selected to build two desalination plants following a call for tenders launched in 2016. The construction of the plants
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has been in the pipeline for many months. In May 2018, Pumps Africa highlighted that Spain’s Almar Water Solutions had pre-qualified for a design, build, operate, transfer (DBOT) of the projects in Mombasa County. According to Carlos Cosín, the company’s CEO, Almar Water Solutions will build a desalination plant with a capacity of 100,000 m3 per day on the island of Mombasa
and the amount of water produced by the plant will supply one million people. Another desalination plant with a capacity of 30,000 m3 of water per day will be built in Likoni, undertaken by Aqua Swiss. The construction of the two desalination plants – estimated to cost nearly $157 million – is scheduled to start in June 2019 and expected to be completed in 2021.
PROJECTS
Construction of East Africa’s first trans-border gas pipeline set to begin By Harriet Mkhaye
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he Tanzanian government is planning to build a pipeline to pump natural gas to their neighboring Uganda. This will be another step in the two countries’ bid to expand energy cooperation.
“We are looking forward to hiring a contractor to conduct a feasibility study to determine current and future natural gas demand; the study would also establish the most economically viable route for the pipeline.
In 2016, Tanzania and Uganda agreed to develop a crude oil export pipeline to help with the transportation of the land-locked Uganda’s crude reserves from fields in the country’s west to offshore markets.
This will be made easier by identifying all potential customers” it said, though it did not give an estimated volume.
The project will be the first transborder gas pipeline in the East Africa region since 2004 when the extraction of natural gas commenced at the Songosongo Island in Lindi.
Tanzania boasts estimated recoverable natural gas reserves of more than 57-trillion cubic feet (tcf), mostly in offshore fields in the south of the country.
Tanzania’s President, John Magufuli and his Uganda counterpart, Yoweri Museveni launched the project in Tanga, led by French oil multinational Total as the main contractor.
“I am confident the pipeline construction will be successful given the expertise and experience gained through the construction
About 10 to 15 regions in Tanzania will benefit from the pipeline that will also serve as a catalyst for oil and gas exploration in the region.
The State-run, Tanzania Petroleum Development Corporation (TPDC), said that the project is expected to start from its capital Dar es Salaam, and passing through Indian Ocean port of Tanga to Mwanza port on Lake Victoria before crossing the border to Uganda.
and servicing of two pipelines — the 532km Mtwara-Dar es Salaam one and the crude oil pipeline that is underway,” TPDC managing director Kapuulya Musomba said.
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PROJECTS
Stigler Gorge water project
nears completion amid concerns By Nita Karume
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onstruction of a water project in Tanzania which is part of the initial preparations for the development of a huge hydroelectric project in the country is nearing completion. According to Tanzania’s minister for Water and Irrigation, Professor Makame Mbarawa, the Stigler Gorge water project is 80% complete. Upon completion the water project will have the capacity to produce 209,000 litres of water per day. “The water project will supply the contractor and the team at the Rufiji Hydroelectricity site with clean water and the amount of water required.’’ Said Mr Mbarawa. The project is being implemented through the Dar es Salaam Water and Sewerage Authority (DAWASA) and a Chinese company, China Henan International Cooperation Group Co Limited, is undertaking the construction as a supplement of the ongoing mega water project in Kisarawe District. Completion of the water project will pave way for construction of the Stigler Gorge hydroelectric project to start in earnest. But environmentalists are opposed to the hydroelectric project saying it threatens the ecosystem of the Sealous Game reserve thereby
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endangering animals like lions and rhinos. The hydro-electric project will be located at the heart of the Selous Game Reserve a Unesco world heritage site. The World Bank has also raised its objection to the project’s construction saying it will create severe water shortages in the Selous Game Reserve to the detriment of the flora and fauna in the area. In a recent report, the World bank notes that the demand for water in some of the areas where the government is planning to construct hydropower facilities such as Rufiji, Nyasa, Rukwa and Lake Victoria
basins already exceeded supply. “The location of the projects (upstream or downstream) makes it difficult for the projects to be sustainable,’’ reads the report in part. However, in June this year, President John Magufuli said the project would go on as planned with the tender for the construction of the project being set for end of August. The project is estimated to cost approximately US $4Bn. This is according to Brazil’s Odebrecht, which signed an MoU with the Rufiji River Basin Authority (Rubada) in July 2012 for the development of the project.
PROJECTS
Malawi’s multibillion water project to tackle water woes in Mzimba district
blunt of water shortage in Mzimba. For instance, the Mzimba South District Hospital at times struggles to provide quality health service because of water shortage challenge. The Hospital’s district environmental health officer (DEHO) Bestido Nkhoma has since decried challenges in day to day operations as a result of low water pressure or no supply at all.
The new water supply system is targeting a population of 48,000 people.
The upgraded water supply scheme is tapping water from Mzimba River, right inside Chikangawa Forest Reserve, 45 km South East of Mzimba Boma. Among other infrastructure works at the site is construction of a dam at the water source. This, according to Water and Sanitation Engineer, Jackson Mtungila, has since reached completion.
By Nita Karume
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US $22.85m water project is expected to tackle the prevalent water woes in Malawi’s Mzimba urban area. The water sector in the country has had its fair share of challenges especially in supply of adequate and safe water to large sections of the population, with the gradual increase in population worsening the already challenging situation.
dry taps. This, he says, is attributed to lack of proper water system infrastructure, as the existing ones are unable to withstand the increased water demand. The water system, run by NRWB was instituted in 1950; and as such was tailored to cater for the population of that time. Unfortunately, households and public institutions have often bore the
According to NRWB chief executive officer Titus Mtegha, the new water system will improve the health and livelihood people through improved access to potable water, hygiene and sanitation services. It will also spell the end of erratic water supply once it’s up and running.
The new water supply system is targeting a population of 48,000 people. It is also expected to pump out a water volume of 12m liters in a day. The project, which started in April 2017, is expected to end in October this year.
The project is championed by the government and will be implemented through the Northern Region Water Board (NRWB). On the other hand, loans from OPEC Fund for International Development (OFID) amounting to US $14.5m, African Development Bank (ADB) US $5m and a US $3m commitment from government are backing the project. Mzimba district’s water officer Khuta Mzguli says Mzimba has been perennially hit with the problem of
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PROJECTS
Construction of Kafubu water project in Zambia begins By Harriet Mkhaye
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he construction of Kafubu water project in Zambia has begun. The US$450 million project, being undertaken by China Complete Engineering Cooperation, is set to reduce non-revenue water from the current 50 percent to less than 20 percent upon completion. Non-revenue water is water pumped but not billed as a result of leakages and transmission losses. According to Bernard Phiri, The Director of Engineering at Kafubu
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Water and Sewerage Company, the 120 million cubic meters dam will improve the supply of water in neighboring areas. “268 houses have so far been constructed, with 30 of the affected families relocated. This will be facilitated by US $1.5m that has since been set aside for resettlement compensation,� he said. He further added that equipment like pipes are being imported from China and will be installed from the copper belt regions of Masaiti to Ndola,
covering a distance of approximately 45 kilometers. Mr. Phiri also divulged plans to put up an overhead reservoir tank at Kafulafuta. This will pump water from the dam to enable constant water supply. He also added that the water utility has noticed cases of vandalism with regards to the pipes, leading to unnecessary leakages. As such, he warned the members of the public against indulging in illegal connections of sewer system. This, he said, is with a view to avoiding both water and environment pollution. Presently, non-revenue water and competitive water tariffs are one of the biggest challenges facing the water and sewerage utilities in Zambia. This is in their bid to improve profitability and revenue generation power. Social and political consideration is also acting as a hindrance since the cutting supply to high density residential areas is more or less a health and political matter.
MINING
Metso to launch Groundbreaking innovations at Bauma 2019 The launches include technologies and services that enable improving productivity and driving down costs for aggregates and mining industries. By Harriet Mkhaye
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etso is introducing a number of new, state of the art solutions for the aggregate, construction, and mining industries in Bauma 2019, the industry’s leading trades show in Munich, April 8-14. The launches include technologies and services that enable improving productivity and driving down costs. The preview of the new solutions will take place at Metso’s booth FS.1111/2 on April 8 at 11.00 a.m. “Metso continues to invest in the development of solutions for aggregates and mining segments and we are extremely excited to be able to launch these latest innovations at Bauma,” says Olli-Pekka Oksanen, vice president, West Europe market area at Metso. “Many of the developments we are showcasing at Bauma are based on our customers’ feedback on product capabilities and their business requirements. These solutions help our customers to improve the performance of existing operations and to control cost per ton.” Along with the new crushing and screening solutions, Metso will unveil a groundbreaking innovation for offhighway trucks, enabling mines and quarries to haul more with less. This major product launch will expand Metso’s offering into completely new territory and help customers reach a higher payload while lowering their operating costs.
and opens new opportunities for the crushing business.
In addition to the key launches to be published at the event, Metso will showcase a broad range of equipment, wear and spare parts as well as services designed to help make operations more efficient and assets work harder. The solutions to be featured will include: The Metso Lokotrack® LT200HP mobile cone crushing plant designed for secondary and tertiary crushing operations such as producing aggregates for railway ballast, road construction, asphalt, and concrete fractions. The LT200HP complies with European Stage V emission regulations. The Metso MX(TM) cone crusher with patented Multi-Action crushing technology designed to cut the operational costs of crushers and to provide more uptime compared to traditional cone crushers. Since its introduction in 2017, Metso has sold 50 MX crushers worldwide. The Metso Lokotrack® Urban(TM) range revolutionizes crushing in densely populated environments, such as city centers. It enables up to 60% better noise protection and cuts dust emissions. This can make the environmental permit process easier
The Metso slurry pump range is optimized for maximum uptime and reduced operating costs. Our slurry pump maintenance slide base offers fast, safe and easy wear component change or pump inspection. Leaving the suction and discharge pipe undisturbed during inspection, the entire rotating assembly and motor configuration is slid back. Financial services make investing in new equipment simple. Metso’s leasing models allow you to better match your costs with your production revenues. As part of the Metso Life Cycle Services for Aggregates, Equipment Protection Services (EPS) brings you added protection for your most valuable assets. This comprehensive plan includes extended warranties, scheduled inspections with Metso-certified technicians and Metso Metrics Services for remote monitoring and data visualization. High-performance Poly-Cer wear lining enabling up to four times or more wear life compared to traditional steel lining. This long wear life in combination with quick and safe change-outs keeps downtime to a minimum and results in the lowest operating costs over time. Metso’s screening media are optimized for every application, ensuring long wear life and high operational open area.
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FEATURE
Extending the mechanical seal life of your Centrifugal Slurry Pump By Harriet Mkhaye
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umping slurry is one of the most demanding applications for any pump. Parts wear out, maintenance and repair costs are high. In many cases, frequent pump failures lead to costly production downtime. Also, excess sediment build-up in a sump cost time and money to remove. Like any other machine, slurry pumps require regular maintenance to function optimally and reliably. Without proper care, pumps can suffer catastrophic failures, which can result in unscheduled repairs, potential injury, and facility downtime. Maintenance and Operation of Centrifugal Slurry Pumps offers a unique opportunity to gain insight into slurry pump maintenance and operation. Routine servicing of your submersible slurry pumps is essential, and a key factor to avoid unnecessary expense. Poor pumps maintenance can lose up to 15% of pumps efficiency; costing pump owners reduced output and hurting their bottom lines. However, while pump owners and operators can perform some
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of this maintenance on their own, some situations require calls to the professionals. Don’t wait until your pump becomes problematic. “Prior to performing any maintenance, you should develop an inspection plan to conduct tests and ensure that, if possible, the problem in question will not re-occur. The inspection plan is also used as a guide for adhoc / regular inspections so that you can identify any symptoms which may cause damage to the pumps. These mandatory checks include,
pump surging which can be caused by air entrainment into the pump, electrical fault, excessive power consumption, low or no flow, low discharge pressure, vibration or noise, and bearing temperature.” Said Graham Van Bosch, Regional Senior Manager, Metso Pumps Solution. Van Bosch further advises that regular maintenance is essential to keep mining equipment, machines and the work environment safe and reliable. Lack of maintenance or inadequate maintenance can lead to dangerous situations, accidents and health problems not to mention the cost thereof. According to Kunming Kunshui Industrial Pump Co.,Ltd, China’s professional manufacturer of slurry pumps with more than 10 years’ experience, the pump is durable, with reasonable assembly and installation, it will show the superiority of reliable, long working life and low maintenance. The following should be checked monthly: (a), Shaft Seal Repair Packing seal pumps should
regularly check the seal water flow and pressure, and always maintain a small amount of clean water flow through the shaft. To make this, you have to adjust the packing gland on a regular basis, if the filler cannot be re-used, should be to replace all. Expeller sealed pumps use oil cup, more economical, but need to regularly lubricate sealed chamber, rubber expeller ring need not lubrication (some pumps exceptions). Donovan Higginson, KETO Technical Director, Africa advises on the main steps to consider when maintaining slurry pumps is to ensure that there is minimal leakage from the shaft sealing, as this tends to cause premature bearing failure. The lubrication of the bearing assemblies must be properly administered in accordance with the pump manufactures specifications and standards. Daily inspection of the pump to ensure that there are no inherent problems such as overheating both on the bearings and the pump casings. KETO are specialists in the design, manufacture and service of pumps, parts and associated products. They cover the most aggressive applications including mining, aggregate and industrial markets. (b), Impeller Adjust The pump performance becomes deterioration as the open impeller and the suction side of the plate gap increasing. This impact for closed impeller pump is not obvious, but there are exceptions.Due to wear and tear, the gap increases and pump efficiency is reduced. In order to maintain the high efficiency of the pump, impeller must be timely moved forward, this adjustment just a few minutes and without disassembly any parts.After adjusted, it needs to check the impeller rotation before start the pump, and also check the bearing housing fastening bolts are tightened.
GIWÂŽ Minerals MHD Slurry Pump
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FEATURE
and flow) is verified monthly against the original or start-up duty point, as this will indicate the condition of the wearing parts.
(c), Bearing Lubrication Bearing components properly assembled and pre-grease lubrication, after shaft-mounted to the bearing housing, if there is no water or other sundries intrusion and timely maintenance, the bearing components are not only reliable but also long life. Maintenance technician must check the bearing box to observe the bearing and grease regularly(interval not more than 12 months). The number of regular lubrication and the injection of grease depends on many factors and the interaction of them. They are include speed, bearing specifications, continuous working hours, the pump stop and work time ratio, the working environment – for example, cycle and operation temperature , splash, contamination or the presence of impurities. Most of the pump bearings run low speed, but there is the risk of damage, mainly due to excessive lubrication of bearings, but preventive measures of avoiding excessive lubrication cannot completely guarantee the maintenance of bearings, the ultimate deciding factors are lubrication experience and judgment to determine the lubrication program, the better approach is to persistent observation the early stages of bearings operation, carefully recorded the unusual circumstances, for example, temperature and purity. For continuous operation, the bearing operating temperature shall not exceed the grease to lose its sealing ability. (d), Replacement of Wearing Parts The slurry pump bearing wear wear rate is a function of abrasive characteristics and materials of pump and working conditions. The life of wearing parts such as impeller and liner are different of pumps and pumping stations.
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According to Sara Johnston from KETO, regular adjustment and lubrication of the glands preventing premature failure of the shaft sleeve due to the ingress of slurry into the packings. Regular adjustment of the pumps impeller clearances, to ensure optimum performances of the pump throughout its life cycle.
The life of wearing parts such as impeller and liner are different of pumps and pumping stations. When the pump is first to be used for specific conditions, accident may happened especially during this operation cause of wearing parts losing effectiveness, you should regularly check the pump and bearing wear, to estimate the degree of wear in order to estimate its useful life. (e), Standby Pump Maintenance The standby pump should be turned 1/4 rotation a week, in this way, all bearing rotation under static and external vibration. Bill Naokes of Atlanting pumps advices that, slurry pumps are designed and specified to last as long as possible in the applications in which they work. However, there are some parts that are wear parts by the very nature of the pump and applications to which it is applied, such as the impeller, the volute liners, and components of the sealing system and the bearing assembly. Mr. Naokes recommend that the pump user carries a stock of the main wearing parts to minimize downtime. The frequency with which the pump needs servicing depends largely on the application, but its recommended that the pumps performance (head
Slurry pump technology New technologies are mainly based around the development of higher resistance to wear materials. Depending on the application of the pump, wear is often a higher cost factor than higher efficiency or lower power consumption. When applying a Total Ownership Cost (TOC) to a pump, the cost of downtime and spare parts often out ways the cost of power. KETO have a number of TOC models that can be used to assist in establishing control of these costs. Condition monitoring is being applied more and more to the pumps, as this is helping to more accurately predict Mean Time Between Failures (MTBF), preventing unscheduled downtime. KETO can assist in establishing and providing a tailor-made Condition Monitoring system to meet the various requirement. According to Bill Naokes, Centrifugal pump technology is decades old, however new materials such as polyurethane are now being used instead of the traditional rubber or high-chrome wearing parts in some applications. Big advances are being made in remote sensor technology, which allows pump users to remotely monitor the condition of their pumps, and intervene before the pump fails when a problem is detected. At Metso, they continuously seek new ways of thinking and better
ways of working. Additional to this, they encourage the introduction of new technologies, and they value innovative ideas and practices. A good example is the Condition Monitoring Technology (CMT). CMT monitors and predicts possible failure causes that the slurry pumps may be exposed to and helps you to proactively eliminate those problems. In this way, your maintenance plan is based on a proactive action plan instead of a reactive plan. Africa slurry pump challenges Environment and climatic conditions are often uncontrollable, however, social, health and pollution awareness training programmes are all important considerations. Improving and developing equipment which can operate using less water, i.e. pumping higher density slurries. KETO provides training in a number of these areas, on-site and off-site “The African market presents both challenges and opportunities for the slurry pump market. Significant mineral deposits are spread over large areas with challenges from a hostile climate, areas of unrest politically, and infrastructure that is in need of improvement. This leads to difficulties in getting pumps and spares to site. Pumps also require a large amount of electricity to run, and this power is required in remote areas and also in remote parts of a mine,” says Bill Naokes He adds that, with years of development and deployment, slurry pumps can be built to cope with the most demanding of conditions and transport the most abrasive and corrosive liquids. In cases where electricity is unavailable or unreliable diesel pump sets can be used or diesel generators. According to bill, as confidence returns to the mining industry,
investments will be made in expanding the industry and the infrastructure to support it, given that umps are getting more efficient and easier to monitor and control from a remote location. This can only be good for slurry pumping in Africa. However, Metso offers skills transfer services through various training programs to combat this challenges. Additionally, Metso, offer comprehensive Life Cycle Services (LCS) that can also include pumps maintenance. Their LCS offering includes the entire range of their leading services and equipment ranging from basics to more complete solutions. They offer four types of LCS packages that are adaptable to the customer’s needs: Scheduled inspections: Their service technicians reduce the customer’s risk of major equipment failure, critical parts damage and safety issues through early detection of potential problems and recommended maintenance strategies. Shutdown and wear parts optimization: This serves as the backbone of every successful shutdown. Their first focus is on increasing availability by getting the customer’s equipment back up
and running after a shutdown to minimizing lost production time. Secondly, they improve customer efficiency by optimizing process equipment’s wear and spare parts for longevity and highest productivity rate. Basically, they take care of every shutdown step and process. Shutdown and process optimization: This module helps improve the mineral processing workflow. With their equipment expertise complementing the customer’s operational knowledge, they help optimize the operations shutdowns, equipment set up, controls and blasting practices to ensure production gains, safety and efficiency. Maintenance and process optimization focuses on developing complete maintenance strategy based on the customer’s specific site conditions, to increase reliability and maintenance efficiency. Metso is the only company that offers a single package covering the build, operation and maintenance of customers’ equipment. Considering the increase in copper price and the high demand in metal, cobalt, graphite and the likes, indicates that the future looks positive for slurry pumps in Africa. Many of the EPC brown fields and green fields projects currently worked are entering into an execution stage during 2019. However, the future outlook for slurry pumping in Africa is improving due to the increased demands for the various minerals currently being mined. Political stability will also play a major role in the future outlook for slurry pumping in Africa. KETO are currently addressing many of these issues with improved component designs, new and improved materials to improve part life and performance.
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REPORT
of Cape Town to undertake, it may have been the single most successful intervention in changing Capetonians’ behaviour as far as water usage is concerned.”
Fear helped avert Day Zero in Cape Town This is one of the major findings of a study by researchers from Stellenbosch University (SU) and the University Cape Town (UCT).
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hreats about Day Zero when taps would run dry, had a far greater impact on Capetonians’ water usage than water restrictions. This is one of the major findings of a study by researchers from Stellenbosch University (SU) and the University Cape Town (UCT). The study was published recently in the online version of the journal Water Research. The printed version will be available in February 2019. “Our findings suggest that Capetonians responded more strongly to the threat of waterless taps than to the implemented levels
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of water restrictions. Our smart water meter data combined with billing data from the City points to a remarkable success on the side of citizens to drastically change their consumption patterns over a relatively short period of time,” says one of the researchers Prof Thinus Booysen from the Department of Electrical and Electronic Engineering at SU. Booysen conducted the study with Martine Visser from the School of Economics at UCT and Ronelle Burger from the Department of Economics at SU. “Our study seems to indicate that while inciting some level of fear may have been a risky strategy for the City
Booysen and his fellow researchers looked at the sequence of events leading up to Cape Town’s purported “Day Zero” in 2017 and 2018, and connected key events to the changes in behaviour of households that used hot and cold smart water meters that measured water usage. Hot water meters (Geasies) were installed in the Mpumalanga, Gauteng and the Western Cape from June 2015 to December 2016, while cold water meters (Dropulas) were installed in Cape Town from October 2016 to August 2017. Geasies enabled the researchers to compare the hot water usage in the three provinces. Booysen says they compared hot water usage in Cape Town to that of Mpumalanga and Gauteng because although these provinces were unaffected by drought, they experienced many of the same drivers of change as Cape Town. He adds that since households with Geasies and Dropulas are predominantly from the highest income quintile, and probably more informed and responsive to conservation messaging, they crosschecked their findings by mapping their data against that of the City of Cape Town’s domestic users’ total water consumption, as well as those in the highest income quintile amongst the City’s users. Booysen points out that these households also use the most water. He says their study shows there was an increase in water usage after the first week of September 2017 when the Level 5 restrictions were implemented and after 31 January 2018 when Level 6B restrictions were implemented.
“At this point the smart meter users were at 250L per day, which equates to 7,5 kilolitres per month (the Cape Town average was at 300L per day per over the month). The perverse effect of the contradiction in the Level 5 restrictions may explain the increase in usage to over 350L per day (or 10,5 kilolitres per month) at the end of the September school break.” As far as the difference in water usage between Cape Town and the two other provinces is concerned, Booysen says it dropped from the middle of August 2017, after the release of the Water Resilience Plan, but continued to increase to a peak difference of 9L per day after the second week of September. He points to three events in the first two weeks of August that might explain the apparent levelling off and subsequent reduction in the last half of August: the national government derided the City of Cape Town for not reacting adequately to the drought crisis, the City threatened to install water restriction devices for heavy users, and the mainstay annual West Coast Flower Show was cancelled because of the drought. Booysen says a week after the announcement of the disaster plan on 4 October 2017, the difference between the regions started to increase, reaching 21L per day in the first week of November, indicating a substantial reduction in Capetonian’s water usage. In mid-November, after the intervention by the premier and the national minister, the difference decreased to 6L per day at the start of the holiday period (18 December 2017 to 7 January 2018). “A week after the Level 5 restrictions were introduced, hot water usage in Cape Town perversely increased, and the difference between the two
samples quickly reduced to 2L per day in the following four weeks, apparently indicating diminished savings subsequent to Level 5 implementation.” “After the holiday, which overlapped with the implementation of Level 6 restrictions, the difference between the groups increased steadily, reaching 33L per day in the last week of January 2018, as Capetonians used less water in response to the looming crisis and the introduction of Level 6B restrictions.” Booysen says the cold water usage of households with Dropulas was similar to the City of Cape Town’s. “However, after the second week in January usage increased steadily to levels higher than before the holiday period, matching an increase in the City of Cape Town household data. This increase peaked shortly after the City’s announcement of Level 6B restrictions. A further reduction followed the implementation of Level 6B on 1 February, after which usage plateaued and slightly increased with the announcement on 22 February that Day Zero had been postponed to July.” Mainstream media and social media The researchers also analysed mainstream media and social media reactions to government announcements by searching for terms related to the water restriction levels and those related to the fear of the drought and its consequences. They looked for terms such as “Level 5 or Level 5 restrictions or Level 5 water restrictions or water restrictions”, “collection points”, “disaster”, “crisis”, “South African National Defence Force”, “bottled water”, and “borehole”. “We wanted to identify points of
heightened public engagement with the threat of empty taps, to understand how Capetonians digested, assessed and navigated the barrage of notices and news during the crisis,” says Booysen. He adds that they restricted their searches to August 2017 to October 2017 because their data suggested there had been a strong and consistent decrease in water use by their sample of households in this period. “Our analysis of the terms used during this period shows that the biggest response was observed, not when the restrictions or tariff increases were imposed, but in response to a three-phased disaster plan that warned of disastrous outcomes. “During the week preceding the drop in usage there was an increase in terms related to drought panic and a decrease in terms relating to the Level 5 restrictions. Spikes in the frequency of terms related to drought panic, however, do not overlap with the announcement of Level 5 on 3 September.” Booysen says these spikes give the impression that the announcement of tighter water restrictions may have had less effects than the media frenzy and scaremongering that ensued after the release of the Critical Water Shortage Disaster Plan, which referred to the risk of running out of water, the possibility of having to queue for a ration of drinking water at collection points, and the increased threat of fire and disease in crowded settlements. Source: Stellenbosch University (SU)
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REPORT
ZIMBABWE CAPITAL WATER WOES MAY LEAD TO RATIONING According to the City Council, the controlled water supply will see some suburbs getting water three days in a week following low rainfall experienced in the country.
By Pumps Africa
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imbabwe’s capital, Harare, is poised to experience water shortages after The Harare City Council announced the introduction of water rationing system in the city. According to the City Council, the controlled water supply will see some suburbs getting water three days in a week following low rainfall experienced in the country this season. Harare Town Clerk, Engineer Hosea Chisango revealed that suburbs in the capital will go without water as a key water treatment plant will be closed for maintenance following the reduction of water levels in the dam.
“This year there are predictions of low rainfall compelling the city council to introduce water rationing system in order to ensure residents get water throughout the season, and the cleaning of the water treatment plant is aimed at removing algae so that residents can get clean water,” he said. Currently, Morton Jaffray Waterworks is pumping about 350 megalitres to Harare, a drop from 540 megalitres in recent months due to a prolonged drought and shortage of water treatment chemicals. Harare requires 1200 megalitres of treated water a day. Meanwhile, Bulawayo, the second
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largest city after Harare, is mulling over the introduction of water flow limiters in a bid to manage the use of the natural resource. Flow limiters/restrictors are gadgets installed on a water tap to limit the flow of water from one’s tap without reducing water pressure. The city, which has had its own perennial water challenges, has since been forced to disconnect water supplies to households that have defaulted on bill payments. According to Bulawayo City Council (BCC), the water restricting gadgets will assist residents saddled
with council debt. “The device restricted one’s consumption to predetermined levels of supply and it was most useful to those residents who could not afford to pay their bills. It would restrict them to the allocation of 5 kiloliters, specific water meters who need to be installed as the old water meters are not suitable for this exercise.” read the city’s Future Water Supplies and Water Action Committee report. According to the report, the city’s six supply dams are 65.58 percent full with the current water supplies expected to sustain the city until 2021.
INDUSTRY TIPS
How to measure corrosion in pumps By Nita Karume
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orrosion in pumps is a serious concern in pumping systems. This is because lack of proper pump monitoring could lead to catastrophic failure of a pump. That being said, the selection of the proper material for the pump is extremely important in addressing this concern.
To avoid and or prevent the dangers of corrosion in pumps altogether, it is advisable to keep in constant check the pumps applied in systems where corrosion is a known risk. This will help ensure normal operation. On the other hand, there are several methods for corrosion monitoring that have been proven to work.
Moreover, the material selection is dependent on other factors such as the fluid being pumped or speed of rotation of the pump. Failure to select the correct material for an application has been proven to accelerate the effects of corrosion.
For instance, visual inspection of the pump is the easiest and can reveal corrosion damage occurring in the pump. This, however, comes with a major drawback as it requires the pump to be shut off and taken apart.
Similarly, choosing the best-suited material for an application will dramatically reduce the effects of corrosion.
Additionally, stress cracking could have no visible signs in the visual check, but later cause sudden distress that will prove to be catastrophic to the pumping system.
On the other hand, general corrosion can be detected through the use of a metal probe to measure the electrical resistance. This works such that when the cross section is reduced by corrosion, the measured electrical resistance will increase. Metal probes can also be used to measure the linear polarization resistance. A voltage is applied using the probes, and the resulting current is proportional to corrosion rate. Finally, ultrasonic thickness measurement can be used to determine the thickness of an area on the pump. This will then indicate if thickness is being lost due to corrosion.
INDUSTRY TIPS
5 Factors to consider when choosing irrigation pump By Harriet Mkhaye
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he innovations in pump systems play a vital role in today’s agriculture. Modern agriculture can be defined as the interaction of sustainable energy consumption, water use, market conditions, and the application of experience and knowledge to ensure the best design for agriculture applications. Irrigation pumps are usually used to pump water from a lower to a higher level from which the water then flows through channels to the fields requiring irrigation or to raise it to the required pressure head in order to spray the fields via piping systems (sprinkling). The heads involved range from approx. 1 m for normal lift operation to 40 m for sprinkling. Ocassionally, heads more than 100 m may be required. At times, irrigation pumps are usually not equipped with variable speed drives. The flow rate can therefore be controlled by either switching the pumps on and off, or by using a throttling valve in the discharge pipe, pre-swirl control (e. g. cooling
water pumps), rotational speed or impeller blade pitch adjustment. Both horizontal and vertical pumps (e. g. tubular casing pump) are used as irrigation pumps. For more than 2,000 years farmers have used irrigation to grow food for the world. However, this does not mean that all irrigation methods are equally useful. Knowing what will work best in your situation requires knowledge about the options available, including the advantages and disadvantages of each. With that in mind, here is a look at five things to consider in getting water to your crops: 1. Soil type. The type of soil in an area can affect not only the type of irrigation method used but also the irrigation run times. Sandy soils typically require frequent applications of water at a high rate to keep moisture in the root zone. Clay soils has a characteristic of holding moisture longer that sandy soils, even so, this may require frequent
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applications at a lower rate to prevent runoff. Land topography. When it comes to land considerations, hilly or sloping land can be a challenge. Drip irrigation works well if the laterals can be run along topographic lines. Often system run times may need to be adjusted to prevent runoff. Travelers and center pivot systems are usually out of the question on hilly and severely sloping land. Local weather patterns. In this case, sprinklers are less desirable in areas where high winds are common and in arid areas with a low humidity since water losses due to evaporation can be extremely high. Drip irrigation works well for both of the above mentioned situations. Type of crops grown. Sprinkler and drip systems can require high levels of investment. Therefore, it’s better to reserve their use for high-value crops like vegetables, small fruits and orchard crops rather than applying them to commodity crops like wheat and soybeans. Water quality. All drip irrigation systems require some type of filtration. Overhead systems such as sprinklers seldom require filtration. Irrigation water should be tested for water borne pathogens. Depending on the crop grown and irrigation method used chlorine injection may be required. Other water quality issues that could be of concern include levels of soluble iron and other dissolved minerals.
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INTERVIEW
Diesel engine maintenance
for construction machinery consumers in Africa
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ummins Inc., a global power leader, is a corporation of complementary business segments that design, manufacture, distribute and service a broad portfolio of power solutions. The company’s products range from diesel and natural gas engines to hybrid and electric platforms, as well as related technologies, including battery systems, fuel systems, controls, air handling, filtration, emission solutions and electrical power generation systems. Headquartered in Columbus, Indiana (U.S.A.), since its founding in 1919, Cummins currently employs approximately 58,600 people committed to powering a more prosperous world. Cummins serves customers in about 190 countries and territories through a network of some 500 company-owned and independent distributor locations and approximately 7,500 dealer locations. Construction Review magazine conducted an exclusive interview with, Cummin’s Christopher Judd, Service Engineering Lead – SubSaharan Africa in regards to the diesel engine market in Africa. 1. How is the African diesel engine market in general? This year is a milestone for Cummins as it is our centennial. We will set a new record by manufacturing over 1.5 million engines in 2019, and servicing about 12 million engines in the field globally. What that means is that there are big opportunities for business, particularly in Africa. In terms of both new and existing customers, these opportunities extend to first fit and repowers, which means taking an existing piece
How are your diesel engines best suited for the African market? Africa is an interesting continent in that it is non-regulated in terms of emissions. The rest of the world is divided into two broad bands: The Northern Hemisphere, which subscribes mostly to Environmental Protection Agency (EPA) emissions regulations, and the Southern Hemisphere, where European Union (EU) agencies regulate Latin America, Africa, and Australia.
Christopher Judd, Service Engineering Lead – Sub-Saharan Africa
of equipment with a different engine, and how it can be improved with a Cummins solution. Competition is strong on the continent. Our strategy to ensure our customers have the lowest total cost of ownership (TCO) is fourfold: Reducing repair cost, maintenance cost and time, rebuild cost, and fuel economy. Fuel comprises approximately 75% of the TCO. Not only do customers have to purchase the equipment, it also needs to be maintained properly in order to extend its useable life. Running costs are critical, which is an area where the competition is the toughest. In terms of the engines we currently rebuild for the construction industry, we upgrade to the latest technology, which not only allows for the most efficient engines, but is still within the customers’ price range.
International companies not only have a major drive for emissions compliance from a regulatory point of view, but also because it impacts positively on their corporate image globally. South Africa is slowly coming into line, mainly in the bus and automotive industries, in terms of NO and particulate matter emissions. Hence the main driver in Africa are these international companies. Our issue as a supplier of engines that adhere to strict emissions controls is the quality of the fuel supply. Our after treatment systems rely on ultra-low sulphur diesel, which is not readily available on the continent. Are there any new technologies in the market with regards to environmental conservation? Diesel as a primary fuel is going to be around for a long time. The technology will, in most cases, be more cost effective than gasoline due to its efficiency. However, Cummins also offers a large range of natural gas engines. We are fully set-up to provide support in this regard. Then we also offer dual-fuel engines, which is an ideal solution for customers in remote areas of Africa where they
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INTERVIEW
have an unreliable diesel supply. A good value-add we offer for the construction industry in particular is that if a customer wants to purchase a second-hand piece of equipment from the Europe or the US, for example, where it is required to conform to a specific emissions level, we offer a sulphur tolerance kit that essentially removes the after treatment components and modified the electronic controls so it becomes a lower-tiered engine specifically for African conditions. This is an ideal solution for costconscious owners of large equipment fleets, such as the construction industry and mining. However, fully electronic engines with after treatment technology as opposed to purely mechanical engines are a future trend. In South Africa we are carrying out some work on after treatment systems in particular in order to slowly start moving towards this goal. Globally Cummins is also adopting an electrification strategy. In terms of alternative fuel sources, whether natural gas or diesel, one has to bear in mind the specific high torque requirements of heavy duty construction equipment. Cummins’ electrified power strategies will mainly focus on on-highway applications and port equipment but we are constantly exploring new ways to bring customised solutions to ensure success for all of our customers. How is the reception of these technologies? The market in Africa is particularly difficult as we need to service the requirements of customers wanting more uptime from their equipment, and customers focusing on the bigger picture in terms of the TCO and wanting to reduce their fuel consumption. Ultimately, we will always supply the best solution for the customer and the application, be it an electronic or mechanical engine.
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Sometimes when we encounter product issues in the field, it is often due to misapplication, such as engines being used in dusty environments without adequate filtration and/or maintenance strategies. We have a team with specialised tools, equipment, and knowledge to assess a customer’s fleet – from construction to mining. For example, our engine engineering team can advise on how best to store and handle fuel, oil, and coolant on-site in order to prevent contamination. This is critical, as we have a lot of remote customers in Africa. I would say that, as long as there are no regulations pertaining to emissions, and as long as fuel-supply quality issues predominate, customers will opt for engines without after treatment, as these deliver a lower TCO and also meet the specific application requirements. As an engine supplier though, we have to be sufficiently dynamic and flexible to inform our customers that we have two main options, mechanical and electronic, and will specify the best solution possible. If a customer is operating in remote areas where there isn’t a lot of service support and the fuel quality is not ideal, then opting for mechanical engines is best. Of course, this is an older technology, but it is more robust and can deal with more arduous operating conditions. At the same time, however, these customers are not getting the maximum benefit from fuel-cost savings. Cummins’ electronic engines have modular common rail systems that provide high performance combined with reduced fuel economy. At the same time, they are highly susceptible to dirt and contamination, which calls for an excellent maintenance regimen. Here it is often difficult for a customer to know what
is best. Hence, we often take a step back to work closely with the OEM or equipment supplier to explain the specific requirements upfront in terms of duty cycles and load conditions in order for customers to have access to the most optimal solution possible. It is getting better. There continue to be issues in terms of misapplication, and we sometimes have to favour mechanical engines over electronic ones, but customers are becoming more aware of the importance of preventative maintenance. A lot of the time we rely on information from the service intervals to tell us when to look at an engine, especially in the construction, mining, and industrial segments. However, the service intervals are generally just a broad indicator. Conditions and applications differ, which impacts on maintenance requirements. Here is where Cummins can offer a solution. Obviously, our customers cannot be monitoring their engines 24/7. That is not their core business. We can provide solutions that do just that, setting limits for service intervals, and recommending the lubricants, oils, and coolants – all based on hard data. The drive for remote monitoring systems and to improve our diagnostic support is a major push for Cummins. What advice would you give to construction machinery consumers with regards to diesel engine maintenance? Fuel contamination is probably the single biggest maintenance issue in Africa. From a superficial perspective, customers tend to think that if the fuel looks clean, it is. However, the reality is that there is both soft and hard contamination that is not visible to the naked eye. In terms of maintenance, the market has to be educated about contamination at the microscopic level. That extends to all the engine systems, not only
fuel, but also air intake, cooling, and lubrication systems. Our construction customers in particular typically have large fleets, ranging from 50 to 100 pieces of equipment in different locations. My advice to these customers doing their own services as an authorized entity is to keep accurate records of all service and maintenance. It is quite difficult with remote locations to rely on a service manager to record everything, as well as to ensure that all equipment operators abide by the operating instructions and guidelines. Another major issue is storage and handling, which not only refers to spare parts and components, but includes coolant, lubricants, and the fuel itself. All dispensing nozzles, for example, have to be kept off the ground and capped at all times in order to prevent contamination. Handling is critical, as contamination can be introduced without the customer even being aware of it. Customers have to bear in mind that when a service engineer comes to site, in order to get to the root cause of any failure, we require accurate service and maintenance records to determine precisely what happened prior to engine failure. The construction industry presents us with typical issues that have to be distinguished between genuine product issues or operational and maintenance issues. Has the application been catered for adequately? Is there an element of misuse whereby an engine is being operated
outside its recommended guidelines? This is easier to analyse with an electronic engine, which has an electronic control module that logs all events on-site, as opposed to purely mechanical engines that do not have remote monitoring or diagnostic capabilities. What is the future of Cummins for the African consumers? Sub-Saharan Africa includes West, Central, Eastern, and Southern Africa, from Senegal to Djibouti. The merger of the African and Middle Eastern business units in 2016 has required us to adapt. The customer base in the latter is different, and so are the operating conditions, which are focused on extreme temperatures. In Africa, my team’s focus is to identify and prioritise any emerging product issues in the field. We also support hard-to-diagnose complex troubleshooting, whereby we liaise closely with our factories in the UK, the US, and China. Lastly, we also provide training and communication
for any new product releases, including processes and tools. Our team supports all types of equipment and applications, from on-highway vehicles to forklifts and reach stackers and tractors in the agricultural space. Mining is a big portion of our business, and is a large focus for our future direction. We have just established a Master Rebuild Centre and Parts Distribution Centre in Morocco to service the mining industry in Northern Africa. We are investing significantly in the mining space. One has to bear in mind that engines are but a single component we supply, and they also form part of gensets, which also include cooling packs, controls, and alternators. Here we have a power generation team dealing with any issues in this regard. What continues to give us the leading edge in Africa is our Fleetguard filtration product range, for which we have both technical and sales support across the continent. A lot of engine suppliers do not offer that, which makes us a much more favourable choice in terms of ensuring the lowest TCO. What continues to give Cummins the leading edge globally is its depth of experience and support, all the way back to the factory. We are also adopting a smarter approach in that we are being much more proactive, and anticipating any product issues before they become problems in the field. We are closing the loop between the customer and the OEM.
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INTERVIEW
The Unexpected Job Market being created by Renewable Energy
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he renewable energy sector could provide an unexpected but much-needed jobs boost to South Africa’s employment levels, as the sector continues to mature.
place a moratorium on job cuts as the private sector and government tries to weather the recession. Stats SA’s Quarterly Employment Statistics for June 2018, showed that quarter-on-quarter, the economy shed 69 000 jobs – from 9 817 000 in March to 9 748 000 in June.
This is the view of renewables experts SOLA Future Energy, the company that replaced Robben Island’s dieselpowered electricity supply with a grid driven by solar energy. This work earned them a nomination in the recent Vision 2030 awards, a contest that recognises organisations, enterprises and individuals that are aligned with the government’s NinePoint Plan to boost economic growth, and the National Development Plan (NDP). According to Dom Wills, Chief Executive of SOLA Future Energy, the more that new solar systems are built and come online, the greater the growth in the ongoing job opportunities in both the operation and maintenance of these facilities. “Although the job prospects for the construction of renewable energy projects are well understood, ongoing and permanent career opportunities created by the operation and maintenance of the solar systems are just as important and should not be underestimated,” added Wills. This also comes after a call to business by President Cyril Ramaphosa in early September to
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Dominic Wills, Chief Executive of SOLA Future Energy He is an Electrical Engineer, completing studies with a PhD in wind generator design at Stellenbosch University in 2009. After a brief period at optimal energy working in electric vehicle technology, Dom joined Aurora Power Solutions in solar PV in 2010. Dom was involved in developing 225 MW of successful solar PV projects in round 1,3,4 of the REIPPP projects. In 2013, Dom co-founded SOLA Future Energy where his focus is to propel the widespread adoption of embedded solar power in Africa. At SOLA Future Energy, he has overseen the build of over 25MWp of solar projects.
Wills says the most common misconception about the renewable energy sector is that it lacks job opportunities. “At first, those seeking jobs in the energy sector in South Africa were just looking to work for entities like Eskom.” “As more people understood that installed solar panels needed maintenance, interest in the sector grew. As the sector has grown, the opportunities have expanded and also become more specialised,” he adds. Like any construction project, after a solar system is commissioned it requires ongoing upkeep, monitoring and care. But, many renewables jobs creation projections underestimate the operations and maintenance needed after construction. The European market shows that for every MW of solar installed, some 28 job-years per MW were created. Closer to home, across SOLA’s operations portfolio of 23.5 MW, 4 people are employed full time and one part time, to operate these facilities.
“If we extrapolate this to cover the entire embedded market, we estimate that at least 37 people are employed, full time, for South Africa’s current 200 MW of embedded generation. The market potential of 5000 MW means that at least 900 potential jobs could exist,” adds Wills. Wills confirms, “these job estimates exclude the operation of utility-scale plants, as well the other types of maintenance – such as cleaning and landscaping – that are also required to maintain solar facilities.”
renewable energy sector.” He points out that the sector, in particular, needs more qualified electrical engineers, as well as analyst and business data specialists who would be employed to monitor and collate data after installation.
The type of work in operations and maintenance includes: Continuing to monitor the project remotely after installation – this function needs data analysts with experience in electrical installations and yield modelling. Technical maintenance, fault Wills explains that the sector requires finding, mechanical and electrical a host of different skills – from inspections. engineering to the legal aspects of Administrative work including the job. “There are various sectors reporting and invoicing that are involved in the ongoing upkeepPower andAd operations within the3 2018/10/03Repairs and upkeep of various Half landscape REPRO.pdf 13:18
solar components, including modules, inverters and batteries depending on warranties “As the renewable energy sector matures, the sector is able to create sustainable jobs,” Wills concludes. About SOLA Future Energy SOLA is a dynamic company that aims to propel the widespread adoption of solar energy systems in Africa. They believe in creating an abundant world where more people have access to cheaper, cleaner energy. From their offices in Cape Town, Johannesburg and Windhoek, they service clients across Africa. Their team is built of highly capable and educated staff who are ready to handle any project.
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sustainable & long term
WATER
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2018-11-12 02:53:28 PM
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