sa mechanical engineer july 2012

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 62 July 2012 1

www.munters.co.za

2 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 62 July 2012

www.nkosishaven.org


AN ENGINEER’S VIEW

Chris ReayChairman of the Working

Committee: Communications(SA Institution of Mechanical

Engineering)

all will benefit from the process. Does the tendency for economies to exhibit this shifting of the wealth upwards then correlate to the emergence of large monopolistic businesses and over-indulgent govern-ment, and to the impact of the lack of bank credit to the small business and individual who were, and are, so affected by the credit crisis? It is otherwise commonly called greed.

It is interesting to note that in Australia, most of the millionaires are from the small, entrepreneurial business sector and that the impact of the credit crisis was minimal on that country. The chances of the big banks, financial institutions and businesses taking risks with others’ money was clearly lower. Is this a lesson to South Africa and the world at large to enable small business to thrive?

If the poor continue to get poorer then there must at some stage be a situation where the inevitable happens: the pyramid scheme collapses, and many irate investors (read taxpayers and consumers) get active to ban the scheme.

Accountants before engineersWhere would engineering as a role fit into this? I do believe that in any engineering transaction which has an objective to create the built environment, the exchange of money for product is probably pretty reasonable. The product is evident, well defined, built to proven specifications by persons who are qualified and usually sufficiently experienced to do it right. When, however, I see evidence that the lawyers are likely to make more out of the renew-able energy contracts than many of the Engineers involved, I wonder if that is contributing to the award of wealth without commensurate productivity. No names are mentioned in order to protect the guilty.

A Giant Scheme?Is the Modern Economy a Giant Pyramid Scheme? Think about it. As a taxpayer

and voter, you are promised by politicians that if you vote for them they will provide you with all sorts of benefits in exchange for your vote. You earn money

in your job and pay tax to the government so that it has funds to provide you with the promised benefits: education for your children, health services, and

infrastructure in the form of roads, municipal services, police services, judiciary, economic and fiscal responsibility to name some of them. The mix depends on the

policies of each government. In South Africa you may only get the party’s tee shirt.

Many irate investors (read taxpayers and consumers) get active to ban the scheme

Let’s take a look at our situation. We have what the population has been assured is the best constitution money can buy. If you look care-fully you realise that, in fact, you cannot be

assured that the person you vote for will represent you because the political party will decide who to appoint to that role. But let’s not get into politics; we have enough hot air on that topic to cause climate change. What we do witness is that the persons appointed to government at the top are very well paid and appear to earn a lot more than the delivery for which they are responsible. The rules set up by the government whether by statute or by practice enable this to happen. They could be said to be tak-ing money from the down-line without providing the appropriate product in return. How does this differ from the structures of a pyramid scheme? There is no observable exchange of value.

Obscene amounts of moneyLet’s rather look at what happens to a lot of the money that feeds upwards to the top both via taxes as well as the flow of money to the providers of many near monopolistic trade structures. It seems fairly well-documented globally that the rich are getting richer while the poor are getting poorer. This is happening whether one is in a typically western capitalistic economy or a socialist economy as we can observe in both the USA and Europe. Think of the outcome of the credit crisis: many top bankers and investors made huge and obscene amounts of money via a system they developed to get the money out of the general population.

The overwhelming common factor behind all these processes is that money is flowing up to the top without the commensurate product or service flowing back down accompanied by broken assurances that


AXIOM

AXIOM HYDRAULICS (PTY) LTD

HA

Tel: (011) 334-3068 / 334-3086 Fax: (011) 334-4543E-mail: [email protected]

SAMHYDRAULIK, which is one of the leaders in the field of hydraulictransmission, has been operating for over 25 years in the internationalmarket, offering a complete range of orbital hydraulic motors and power steering units, axial pumps andmotors for medium and highpressure ranges, all characterisedby excellent performances.

SAMHYDRAULIK employs 120people who operate inside avery modern and efficient plantthat spans over 6 000 squaremetres to assure a high standardand flexible production capacity.The latest computer technologyis used for both design andproduction, combined withstrict quality control proceduresduring all production phases,which translates into innovative,reliable and functionalproducts that meet the various needs of the market.Its ISO 9001 certification,held since 1994, is theresult of a quality-orientated philosophyon which SAMHYDRAULIKhas always based itsoperation.

17 Heidelberg Road, Village Main, Johannesburg, 2000P O Box 260248, Excom, South Africa, 2023

mailto:[email protected]


Produced by: PROMECH PUBLISHING, P O Box 373, Pinegowrie, 2123, Republic of South AfricaTel: (011) 781-1401, Fax: (011) 781-1403Email: [email protected], www.promech.co.zaManaging Editor Susan Custers Editor Kowie HammanCirculation Catherine Macdiva Advertising Mark BennettDTP Zinobia Docrat / Donovan VadivaluSubscriptions Please email us at [email protected] you wish to subscribe to “SA Mechanical Engineer” at R405,00 (incl postage and VAT) per year; R1 020,00 per year for Africa/Overseas.

DisclaimerPROMECH Publishing and The South African Institution of Mechanical Engineering as well as any other body do not take responsibility for the opinions expressed by individuals.Printed by: Typo Colour Printing, Tel: (011) 402-3468/9FSC (Forestry Stewardship Accreditation)

Cover Story8 Clean Air for Top Performance

CESA10 Lack of Skills

Monthly Column11 Prominent Professionals

Opinion12 Soapbox

HVAC - Heating, Ventilation & Cooling13 Quality at Low Prices?15 Chilled Water Project

CCCCoooommpmpppmm rreeeessssssssssooorrrs,s,s,s AAAAAiirir MMMMoootttoooorrssss &&& &VVVVaaaV ccccuuuuummmmmu PPPPPPuuummmmuu pspsssp17 Explosive Dust19 Joining Forces for Better Service

SAEE22 National Energy Barometer Survey

POWER GENERATION TODAY23 PV Power for South Africa26 Power Generation News

Contents

The monthly circulation is 4 242

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

July 2012 VOLUME 62 NUMBER 7

On the cover:

MuntersTel: (011) 997-2000www.munters.co.za

Exhibitions31 Electra Mining Africa

Hydraulics & Pneumatics32 Spill-free Connectors35 Bionic Learning Network

Regulars3 An Engineer’s View6 Institution News30 SAINT37 SAIT39 Market Forum

www.promech.co.za


http://www.promech.co.za


http://www.munters.co.za



Council 2011/2012

Office BearersPresident .......................... . . . . . . . . . . . . . . . . . . . . . . . . G Barbic (George)Vice President ............................ . . . . . . . . . . . . . . . ... D Findeis (Dirk)National Treasurer ............................... KK Nyangoni (Kudzai)

Branch ChairpersonsCentral ..................................... . . . . . . . . . . . . . . . . . M Cramer (Mike)Eastern Cape ................................................ W Rall (William)KwaZulu/Natal ................................................. J Moto (John)Mpumalanga Highveld.............................. L Odendaal (Louis)Western Cape ........................................... Dr D Blaine (Debbie)

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

Chief Executive Officer: Vaughan Rimbault

National Office Manager: Anisa Nanabhay

PO Box 511, Bruma, 2026

Tel: (011) 615-5660, Fax: (011) 388-5356

Email: [email protected]

Website: www.saimeche.org.za

Membership: Central, Eastern Cape, Mpumalanga & KZN:

[email protected]

Membership: Western Cape: [email protected]

Company AffiliatesAlstom Power Service SA

Babcock Africa Limited

Bateman Engineered Technologies

Bosch Projects

Fluor SA

GEA Air-cooled Systems

Hansen Transmissions SA

Hatch Africa

Howden Power

Howden Projects

Industrial Water Cooling

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

Megchem Eng & Drafting Services

Mod-U-Flow

Osborn Engineered Products SA

THE SA INSTITUTION OF MECHANICAL ENGINEERING

Rotek Engineering

RSD a division of DCD-Dorbyl

S.A.M.E Water

Sasol Technologies

SEW Eurodrive

Siemens

SNC-Lavalin SA

Spicer Axle SA

Spirax Sarco SA

Technical Systems

Thyssenkrupp Engineering

Transvaal Pressed Nuts & Bolts

Ultra-Flow Engineering Services

Vital Engineering

Weir Minerals Africa

Winder Controls

Soap Box Opportunity for Exhibitorsat Electra Mining 2012second largest mining show in the world

Expo Centre, Cnr. Rand Show and Nasrec Roads, Nasrec, Johannesburg

10 – 14 September 2012

Be sure to visit Electra Mining, the world’s second largest mining exhibition, and gain free attendance to the Exhibitors Soapbox sessions organised by SAIMechE in the MAN Building, Expo Conference Centre, Nasrec.

30 minute corporate presentations on products, services, technologies and trends will be given throughout each day of the exhibition.

This first time ever Electra Mining Exhibition feature is designed to give the discerning user/purchaser the opportunity to make informed decisions. A programme of the sessions will be published in due course.

Obtain a Soap Box application form from:

Carey Evans - [email protected] Tel. (031) 764-7136, www.saimeche.org.za

Over 20 & 21 June, around 100 post-graduate engineering students from Western Cape higher education institutions Cape Peninsula University of Technology, University of Cape Town and Stellenbosch University gathered at CPUT’s Bellville Campus to share their research in the fields of materials, manu-facturing and mechanical engineering. The two-day conference, funded by a donation from the Cape Initiative in Materials and Manufacturing (CIMM), was endorsed by SAIMechE WC and drew a strong

Western Cape Post-Graduate Students Showcase their Research at Local Conference


http://www.saimeche.org.za






THE SA INSTITUTION OF MECHANICAL ENGINEERING

National Welding and Fabrication Multi-Speaker Seminar

crowd of vibrant engineering students engaged in their masters and doctoral studies.

Presentations from the students were of an excel-lent caliber, and it was a proud couple of days for academic supervisors and the organisers to witness the professionalism and engineering expertise of participants. In an environment in South Africa where education quality is critical and in which pressure on graduate engineering students is high, it was very encouraging to see how well our post-graduate students faired. The participants were a shining example of the future for collaboration between research groups, exchanging constructive and thoughtful ideas on each other’s work, moving towards a multi-disciplinary, inter-institutional, interactive space where the goal is the pursuit of knowledge and advancement of science.

The topics presented covered a wide range of fields, from research into explosive blasting, internal combustion engines and new types of fuel, novel materials and metal alloys, compressor design, to

reconfigurable manufacturing systems. The skills and capabilities of the various research units and departments at the institutions were well-represented.

This conference was run as a pilot project with the vision of scaling it up to run regionally through-out South Africa, and ultimately culminating in a national conference for post-graduate research in mechanical engineering and related fields. If the success of this first run is anything to go by, South Africa should look forward to exciting forums for sharing of ideas and networking opportunities for our post-graduate students.

Dr Deborah Blaine, Senior Lecturer, Mechanical and Mechatronics Engineering, Stellenbosch University, WC SAIMechE chair

East Rand22 August 2012Contributing expertise

from:

Air Liquide

Afrox

Genrec Engineering

NDE Stainless Steel

Steinmuller

FeaturingEffects of various components of shielding gases during mig-mag welding of ferrous & nonferrous materials

National standards on gas equipment & safety

Duplex & super duplex materials

Welding gases

Welding 3CR12 (chrome steels)

Controversy of low cost fabricated steel vs. reduced mass

Preferred welding processes

WorkshopsCode Abbreviated Title Date – Start Date – End Region

A2712 Refrigeration Explained – Advanced

25 Jul 12 26 Jul 12 Durban

E0112 Introduction to Steam; Steam Principles

1 Aug 12 3 Aug 12 East Rand

B2512 Effective Management Roles 1 Aug 12 1 Aug 12 Port Elizabeth

C4412 Pump Technology – 1 7 Aug 12 7 Aug 12 Cape Town

C4512 Pump Technology – 2 8 Aug 12 9 Aug 12 Cape Town

E4412 Pump Technology – 1 14 Aug 12 14 Aug 12 East Rand

E4512 Pump Technology – 2 15 Aug 12 16 Aug 12 East Rand

F2512 Effective Management Roles 15 Aug 12 15 Aug 12 Secunda

A0112 Introduction to Steam; Steam Principles

29 Aug 12 31 Aug 12 Durban

C2512 Effective Management Roles 26 Sep 12 26 Sep 12 Cape Town

E2912 Lubrication & Lubricants 17 Oct 12 17 Oct 12 East Rand

C0212 Boiler House; Safety Valves 5 Sep 12 7 Sep 12 Cape Town

E0212 Boiler House; Safety Valves 3 Oct 12 5 Oct 12 East Rand

A0212 Boiler House; Safety Valves 10 Oct 12 12 Oct 12 Durban

Carey Evans - [email protected], Tel. 031 764 7136or via SAIMechE’s Website www.saimeche.org.za




COVER STORY

Salty air filled with corrosive particles is, for example, the last thing you want to go into an internal combustion engine driving a generator or pump on the coast, not only in

terms of internal damage to the engine, but also to prevent external damage to electronics and other components around the engine.

A company which specialises in mist elimination and air scrubbing from either an intake or an air outlet perspective is Munters, based in Edenvale near Johannesburg. “SA Mechanical Engineer” speaks to managing director, John Andersen, about a particular challenge they faced recently with the air intakes of a power generator installation on the tropical coast of Madagascar.

Removing salt“Cummins Diesel South Africa approached us for an air cleaning solution for the diesel generators sets they installed at a power generation plant for a new cobalt and nickel processing plant right on the coast,” he explains. “Apart from sea-spray air being taken directly into the engines of the plant, the area is plagued by cyclones which create even more moist air, hampering the performance of the large diesel engines driving the generators. Being a critical component in the aluminium-making process, the client cannot afford for this genset to fail unexpectedly through environment-based corrosion.

“The equipment we designed as a solution not only

Clean Air for Top Performance

In a similar way that harmful particles are removed from the air streams of process gas, or that chemical particles are taken out of chemical processes, so can unwanted particles be removed from air intake systems

to eliminate damage to equipment down the line utilising the air.

The equipment we designed as a solution not only protects the equipment from water ingress in heavy rain, but it also scrubs the sea mist entering the generator units to eliminate corrosion

John Andersen, managing director of Munters

Phillip Dickinson, sales manager at Munters


COVER STORY

protects the equipment from water ingress in heavy rain, but it also scrubs the sea mist entering the generator units to eliminate corrosion,” says John. “With our mist eliminators being effective right down to 10 micron and sea mist salt crystals being 13 micron, it’s the ideal system to prevent these harmful particles from getting into the containers housing the generators and ancillary equipment.”

Based on experienceThe effective design of this system is based on a similar problem Munters faced a while back on a large compressor plant on the West Coast near Saldanha. “Moisture from the sea mist was settling on the elements of the air filters, wetting the filters and thereby blocking them to create a pressure differential which ended up tripping the compressor system,” explains John. “The technol-ogy we used to solve this problem, combined with our experience with air cleaning technology in mine shaft ventilation and cooling, meant we could de-sign a specific solution for Madagascar which is second to none,” says Phillip Dickinson, Munters’ sales manager heading the team working on the Madagascar project.

“The three generator sets are housed in special twelve-metre by three-metre squared containers, purpose built for this project, but initially they only had weather louvres fitted for the air intakes at each end of the container. This may be aestheti-cally pleasing but it does not stop any salt ingress, especially down to the 10 micron size.

It’s all in the profiles“The generator solution utilises a vertical mist eliminator for horizontal air flow,” adds Phillip. “It’s just one of the various technology combinations we can use to solve specific problems in different applications. The choice varies from an array of blades with different profiles depending on the pressure drop, in flow rate in the system and the micron size of the particles you want to eliminate from the air flow.”

But eliminating particles from air intakes is not all mist eliminators are good for. “We’re very actively involved in the pulp & paper industry for which we have a whole list of application-orientated solutions,” says John. “Black liquor, for example,

Multi-stage evaporation, followed by efficient mist elimination capable of handling high velocities, can yield up to 70% dry material together

produced during wood pulping, contains a high concentration of chemicals and solid wood fibres. Multi-stage evaporation, followed by efficient mist elimination capable of handling high velocities, can yield up to 70% dry material together with the recovery of process chemicals.”

Flue gasMunters also has a long list of clients in the pro-cess gas industry. “We’ve been awarded Flue Gas Desulphurisation (FGD) elimination systems for one of the new Eskom power stations currently being built,” says John. “The growing efficiency of wet gas scrubbers in removing contaminants from industrial process gas streams requires highly efficient mist eliminators to remove entrained scrubber reagents or contaminants. By preventing the carry-over of liquid by efficient elimination, the downstream components are protected from damage. An added bonus is an energy efficient and safe process.

“Stack rain is one consequence of the most visible industrial process, occurring when saturated and warm exhaust gas is released into a colder atmo-sphere. Our solution to this problem is spin vane technology which can also be used very effectively to avoid product loss inside a process.”

HVACYet another discipline where Munters’ mist elimi-nation technology is widely used is air intakes for HVAC systems. “Specific profiles and combinations of mist elimination technology are used to remove moisture and droplets from air before it enters HVAC systems to prevent filters from getting wet and restricting the flow and directly impacting on the efficiency of air cooling system,” John says in conclusion. “Regardless of the application, when it comes to clean dry air, we have a mist elimina-tion solution for each and every challenge that may crop up.”

Phillip Dickinson, Munters, Tel: (011) 997-2000, Email: [email protected]



CONSULTING ENGINEERS SOUTH AFRICA

Says Graham Pirie, CEO of CESA, “At provincial and municipal level, there is a grave lack of general engineering skill. The internal staff are not equipped to produce clear Terms of Refer-

ences (TORs) or even assess the final tenders due to lack of experience. This causes backlogs in the project process and spills over to the overall monitoring of deliverables.”

But experience is not the only problem, the lack of infrastructure projects being undertaken is also the result of the inconsistency in management and top leadership. Currently a significant number of CEOs, Director-Generals and top management are under suspension due to alleged corruption.

No decision-makingThis leads to top posts being under custodianship and the substitute person simply ‘gatekeeps’ the position with absolutely no decision-making undertaken dur-ing that time. Says Graham, “It is time to sort out the corruption and improve the process of procurement in the built environment. The private sector has a great deal of skill and experience and should be encouraged to assist government.” CESA is also concerned about the resignations of CEO’s and senior staff from vari-ous parastatal’s and government departments coupled with no clear succession plan or announcement of incumbents.

Graham Pirie, CESA, Tel: (011) 463-2022, Email: [email protected]

The internal staff are not equipped to assess the final tenders due to lack of experience

Lack of SkillsConsulting Engineers South Africa (CESA) has reiterated the

need for Government to get its house in order. The lack of infrastructure

development due to projects not being undertaken as well as tender processes taking up to three

years to materialise is in large part,

due to the lack of leadership within the government organisations.

Graham Pirie

Pre-registration is now open for Electra Mining Africa, the ultimate market place for all stakeholders involved in the mining, construction, industrial and power generation industries.

Visitors can expect to see leading local and international industry players in the packed halls and outside precincts. It’s the ideal place to view the latest in technology and equipment, innovative products and new supplies and services.

Experts will be on hand to give advice, live demonstrations will be happening daily and co-located conferences and workshops will add even greater value.

Electra Mining Africa is recognized as the second largest mining show in the world and the biggest trade exhibition in southern Africa with global recognition for its broad reach across mining, construction, industrial and power generation industries.

Electra Mining Africa and co-located Elenex Africa, Machine Tools Africa and Transport Expo runs from 10-14 September 2012 at the Expo Centre, Nasrec, Johannesburg, South Africa.

10 - 1

4 September 2

012

Expo Centre

, Nas

rec,

South A

frica

T r a n s p o r t f o r t h e M i n i n g I n d u s t r y

THE BIGGEST M

ININ

G

AND ELECTRIC

AL TRADE

SHOW IN

SOUTHERN AFRIC

A

PRE-REGISTER AND BE PART OF THE IN-CROWD

INTERNATIONAL MINING, INDUSTRIAL, CONSTRUCTION AND POWER GENERATION EXHIBITION SHOWCASES

NEW INNOVATIONS, PRODUCTS, SERVICES AND TECHNOLOGIES

VISIT

co-locating in hall 9

Contact the Marketing Director at Specialised ExhibitionsLeatitia van Straten

[email protected]+27 (0) 11 835 1565

www.electramining.co.za

PRE-REGISTER FOR FREE ENTRYIt’s simple – just complete the registration form at

www.electramining.co.zaR15 per vehicle, per day for secure parking

SKET

CH 4

490/

12


http://www.electramining.co.za




MONTHLY COLUMN

Prominent ProfessionalsMlamuli Martin Buthelezi: Transnet Freight Rail Chief Operating Officer.

Academic

School: Matriculated from Vukuzakhe High School, 1982, Post Matric: Hilton College.

Graduate studies: National Diploma: Mechanical Engineering, Mangosuthu University of Technology; Higher National Diploma: Me-chanical Engineering, Durban University of Technology, 1987; Bachelor of Science: Mechanical Engineering, Tulane University, New Orleans, USA, 1993.

Post-graduate: MBL, University of South Africa, 2003.

Professional BodiesSAIMechE, NSBE (National Society of Black Engineers).

Career Path

First employerSapref, Assistant Engineer in 1987.

Growth pathRefinery Engineer, Engen, 1993; Packaging Engineer, South African Breweries (SAB) Prospecton, 1997; Engineering Manager, SAB Prospecton, 1998; GM: Marine and Engineer-ing, Transnet National Ports Authority(TNPA), 2000; GM: Landlord Services, TNPA, 2001; GM Rosslyn Brewery and Polokwane Brewery, SAB(2004); Entrepreneur in the energy sector, 2008; Chairperson of Ithala Bank, 2010.

Present employer and position Chief Operating Officer (COO), Transnet Freight Rail.

Achievements

A designMillenium Tower – Port of Durban.

Future – a concept, a dream or a wishAn integrated logistics network across Africa.

Projects

Most challengingConstruction of the Port of Ngqura.

Most rewardingPort of Ngqura – completion of first phase and subsequent flooding of the port.

Commentary

Are there shortcomings in the Mechanical Engi-neering Industry in South Africa?Yes. Not enough pipeline to meet the needs of the economy and the continent. Skills plight has also left us with a gap that needs urgent attention.

How would you mend this?We need incentives for industries to train engineers and tech-nicians again. This must be coupled with a deliberate effort to mentor and remunerate our up-and-coming technocrats.

Message to young engineersThis is a very exciting period to have an engineering quali-fication in Africa. Be part of the generation that led the reconstruction of our continent.

Mlamuli Martin Buthelezi

www.pps.co.za


Brian Volk of PHC Projects An Architect or Civil Engineer

Phildy Schlotz of DRA Be a dentist – because you’re your own boss and

can work anywhere you like… as opposed to engi-neering where you usually have to work in groups and be based in a main centre like Johannesburg where the work is.

Thalefang Mtombeni of Schaeffler I’d be a dancer – that’s what I do part time now

anyway. I do ballroom, Latin, contemporary…

Izak van Niekerk of Bell Equipment A doctor…

Konnie de Boom of Megchem As an alternative I would have preferred a profes-

sional route such as a veterinary surgeon or possibly a dentist (specializing). But I must say that being a mechanical engineer is fabulous! Having been involved for almost 40 years at a petrochemical plant in Mpumalanga, the plant has gone through various stages such as grass roots, commissioning, process modifications, upgrading etc. Challenges such as erosion, corrosion, fatigue, maintainability and safety are now becoming major concerns, which is a Mecca for mechanical engineering, especially for young engineers.

OPINION

On his rounds, Kowie Hamman, our Editor, is conducting an informal survey on the lighter side of engineering. We follow up from last month with two

pertinent questions. SOAPBOXX

SSSOASOASOAPBO

SOAPBOAPBOXAPBOX

BOXBOX

Soapbox

If you weren’t a mechanical engineer, what would you be?

What do you think of Electrical Engineers?

In your book, what is the most pivotal invention ever?

Brian Volk of PHC Projects I know many good Electrical Engineers who are

good people as well, so I respect their knowledge and ability.

Phildy Schlotz of DRA They are absolutely necessary. At DRA we’re

Brian Volk of PHC Projects Probably fire or the wheel because without them

we would not have been able to make any of the later inventions

Phildy Schlotz of DRA Ummm, the wheel…

Tom Esterhuizen of Tom Esterhuizen & Associates

Haven’t thought about this at all, but I’d imagine the personal computer has made huge changes in all our lives and has made engineering much easier…

Thalefang Mtombeni of Schaeffler A bearing… Yes, definitely a bearing. If you

look at the evolution of a bearing since 1883, it’s just amazing how much technology actually goes into making a good bearing today. You can’t move anything without a bearing.

Izak van Niekerk of Bell Equipment Mobile phones!

a multi-disciplinary company and we all work together to deliver a product, we just can’t do it without each other…

Tom Esterhuizen of Tom Esterhuizen & Associates

In general, electrical engineers are much more detail driven than mechanical engineers. This is probably something we can learn from them, pay more attention to the finer details…

Thalefang Mtombeni of Schaeffler We’re better than them, of course…

Izak van Niekerk of Bell Equipment They are extremely clever!


HVAC - HEATING, VENTILATION & COOLING

“W e are appointed as one of only three agents in South Africa for Bock compressors from Germany and also deal extensively in

Danfoss refrigeration equipment, yet some com-petitors are now saying our products are fake just because our prices are low,” he tells “SA Mechanical Engineer” during an interview at the company’s warehouse in Randfontein. “As a fairly new player in this market, we’ve adopted a business strategy of low margins so that we can get into the market, but there’s been some resistance from some of the long-standing players.”

Fazal came from India to settle in South Africa over 20 years ago to work in the oil and gas industry as an IT systems engineer for many years before getting involved in the refrigeration industry. Today he owns the Coldpoint brand of coolers and industrial fridges manufactured in Swaziland and recently opened up

Refrimate to design and supply industrial cooling systems into the local market.

Middle market“We cover the middle market in industrial and commercial cooling, mainly supplying spare parts to contractors who do the repair work to existing installations,” he says. “In terms of new installa-tions, we have the experience to design complete chilling, cooling and freezing systems for which we supply all the components needed by the installa-tion contractor. We also have extensive experience in developing control programming for the systems we design.

“With Bock being the premium brand in cooling system compressors, we obviously always recom-mend the brand, but it’s up to the client to decide and therefore we do deal in other brands as well,” Fazal says. “Some of our product is imported from China but this is strictly from manufacturers who we’ve dealt with before and whose products we’ve tried and tested for quality and reliability.

Direct business“One of the other reasons we’re able to offer good quality products at lower prices is because we don’t

Quality at Low Prices?

Very often, low prices are an indication of fake or inferior products, or it could simply mean that the supplier is prepared to take a lower mark-up than others. Some buyers look askance

at Fazal Patel of Refrimate, for example, who believes he is to a certain extent the victim of this disbelief in terms of the

refrigeration equipment, components and parts which he imports. This, despite that fact that the company is an agent for well-

known international brands in cooling and refrigeration systems.

R22 gas imported to South Africa

Fazal Patel of Refrimate

Shown one thing during your visit to China, and then getting something completely different


The same applies to refrigerant gases, which varies in price dramatically from one supplier to the next. “The R22 gas is still the most general refrigerant gas used locally and is totally imported,” Fazal says. “Our gas is competitively priced because we import large batches at a time, but here again, you have to be careful who you buy from as there are many backstreet gas suppliers in some countries who fill cylinders in their backyard to sell on very cheaply. In this regard we have learnt to only buy from big suppliers who have been in the business for a long time.”

ComponentsAn area of specialisation for Refrimate is in control-ler and sensor PLC units, components which the company has manufactured for them under their brand name. This is an area where people are often taken for a ride,” says Fazal as he takes one of the units from a display cabinet to show us. “It took a while to find a reliable supplier who can make the sort of good quality product we’re prepared to put our name to, but we’ve pinned one down now and the product has been doing very well locally.”

He continues, “Just as an example, we sell these units at a third of the going rate for similar components in the market. The same applies to a sensoring unit which we sell at 35% of the price of what some suppliers charge. These are highly sensitive parts of the cooling system and an area where you simply can’t get away with using an inferior product, you’d just be throwing away the good name you’re trying to build in the market.”

Time will tellAccording to Fazal he’s spearheading a pioneering breakthrough in the refrigeration market with his sourcing and pricing approach but he is confident he’s on the right path. “It’s been a steep learning curve and challenging in terms of resistance in the market, but it’s just a matter of time before the industry realises that we’re in this for the long haul,” he remarks in conclusion. “Already we’ve had so many instances where customers recog-nise the advice and recommendations we give as professional assessments based on a thorough understanding of the systems and the products we supply.”

Fazal Patel, Refrimate, Tel: (011) 692-2782, Email: [email protected]

buy through an agent like most importers do,” adds Fazal. “We only purchase product from factories I have personally visited. We then deal with them directly. Dealing direct ensures you’re not being shown one thing during your visit to China, paying an agent in between and then getting something completely different very likely made in a different factory altogether.”

Refrimate designs complete chilling, cooling and freezing systems for which they supply all the components

Well-known brands in stock on the shelves

The sort of good quality product we’re prepared to put our name to



www.festo.co.za


The contract was the fastest project that BBE Consulting has undertaken to date, requiring 4 000 design man-hours over a period of four months. The design was required to

complement existing equipment, while remaining flexible for future expansion.

Raymond Funnell, lead engineer at BBE Consulting, says, owing to the complexity of the piping, the entire design was carried out using a 3D model. The mine’s shallower reserves have been accessed from the existing Silver Shaft, but new, deeper reserves will be accessed from the new 1 100m deep No 4 sub-shaft.

Considerable depth“The new reserves will be mined at considerable depth, requiring the intake air from the Silver Shaft to be cooled on 5900 Level, which is 1 800m below surface,” says Raymond. “This is achieved by installing a bank of high-pressure cooling coils. The new chiller plant will be located on 4900 Level

and about 500m from the No 4 Shaft.

“The plant initially comprises three R134a dual screw-compressor machines, providing a total cooling capacity of 3.4 MWR. These machines are relatively compact, which suits the underground layout in terms of installation and future maintenance work. For example, these machines don’t require an overhead crane gantry, as the semi-hermetic compressors weigh less than a ton. The machines produce chilled water at about 5ºC, which is distributed to the 5900 Level bulk air cooler via high pressure pipes in No 4 Shaft. “

Longer termRaymond says provision has been made in the design to upgrade the chiller plant in the longer term to a maximum of six machines, with a total cooling capacity of 6.8 MWR. The smaller module size is important to provide some redundancy during shut-down for routine maintenance. The additional chilled water will be used for secondary cooling nearer the workings.

A high-efficiency condenser spray chamber has been constructed near the upcast shaft — No 2

Chilled Water Project The detailed process, mechanical, piping and civil design of a new underground refrigeration system,

comprising refrigeration machines, condenser spray chambers and closed circuit cooling coils for Hecla’s Lucky Friday silver, lead and zinc mine in northern Idaho, USA, has been completed. This fast-track project was conducted as a sub-contract awarded by Cementation USA, the main contractor for the construction

phase on the mine’s No 4 Shaft Project.

Provision has been made in the design to upgrade the chiller plant



Shaft — to allow the full heat from the six machines to be rejected to the return air. This spray chamber cools the hot return water from the machines to about 37ºC, before being pumped back to the machines via an 1 100 m long HDPE pipeline. HDPE was selected for its lower cost, rapid installation, lower friction and non-corrosive characteristics.

“One of the innovative features of the system design is that up to 75% of the chiller plant heat can be rejected directly to cooling water which is piped from a nearby mountain stream,” says Raymond. “This feature is useful for short periods of operation, when it is necessary to shut down the heat rejection spray chamber to conduct maintenance work in the upcast shaft.

“However, this mode of operation is quite energy-intensive, since the cooling water must be pumped out of the mine using high-pressure pumps. Therefore the preferred normal mode of operation will be heat rejection to the return air.”

BBE provides EPCM or full turnkey service depending on specific customer requirements. Expertise covers a wide range of mining methods in various ore bodies in countries such as South Africa, Australia, Botswana, Brazil, Canada, Ghana, Lesotho, Namibia, Peru, Portugal, Tanzania, USA and Zambia.

BBE Consulting, Raymond Funnell, Tel: (011) 706-9800Email: [email protected]

75% of the chiller plant heat can be rejected directly to cooling water



www.chemsystems.co.za

www.atlascopco.co.za


COMPRESSORS, AIR MOTORS & VACUUM PUMPS

Thus, coal dust collected in bag filters poses a higher danger than the actual pollution risk of coal dust being released into the atmosphere. “A bag filter filled with coal

dust is a potential bomb ready to explode from just one small spark,” Waldo van der Merwe, business unit manager of Engart and Safanco at Howden Fan Equipment, tells “SA Mechanical Engineer.”

A fan solution“We’ve developed a very simple fan-driven solution

which has been proven in over 300 installations in the USA to remove coal dust effectively,” Waldo adds. “It is called the Howden Engart Dust Extractor which has a guaranteed efficiency of removing 97 to 99 % of total dust and 92 to 95 % of respirable dust. The extractor consists of three main components, the fan, a dust box and a sump. This unit takes the contaminated air through just three stages

to remove the dust from the air and deliver dry

dust-free air at the other end of the unit.”

Initially the extractor was developed to fit onto continuous mining machines to extract dust in the immediate working environment, but it has subsequently been applied successfully in all dusty mining situations underground as well as on the surface such as transfer points and rail car tippers where volumes of dust fluctuate.

Cost effective“The system is not well-known locally as yet, but since we now have a proven track record of a cost-effective solution to remove coal dust efficiently, we’ll be promoting the product much more actively in the coming months,” says Waldo. “Apart from costing a fraction of bag filtration systems, the extractor is very flexible in its application as it can be placed just about anywhere out of the way to process air before pumping it back into the work-ing environment. For higher volumes, for example, you simply add more units.”

Axial fans are designed specifically to accommodate large volumes. The Engart units, however, can also handle an extremely aggressive environment. Waldo explains, “Spray nozzles inject water onto a high speed impellor which forces the dust to mix with this water. This dirty wet air then passes through channels around the motor, leaving the motor to operate in a clean safe environment.”

No return air is allowed to either flow or leak over the unit’s motor and, as an added protection, the impellor track is lined with either fibre glass or marine brass. The dust extractor is, therefore, one of the safest dust extraction systems for coal dust available in the world.

Dust boxNext in line is the dust box consisting of a spray chamber, a demisting section and the flow di-verter. “The operational spray system directs water against the airflow to cause the dust and air to mix thoroughly before it reaches the co-agulating medium,” says Waldo. “This spray bank

Explosive Dust

The worst mining accidents in history have been caused by coal dust explosions principally because this dust suspended in air is highly

combustible. Coal dust has far more surface area per unit weight than lumps of coal and is more susceptible to spontaneous combustion. This

means that a nearly empty coal store is at far greater risk than a full one.

wiicWtEgofof9Tththathth

tothe

dustend

The spray bank is in continual operation whereas a second

bank of sprayers is used for flushing the coagulating medium

Removing 97 to 99 % of total dust and 92 to 95 % of respirable dust. The extractor consists of three main components; the fan, a dust box and a sump


is in continual operation whereas a second bank of sprayers is used for flushing the coagulating medium, also refered to as a filter meduim. These sprays are activated at pre-determined intervals every half an hour or 15 minutes or any other pre-determined interval.”

The flow then goes into the demisting section where

a bank of demisting vanes captures the dust laden water. The mesh contains 15 layers of two sizes of knit mesh where the dust particles are separated from the airstreams within the panel which is continually washed by the action of a multi-nozzle spray bank.

The ‘catchment’ vanes are placed in such a way so as to gather and remove all the water which is then dropped into a sump allowing only the dry, clean air to pass through and exit at the rear of the scrubber. Finally a flow diverter simply diverts the system’s exhaust air in the desired direction.

The sumpThe sump is a compartment built into the bottom of the dust box and is designed in such a way so as to receive the water slurry from the knit mesh and demisting panels. “It is designed to allow the slurry to flow out as soon as possible,” explains Waldo. “The sump is as important as any part of the dust extractor, so it is important to ensure free flow into and out of the sump at all times.”

Maintenance on this system is minimal compared with other dust extraction systems. Being essentially self-cleaning, the efficiency of the extractor remains consistent over time even though the volumes of air through the system may fluctuate between high and low extremes. Waldo remarks in conclusion, “The system, designed and built locally entirely, has thoroughly proven itself in coal dust removal under various different conditions, but in future we may very well look at other applications as well.”

Waldo van der Merwe, Howden Fan Equipment, Tel: (011) 240-4000, Email: [email protected]

The dust extractor is, therefore, one of the safest dust extraction systems for coal dust available in the world



www.articdriers.co.za


compressors, and the vacuum pumps from Sullair, more reliable than any other air products on the market,” says Jayson. “The cherry on top is we now have the backing of experienced technical teams to service, repair and maintain the prod-ucts we’ve installed throughout Southern Africa.”

This ‘new’ player in the compressor market came about when Imperial-owned Goscor, the agents for Sullair in the USA, bought out KLG, a com-pressor service company in Alrode who’d been around for thirty years. “It was a case of Goscor farming out all their service work to contractors and KLG not having a specific brand to sell. Therefore, both were losing a large slice of the cake,” Jayson says. “The marriage of the two companies has turned out to be a perfect match between a premium compressor product and a service company with many years’ experience in support and service of all makes of compressors.”

Jayson le Roux, managing director of Goscor KLG

It’s not everyday that you come across a product which, even at a

premium, has so many advantages in its favour, not only technically, but

also in terms of service and support. This is the positive impression “SA Mechanical Engineer” walks away

with after chatting to Jayson le Roux, the managing director of Goscor KLG, distributors of Sullair compressors in

South Africa.

Joining Forces for Better Service

A complete air solution upgrade

Thhheeeee ccccchhheeeeerrrrryryyyy oooonnnnn ttotototooop pp p p iisisssss wwwwwwweeeee nnonononoowwww hahaahahahh veveveeevv tttttheheeeehhh bbbbbbaaacacccaa kkkkinnnnngggg oooof f ffexxxpppppeeerrrir eeennncccceeeedddd tttteeecccchhc nnnnniicccaaaaalll tteteeeeaaamammmmmsss totoootttt sssseeeerrvvvviiivv ccceeee,, rreeeppppaaairrri aaannndddd mmmaaaaainnnttaaaaiiinnnn tthhheeeh ppprrroor ddddduuuuccctctttctsss wwwweweeee’v’v’vv’vveeeee iiiininnnnsssststttaaaalllllleeeeeddd ththhhrroooouuuugggghhhhoooouuuuttt Sooouuuuuttthhhheeeeh rrrnnnnr AAAAAAAfrfrrrff iiciccci aaaaaa

In short, this product has a ten year warranty, something unheard of in terms of compres-sors. “We have mechanical energy-saving features, bio-degradable compressor oil which

lasts a lifetime and above all, particularly robust machine construction which simply makes these



GuaranteesJayson is a young MD, telling us how he started at KLG from the age of 13 when he worked during school holidays for pocket money. He’s been with the company ever since, becoming MD when the two companies joined forces recently. “The time

has long gone where you just sell a product and walk away,” says Jason in terms of his business approach. “Today the differentiator in this highly competitive market is to be able to provide solutions to customers’ air requirements and doing so cost effectively in terms of life cycle costs.”

“Take our warranty, for example, normally you’d get a guarantee of not more than five years, but then it’s provided the user takes out a maintenance contract with the supplier,” elaborates Jayson. “Ours is a warranty for ten years with the only provision that the client only use genuine Sullair spare parts and lubricants in that time. What’s more, the lubricant is a superior grade oil which does not to be changed at all during the ten year guarantee period.”

EnergyApart from variable speed control systems contrib-uting to energy consumption on compressors, the Sullair range also has a mechanical system which controls the capacity in the compressor continu-ously. “An outstanding feature of VCC (Variable Capacity Control) compressors is its perfected capacity control system, which consists of a spiral valve and an inlet butterfly valve,” explains Jayson. “This system delivers greatly improved part-load performance, especially when compared with compressors having suction throttling or no load controls. The compressed air volume is varied by rotating a spiral valve, which opens and closes through by-pass ports in the stator, and returns air to suction rather than compressing it. By matching compressor displacement with output need, this energy-saving system uses up to 17% less power.”

The entire range of compressors has undergone some redesign resulting in energy-efficient machines overall. Jayson adds, “Our products have two modes of operation where you can either run them under constant pressure, or you can have them load and unload which is where the energy savings come in.

Speed control“However, where required we can also fit variable speed control systems to our range of compressors,” Jayson adds. “Using variable speed drives, coupled with Sullair’s Smart Technology system, compres-sors can run more efficiently in environments where demand may vary from season-to-season or from shift-to-shift. In periods of low demand, the control system reduces the compressed air output by reduc-ing the drive speed. This reduction in drive speed saves power and trims operating costs, improving the bottom line.”

In general the Sullair compressor is known as a robust product. “Just take the air ends as an ex-ample,” says Jayson. “On a daily basis we hear of air ends that crash at anything between 20 to 25 000 hours. On our smaller units we comfortably achieve 45 000 hours while the bigger units do 80 000 hours. Other OEM’s specify bearing changes at 20 000 – 24 000 hours while Sullair ’s recom-

A refurbishment ready for delivery

The life cycle costs on rebuilds are a quarter that of other makes of compressors

Ouuuursss iissss aaaa wwwwwwwaaarrrrraaannnntytyyy ffffooororrorr tttteeenenennn yyyyyyyeaeaeaeaeaearsrsssrsr wwwwwittiti hhhhhh thhhhhttt e e oooonnno lylyyyl ppppprroooovvvviiisssiis ooonnnnn thhhaaaaatt ttthhheeee cccliieennnnt ooooonnlllyyy uuuuusseeee ggggeeennnnuuinnneeee SSSSuuuullaaaaaiiri ssppaaap reeee pppppaaarrrrttsss aaaaannnddddd luuubbbbbriicccccaaannnnntttssss iiiinnn ttthhht aaaaatt tttttimmmmmmmmi eeeee



mended bearing replacement is only at 10 0000 hrs. This means that the life cycle costs on rebuilds are one quarter that of other makes of compressors.

Vacuum specialistsA market, where Goscor is at the forefront of technol-ogy, is the medical field where vacuum pumps and compressors are critical equipment in hospitals and clinics. “We have a large installed base of vacuum pumps and compressors at hospitals across the country. In fact, we’re currently busy with a series of upgrades at some of these hospitals,” says Jayson. “As this equipment is critical equipment and cannot be switched off, a special method of installation means we often don’t have to switch the vacuum off at all to do the upgrade which takes less than an hour. We literally set up a complete temporary plant which is up and running before any work is carried out on the old one.”

Goscor KLG has eight service and maintenance teams on the road constantly. “We’ll appoint at least another two technicians this year in a drive to increase our technical strength even more,” Jayson

The Sullair mobile compressor power by Caterpillar

says in conclusion. “ If the technicians are not busy with installations or servicing customers, they’re in the workshop where we undertake rebuilds and repairs to all makes of compressors. As much as we believe in building long-term relationships with our clients, so we believe in proper training. To this end our technicians are constantly kept up to date with the latest technology.”

Jayson le Roux, Goscor KLG, tel: (011) 908-2394, Email: [email protected]

i l i “ If th t h

Stripped for repairs




SAEE

The National Energy Barometer Survey was developed to enable users to quickly access the potential for energy savings in a building.

The National Energy Barometer Survey invites participation in the 2011 survey by registering before 25 July 2012.

Categories available for assessment are hotels, shopping centres, hospitals, bank branches, cor-porate head offices and general office buildings.

The top three in each category is announced annu-ally, past winners include Exxaro, Oriental Plaza, CEF House, Imperial Hotel and N1 City Mall.

How will you benefit from the survey? Find out if your building’s consumption is below or above your industry average.

Get a practical starting point for your energy efficiency strategies and planning (great for facility managers with a large portfolio).

Get an idea of the energy savings potential to get your building to the industry average.

Annual participation will track improvements and progress.

To complete the survey, before 25th July 2012:

1. Register online for participation

2. We will send you an invoice for R 1750 (excl VAT) per annual entry and a link to complete your survey.

3. Discounted packages are offered for multiple entries.

Thieda Ferreira, Tel: (041) 367-1041, Email: [email protected]

National Energy

Barometer Survey

Local as well as international studies have shown energy savings of 20% to be an achievable target in the commercial building sector. In some buildings, the

expected energy savings could be much higher, but in others, it could be lower. The challenge is to start looking at the buildings with the biggest potential for

energy savings.



�� (011) 781-1401�� (011) 781-1403��[email protected]��s��www.promech.co.za��or� Susan Custers��or�� Kowie Hamman��r��s�� Mark Bennett��r��o�� Catherine Macdiva�� Zinobia Docrat/ Donovan Vadivalu��s��rPROMECH Publishing does not take responsibility for the opinions expressed by individuals.

CopyrightAll rights reserved. No editorial matter published in “Power Generation Today” may be reproduced in any form or language without written per-mission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences aris-ing therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either gener-ally or in any particular field or fields.

TICK

ER T

APE

R28bn power projects chosen in the second bidding window (IPP) announced by the Department of Energy sends a clear message that the vision of a South Africa powered to a larger extent by renewable energy is destined to become a reality. These projects have potential to produce 1 044 megawatts (MW) of power. A total of 7 059 jobs during construction and 328 jobs during operations would be created by the projects.

Eskom is keen to understand undersea operations to harness electricity out of the sea, with the R155 million Oceanus power-generating unit, which is a prototype system to har-ness the power of ocean currents.

Eskom effected a saving of 250 gigawatt-hours of electricity a year with the installation of more than 262 000 solar water heaters across the country. It aims to have a million of these heaters installed by 2014. Eskom said the minister of finance had allocated R4.7 billion for the programme over the next three years, ending in March 2015.

POWER GENERATION

A typical PV solar farm as will arise on the South African landscape soon

One of the companies involved in two of 18 chosen solar projects is Tenesol in Cape Town who’ll be building the two PV (pho-

tovoltaic) solar farms near Douglas in the Northern Cape province. “SA Mechanical Engineer” visits the company’s factory in Epping to talk to Fabien Gouzil, director and general manager of Tenesol South Africa to find out more about this French company.

Locally made panelsFabian explains, “Although our core function is that of an equipment manufacturer, we also devise, design, manufacture, install, operate and perform maintenance operations by creating efficient, turnkey PV installa-tions, both on-grid and off-grid.

“We operate globally with installations

ranging from large solar farms to smaller rooftop units making a total installed base of just over 14 000 solar generator installa-tions around the world.” Fabien adds, “This market is supplied from our two PV module manufacturing facilities, one in Toulouse in France and one in Cape Town, both with the same capacity. Due to growing demand, our production capacity at each facility peaked at 170 megawatt-peak (MWp) during 2010, the equivalent of 800 000 photovoltaic modules a year.”

ProjectsAlthough Cape Town has been producing for the international market until now, this is bound to change with the number of PV solar farm projects getting underway in South Africa. “For both the projects at

PV Power for South Africa

While the rest of the world is already generating around 67 000 MW of power utilising photovoltaic technology, South Africa is taking its first baby-steps in harnessing an abundance of sufficient sunlight energy as a renewable energy source for the generation of electricity.




We can meet that need with solar energy solutions comprising the usual array of PV modules, junction boxes, storage batteries and a controller

TICK

ER T

APE Still under construction, a rare earths and thorium

mine, near Vredendal in the Western Cape, is scheduled to start production in the first half of 2013. Rare earths are used in the production of X-ray machines and some medical devices. The mine contains an approximate 4 000 tons of tho-rium. The mine will create 150 jobs and a further 150 jobs by the three beneficiation factories in the Western Cape, South Africa.

POWER GENERATION

Douglas we’ll be providing turnkey solutions, not only by supplying all the PV modules, inverters, structures and control equipment, but installation of the systems as well,” says Fabien. “We have also been appointed as the operator of these facilities which will have a combined capacity of 33 MW to make it one of the bigger solar farm projects now underway in South Africa.”

Tenesol is also well-positioned to open new, largely untapped markets for solar, especially in Africa where a strong presence has already been established with many off-grid systems.

On-grid systemsOn-grid PV systems, like the projects now rolling out in South Africa are large power-generating sys-tems in the form of banks of PV modules mounted on rooftops, warehouses, public buildings or open ground in the form of solar farms. The PV solar panels supply direct current which is converted into alternating current by an inverter and then injected directly into the grid.

Off-gridOriginally, photovoltaic solar power took its first steps in out-of-the-way places with no connection to the public electrical grid. These days, it has become

an attractive option for owners of private homes, commercial buildings and industrial or agricultural facilities. “This is usually called an off-grid, or on-site system,” explains Fabien, “of which there are many installed by us all over South Africa in various applications ranging from water pumping to oil and gas pump stations, remote telecoms relay stations, rural electrification schemes and even small-scale game farm power needs.”

Remote locations and the oil and gas industry go hand-in-hand. Pipelines carry these diminishing resources across some of the most isolated environ-ments on the globe. “In the past, power was supplied to these locations using diesel generators,” explains Fabien. “But for over 25 years, Tenesol has supplied customised turnkey solar solutions to the oil and gas industry at remote on- and off-shore locations. Such installations are designed to suit specific project needs and can cater for any situation regardless of location, power requirement or activity. Systems typically provide power for exploration, tracking, boring, transporting, cathodic protection, lighting, security and emergency shut-down equipment.”

ApplicationsIn the world of telecoms, equipment does not re-quire vast amounts of power so the system does not need to be very large. A solar system can be easily installed without much preparation to surrounding land and it begins generating power immediately.

“There is a growing need for telecommunication

When line workers break for tea, for example, everyone stops right where they are. Work only starts once everyone on the line is in position again

SAEE (Southern African Association for Energy Efficiency) invites nominations for the SAEE Energy Awards 2012. Nominations close 30 September 2012. Nominations open to members only.

Categories: company, project, newcomer, patron, excellence award.

Email: [email protected]



POWER GENERATION

infrastructure in both remote off-grid locations and in urban areas which has raised the need for suitable on-site power sources,” says Fabien. “We can meet that need with solar energy solutions comprising the usual array of PV modules, junction boxes, storage batteries and a controller. We’ve supplied such installations for multiple telecom-munication applications including fixed, mobile and radio operated networks.

Light and waterApart from its industrial uses, solar power is ide-ally suited to humanitarian applications, the most common being rural electrification to bring power to remote off-grid areas. Fabien elborates, “These solar systems are installed on rooftops or small structures and linked to people’s homes. They are provided either on a turnkey basis or as self-contained PV kits, which provide all the necessary components to create a small solar installation without external support.”

In addition to rural electrification, solar water pumping is another on-site humanitarian applica-tion. “Tenesol began to explore the use of solar energy for water pumping in West Africa during the 1980s,” says Fabien. “Since then, the com-pany has installed more than 4 000 solar water pumping systems pumping around 80 000 cubic metres of water a day. We have worked with many different organisations and charities to bring fresh, safe drinking water to rural locations and isolated communities in Africa.”

The factoryWalking through the factory where PV panels in various stages of completion are progressing down a production line, Fabien explains that they have adopted a production line principle similar to the automotive industry. “Not only do we work on a Just in Time (JIT) principle like they do, but the whole operation is run to minimise any chances of faults slipping in because people take breaks during manufacture. When line workers break for tea, for example, everyone stops right where they are. Work only starts once everyone on the line is in position again. This has dramatically reduced faulty units which then have to be rebuilt after the final test.”

Many solar power companies do not manufacture their PV modules themselves, but Tenesol decided to incorporate this factor in 1999 in order to have full control over the photovoltaic chain. Fabien says in conclusion, “This key step means we can attain superior reliability and efficiency in your systems. Not only are our modules guaranteed for ten years, but we also guarantee the production of our photovoltaic panels to 80% of the power over 25 years and 90% of the power over ten years.”

Fabien Gouzil, Tenesol South Africa, Tel: (021) 797-7377 Email: [email protected]


www.horne-group.co.za


According to estimates, the BRICs countries alone account for more than 50% of total infrastructure investments in the world. At present, 15% of the total global gas turbine market revenue comes from the BRICs nations.

The BRIC gas turbine market is expected to experience a considerable growth from $1,432 million in 2005 to $2,623 million in 2015. The major contributing factor for the growth will be growing environmental concerns. At present, BRIC nations are heavily

Optimistic Optimistic

WEG’s innovative three phase W22 motor, available locally from Zest WEG Group, provides an energy efficient solution for reducing industrial energy consumption.

By cutting down on wastage in specific industrial and mining applications, these electric motors not only reduce costs and improve profitability, but also make an important environmental contribu-tion by decreasing the national energy consumption of electric motors. The potential energy saving when using a WEG W22 motor is assumed to be around 30 to 60%.

High efficiency and low cost of ownership throughout the entire motor lifetime have guided the WEG W22’s development. Innovative improvements, supported by patent and registered design applications, deliver lower noise and vibration, even

Motor lifetime

better reliability with a longer working life, easier maintenance and lower cost of ownership.

Maximum heat dissipation is achieved through the WEG W22 motor’s extended

WEG's innovative energy

efficient W

22 motor. The WEG W22 motor

features an oversized

terminal box for easier

and safer connection of

mains and accessories.

frame area. Heat dissipation is boosted by the quantity and distribution of the fins, as well as the quantity of air delivered due to the innovative cooling system developed using the latest design techniques.

Zest Electric Motors Jamie Wilson, Tel : (011) 7236000 Web: www.zest.co.za

The terminal box mounting on the WEG W22 motor allows optimum flexibility enabling reduced inventory and quicker modification.

Vodacom has announced that it is fitting its Century City in Cape Town office with the largest array of solar panels on a single building in Africa and that it has appointed In-Toto Solutions (Pty) Ltd as the EPC contractor for the project. Nearly 2000 mono crystalline solar panels will cover the 3 600m² roof of the building.

The solar array will be completed by August 2012 and is expected to provide up to 75% of all power required by the

building during peak production. The power produced will feed into the two main distribution boards. A display panel installed in the reception area of the building will display instantaneous power yield, energy yield and carbon emission savings.

The photovoltaic array will supply 500 kilo-watt peak (kWp) at peak production to the building and the total annual energy savings is expected to be around 830.1MWh

"The position of the Century City rooftop is perfect for generating a high yield of solar power throughout the year," says Suraya Hamdulay, executive head of corporate citizenship at Vodacom. This project is a part of Vodacom's ongoing drive to reduce the amount of energy it consumes. To date Vodacom has reduced the energy inputs by 12% per base station across the Vodacom Group.

In-Toto, Darryn Brackenridge, Tel: (011) 493-0344,Email: [email protected] Web: www.in-totosolutions.co.za

Largest single rooftop PV array in Africa

POWER GENERATION NEWS

http://www.zest.co.za


http://www.in-totosolutions.co.za


dependent on coal for fulfilling their power needs but gradually BRICs focus is shifting towards gas-based power generation due to its clean nature. The major part of gas turbine revenue comes from China and Russia so any fluctuation in these markets directly affects the entire BRICs scenario. The future looks promising, however, with many gas-fired projects scheduled to go live in the next few years.

GlobalData, Laura Ward, Email: [email protected]

Significant reduction in emissions

Voith SteamTrac, a compact, modern waste heat recovery system for combus-tion engines used in marine applications as well as for rail-, road- and industry applications, achieves a significant reduction of fuel consumption and emissions of toxic and hazardous gases. Apart from its ecological advantages and lower fuel consumption the SteamTrac system also enhances the economy of ship’s drivelines.

The operating principle of our system can be resumed as follows: the heat from the exhaust system is used to warm up the operating medium in the evaporator to superheated steam. The steam is expanded into the expander and generating mechanical energy which can be fed back into the combustion engine’s crankshaft or to a gearbox power take in (PTI).

The operating medium is liquefied downstream from the piston expander in a condenser followed by storage into an operating medium tank. The entire process is controlled and monitored by a control module.

The new technology is suitable for both new marine developments and retrofits and in principle, SteamTracs can be installed to all combustion engines such as inland waterway vessels, short sea ships, fishing boats and ferries.

Voith Turbo, Graham Russell, Tel: (011) 418-4000, Fax: (011) 418-4080Email: [email protected], Web: www.rsa.voithturbo.com

Africa has huge untapped reserves of fossil and hydro resources that can be used for generating electricity. However, electrification and consumption levels are low, particularly in the rural areas as the continent is unable to utilise its reserves due to drought, high oil prices, conflicts and lack of funds. Often the existing transmission and distribution networks are incapable of supporting the entire power supply to an entire nation and there is an urgent need to overhaul entire systems.

To improve the power scenario, countries have introduced reforms such as the restructuring of power utilities, privatising the vertically integrated monopolies, legalising the entry of foreign players and Foreign Direct Investments (FDI) in the power sector and allowing Independent Power Producers (IPPs) into the respective countries. The Private Public Partnership (PPP) in Africa is expected to increase going forward as private players gradually show interest in the continent. The UK-based utility company IPSA's combined heat and Power (CHP) plant in Newcastle is South Africa's first privately-financed independent power plant, which is also South Africa's first independent gas-fired power station. Artumas Group, a Canadian based company is setting up a 300 MW gas plant in Tanzania which is expected to come online in two years. aes-sonel is setting up a 250 MW plant in Cameroon.

GBI Research, Jonathan Cain, Email: [email protected]

Power Market in Africa 2020

Trends Trends




http://www.rsa.voithturbo.com


www.compressed-air.co.za


GE Transportation a subsidiary of GE (NYSE) and one of the world’s leading suppliers to the railroad, transit, and mining industries, providing freight and passenger locomotives, has announced that the most recent locomotive was delivered with local content that ex-ceeds the commitment from GE’s initial Transnet order of 100 locomotives. The locomotive is the most advanced diesel electric locomotive ever built in South Africa.

Lorenzo Simonelli the global President & CEO, GE Transportation says, “We are celebrating the first South African product delivered by our joint venture company GE South Africa Technologies. These locomotives represent great op-portunities for Transnet and South Africa as well as GE. Transnet will be able to significantly improve hauling capability while reducing fuel consumption and greenhouse gas emissions.”

54 Locomotives delivered to date

Pictured above: Chief Executive of Transnet Rail Engineering Richard Vallihu and Global President & CEO of GE Transportation Lorenzo Simonelli all smiles after unveiling of Loco 42. The locomotive is the 42nd locomotive and is the most advanced diesel electric locomotive ever built in South Africa. The official unveiling of the locomotive took place at an event held at Transnet Rail Engineering’s facilities in Koedoespoort, Pretoria

With this order, GE overshot its self-imposed target of 30% local content. The locomotives assembled in South Africa have 37% local content. The partnership has also produced a sig-nificant investment in job development, economic advance-ment and infrastruc-ture growth for all parties.

GE's C30ACi is the first locomotive in the South African region to meet stringent UIC2 emissions standards. The addition of these new locomotives, which will be used to haul freight and coal, will decrease life-cycle costs,


improve fuel efficiency and reduce emissions. Two GE locomotives do the work of three older locomotives, saving 600,000 litres of fuel a year and lowering emissions. It can reduce emissions by 1 500 metric tons of CO2 annually, equivalent to eliminating the emissions from 310 cars on South African roads.

GE’s Model C30ACi is first AC diesel-electric locomotive to be introduced to sub-Saharan Africa. Its engine delivers 3,300 Gross Horse Power (GHP) using an electronic fuel injection system that automatically supplies the exact amount of fuel needed for optimal engine efficiency. These locomotives also feature GE’s unique AC propulsion technology and dynamic braking.

GE Corporate Africa, Thulisile "Thuli" Phiri Tel: (011) 237-0001, Email: [email protected]: www.ge.com/za


http://www.ge.com/za

www.rodeconengineering.co.za


Wind turbine bearingsSKF has introduced an extended range of SKF Nautilus bearing solutions that offer advanced, versatile and integrated features to meet the demands of wind industry. The Nautilus bearing solutions provide designers with the freedom to develop a wide variety of turbines including direct drive; turbines equipped with a gearbox; with outer or inner ring rotation; and mounted on shafts or directly bolted onto the surrounding structure.

The industry trend toward increased turbine size, remote locations and harsh environments calls for technology advances - more compact and lighter nacelles, and components with built-in reliability and serviceability.

The new features of SKF Nautilus include the option to incorporate a bolted inner ring, eliminating the influences of fits and tolerances of the structure surrounding the bearing, reducing pre-load variation and resulting in higher operational

reliability and safety.

Another feature is the integrated seal and pre-greasing to provide optimised lubrication while reducing the

risk of contamination and leakage.

SKF South Africa, Samantha Joubert Tel: (011) 821-3500,

Fax: (011) 821-3501, Email: [email protected],

Web: www.skf.co.za



http://www.skf.co.za

www.interbuild.co.za


SAINT

Dr Mike Farley, (centre) Chairman of the International Committee for NDT, pictured with children who were delighted to be exposed to the NDT inter-active exhibits

SAINT introduced

the NDT education

village idea at

the recent highly-

successfull

international

conference in April

in Durban. Not only

has this concept

been picked up by all

other NDT societies

worldwide but SAINT

is also spreading its

net by getting more

closely involved

with allied training

facilities in South

Africa.

Education is Key

www.animalsindistress.org.za


EXHIBITIONS

International mining, industrial, construction and power generation show, Electra Mining Africa, taking place in September, will help to support and facilitate growth in the South African and

African mining sector. Electra Mining Africa is the second largest mining show in the world and the biggest trade exhibition in Southern Africa.

Gary Corin, Managing Director of show organisers Specialised Exhibitions, says: “Electra Mining Africa is an exciting show that attracts a high-level of local and international interest and produces off-the-floor sales, valuable sales leads and excellent

Electra Mining AfricaThe South African mining industry is the mainstay of South Africa’s R3-trillion-a-year economy. Mining revenue in 2010 was R420-billion and expenditure R440-billion, with R225-billion of the R440-billion expenditure spent on locally-procured goods and services, including steel, cement, electricity and rail

transport. Given that 40% of the world’s natural resources reside in Africa, where spectacular population growth is projected, South Africa is in a strong position to sell its services and products.

business connections for its exhibitors.” Together with co-located shows Machine Tools Africa, Elenex Africa and Transport Expo, Electra Mining Africa will provide visitors with the “ultimate platform to view a vast array of new innovations, products, services, technologies, trends and industry developments in the mining, industrial, construction and power generation industries.”

Captive audienceThis year ’s show will include an Exhibitor Soap-box hosted by the South African Institution of Mechanical Engineering. The Exhibitor Soapbox will give exhibitors a 30 minute opportunity to present their products and services to a captive audience in a separate presentation room, with no restriction on either the format or the content of the presentation. Attendance at the Exhibitor Soapbox will be free to all Electra Mining Africa visitors.

Electra Mining Africa, Expo Centre, Nasrec, Johannesburg, from 10-14 September. Visitor pre-registration is open at www.electramining.co.za

Second largest mining show in the world



A lthough this makes the change-over of equipment a simple plug-in and plug-out operation, the first couplings on the market did have drawbacks in that they

increased the chances of fluid spillage, polluting the environment. Apart from the extra costs incurred to clean up polluted areas, the open end of these connectors made the hydraulic system more sus-ceptible to dirt, causing costly damage and reducing the performance of equipment.

The flat-faceToday this is al-most a thing of the past because of a new design, the flat-face hy-draulic connector, which specifically addresses the problems of connector spillage and fluid contami-nation. “SA Mechanical Engineer” visits hydraulic equipment supplier, Alba Hydraulics in Edenvale to speak to owner Albert Epprecht. “We were the first supplier to bring the flat-face coupling design into South Africa some years back,” he says. “The coal mining industry latched onto the advantages

of this coupler very quickly in spite of it costing a bit more than an ordinary quick-release coupling.

“In the beginning everyone said they were too expensive, but gradually, as people realised how easy and quick it makes the change-over of equipment, they started switching over,” Albert adds. “Despite the flat-face couplings costing more than double, they last much longer than the ordinary pin-and-ball type cou-pling. Today we literally supply hundreds of flat-face couplings to all industries, especially where they have problems with dust and dirt or where there is the slightest chance of spillage polluting the environment.”

Thhee ccooaal mmiinninngg inndduusttryy lattcheed onntoo thee aadvvanntaages off thhiss ccoouuppleerr vveerry qquuicckklyy iin ssppitte oof it coosttinng a bitt mmooree thhaann an oorrdinnaarry qquuicckk-rreleaaasse coupplingg

The flat-face couplings on the left with the old type on the right

Albert Epprecht of Alba Hydraulics

Connectors

Mobile hydraulic equipment is common in the

agricultural, construction, logging, and mining

machinery markets. Mobile hydraulic equipment usually

requires quick and easy coupling and decoupling

to the system on a regular basis. This is commonly achieved with a special quick-release coupling

system.

HYDRAULICS & PNEUMATICS


AdvantagesThe flat-face coupling’s obvious advantage is not only that there is no open hole where dirt can settle when the coupling is disconnected, but the flat surface is easily wiped clean if any dirt does happen to stick to it. It takes just a gentle push against the flat surface to pop the valve away and allow the nipple of the connector to lock into place firmly without a drop of fluid being spilled. This can even be done with only one hand, making connec-tion and disconnection fast and easy.

During connection, the coupling and nipple au-tomatically lock into place. Some makes of this type of coupling even have a locking ring for extra protection against involuntary disconnection. The coupling design includes a manual security-locking feature which is engaged by manually turning the locking sleeve after the connection is made. The lock is released by returning the sleeve to its original position during disconnection.

Majority retainedAlbert has been in the hydraulic market for over twenty years, importing top quality brands mainly from Germany, Switzerland and Italy. “As each of these manufacturers has expanded their product range, so we’ve followed them, constantly bringing the latest technology to South Africa,” says Albert.

“We’ve hired more staff over the years to enable us to service our ever-increasing customer base. For the past 21 years we’ve been able to retain a majority of our staff, which has allowed us to the competence of our staff in order to develop unique relationships with each customer. Today we have more than 16 distinctive product lines, from 13 manufacturers.”

Stock holdingsThe company’s primary focus is on hydraulic steel tube fittings, hydraulic line tubing and pipe clamps. “Normally bookkeepers complain when you hold too much stock, but we’ve learnt that having enough stock available at all times has been a major dif-ferentiator for us in the local market,” says Albert. “Apart from always having stock, especially the parts our regular customers use frequently, we believe in keeping customers informed about technology and changes in product requirements elsewhere in the world.

“For example, in Europe the yellow chromate plat-ing which has been used for ages to protect steel components is today strongly discouraged and in some cases even discontinued by most OEMs because of its toxicity,” says Albert. “Many people don’t know this and when we present them with


TThhee ccoouupppliinngg ddesiggnnn innclluudess a mmaannuual seeeccuurittyy--loocckkiinngg ffeeatttuure wwhhicchh iis ennggaaggeedd bbyy mmaannuuaallyy tturnningg thhee llocckkingg sleeeeevvee aafftteerr tthhee ccoonnnnnecctioonn is mmaadde

A special machine for crimping hydrualic fittings

Special equipment for bending hydraulic pipes

A variety of hydrualic pipe mountings


plating is actually a poisonous process which causes severe damage to the environment, they’re fully on board. After all, it’s still the same part from the same manufacturer.”

Clean fluidIn hydraulics the cleanliness of the fluid is a critical factor for long machinery life, but still an aspect many people grossly neglect. “In our effort to educate people involved in the hydraulics industry we make a point of advocating the importance of clean filters and proper filtration systems,” Albert says in conclusion. “Most of our bigger clients are listening and have programmes in place to ensure regular maintenance on filtration. But there are still many who don’t consider the consequences of unexpected breakdowns, or premature wear because of dirt in their fluids. As a member of the Fluid Power Institute it’s our duty to follow the organisation’s lead in educating users on the importance of proper filtration.”

Albert Epprecht, Alba Hydraulics, Tel: (011) 458-1200, Email: [email protected]

A wide variety of pipe for hydraulic application is stocked

parts which are now a matt silver colour they insist it’s wrong because they’ve always used the yellow ones. Once we explain that the yellow chromate


NNoormmmaallyy bboooookkkkeeeeppeeeerrs coommplaainn wwwhenn yoouu hhooldd toooo mmuucchh ssssttocckk


www.engenoil.com


D rawing inspiration from nature’s ability to achieve maximum performance with minimal energy consumption, the Bionic Learning Network develops decentralised,

self-controlling and self-organising systems. The network’s main focus is on utilising bionics in the formulation of new principles of operation for the delivery of energy efficient, mechanical engineering innovations.

Mass-payload ratioThe Bionic Handling Assistant is the network’s newest offering, providing a completely flexible and safe means of moving objects from one position to

another. Inspired by an elephant’s trunk, the assistant employs innovative biomechatronics technology and introduces a new concept, whereby direct contact between machines and their human operators is no longer hazardous. In the event of contact between the Bionic Handling Assistant and a human, the assistant will yield immediately without modifying its desired overall dynamic behaviour, and will resume its operation once the threat has been averted.

Unlike other heavy industrial robots, this assistant is characterised by an excellent mass-payload ratio. In addition, it provides smooth operating motion with more degrees of freedom and makes efficient use of its resources in production and operation.

Extra degrees of freedomAnother pioneering handling solution from Festo, the BionicTripod 2.0 is derived from the tail fin of

Bionic LearningNetwork

The Bionic Learning Network, is an alliance of educational establishments and specialist companies tasked with exploring bionic solutions for evolutionary automation applications.

Elephant trunk: Drawing inspiration from nature, Festo mimicked the flexibility and versatility of the elephant trunk for its latest design

Open up a host of new application areas that involve direct, non-hazardous contact between humans and robots



The Bionic Handling Assistant offers complete flexibility and the ability to safely move objects from one position to another

Forms energy efficiency may take in the future of automation technology

a fish and can be described as a horizontally-arranged tripod that is rotated at 90° from the conventional tripod configuration. It consists of a drive unit, a tripod structure free to move in all spatial directions, a flexible hand axis and an adaptive FinGripper soft handling unit.

The hand axis is structured similar to that of the Bionic Handling Assistant, with the added advantage of three extra degrees of freedom and a 30° range of deflection. The highly versatile FinGripper constitutes the interface between the object and the actuators and consists of a pneumatic actuator in the form of a bellow and three gripping fingers.

Pliable and flexibleA particular advantage of the BionicTripod 2.0’s horizontal configuration is that objects can be picked up from the working surface and deposited to the side at a different level, a beneficial feature for versatile agricultural applications and for the sorting of materials for recycling. Since the structure is pliable and flexible, it is ideal for tasks in human-machine interaction and can be used in sorting applications or as a “third” hand.

Joanne Dexter, Festo Tel: (011) 971-5560Fax: (011) [email protected]



www.hytec.co.za


SAIT

How did we arrive at this juncture? Technol-ogy engineering qualifications, contrary to the traditional four-year engineering degrees, have suffered major overhauls

every ten to fifteen years since the late fifties/early sixties when the T4 Diploma was established to replace the ATC II. This culminated in the present National Diploma and the BTech degree. The fact that, for the first time, technology professionals had a degree as benchmark qualification was a huge success, as well as a thorn in the flesh of many.

Not to be revivedIn 2007 the Department of Education announced their vision for future tertiary qualifications in the Higher Education Qualification Framework (HEQF). This framework laid down principles and guide-lines wherein all tertiary institutions would develop their qualifications. It did not allow for a BTech degree at all, and, if a UoT wanted to offer a diploma for engineering technicians, that university would have to guarantee the student a placement for his or her year of work-integrated learning. ECSA (for the engineering profession) and many other stakeholders offered comment and sent delegations to the Department

of Higher Education, but the BTech degree was not to be revived.

Meanwhile ECSA’s Engineering Standards Gener-ating Body (ESGB) was hard at work generating suitable benchmark qualifications for engineering technology professionals, which would be in align-ment with the HEQF vision. Since no UoT could guarantee work-integrated learning placements for students, due to the cyclical nature of the South African economy, the only workable qualifications provided for by the HEQF for technicians would have been the consecutive Higher and Advanced

Certificates, each a one-year 120-credit qualifica-tion, with industry making its own provision for introducing the students into the work environment.

Three to four yearsFor engineering technologists, the most suitable qualification would be a three-year Bachelor’s degree in Engineering Technology (BET). At a meet-ing with officials from the Department of Higher Education and Training (DoHET), it was clear that this proposal was not well received, until we ex-plained that we did not foresee any work-integrated learning component in this qualification. It would be a purely academic three-year degree.

The HEQF therefore placed the UoTs into a posi-tion where no work-integrated learning would be provided for as an integrated part of the technology qualifications. ECSA seems to consider increasing the minimum three-year candidate phase for techni-cians and technologists to four years to compensate for this loss.

Top-upThe DoHET revised the HEQF last year, and the latest guidelines provide for a two-year 240-credit Diploma, suitable for the education of engineering technicians, and a three-year 360-credit BET for engineering technologists. The present consecutive model with the BTech degree as a top-up of the Diploma is, however, not acceptable to the DoHET.

The Engineering Faculty of the Tshwane University of Technology did a controlled study, approaching the engineering industry represented through its various Advisory Committees, to determine what qualification industry favoured, and the overwhelm-ing response was for the three-year BET. It remains to be seen what the final decision of the other UoTs will be, but none of these institution has the capacity to provide two parallel qualifications for technicians and technologists. Additional labora-tory space, lecture halls and lecturing staff would be required to provide two parallel qualifications.

It seems therefore that the unintended consequence of the demise of the BTech degree will be a crisis for the education of engineering technicians. This begs the question as to how our future engineering technicians will be educated. Will this be left to the FET colleges?

Engineering technology education is indeed at a crossroads again. Quo Vadis?

This ‘opinion’ was first published in the March 2012 edition of “Civil Engineering”, the magazine of the South African Institution of Civil Engineering”.Johan de Koker, SAIT Committee MemberSAIT, Gill Fuller, Tel: (011) 802-5145/6, Email: [email protected], www.sait.org.za

Unintended Consequence“It seems that no residential University of Technology is

planning to provide for technician education” was an opinion expressed at a recent meeting of the Technology Programme Accreditation Committee at the Engineering Council of South

Africa (ECSA). This seems to be the prevalent thinking in the Universities of Technology (UoTs), or former Technikons. They seem to be planning to provide only the new three-year

Bachelor of Engineering Technology (BET) degree, which will be the new benchmark qualification for professional

engineering technologists.

Johan de Koker

Additional laboratory space, lecture halls and lecturing staff would be required to provide two parallel qualifications


http://www.sait.org.za


www.ils.co.za


MARKET FORUM

The dry milling of ore in Loesche vertical roller mills has shown significant process advantages, as well as economic and ecological benefits. To demonstrate these, a mobile ore-grinding plant, the OGPmobile, has been developed. This allows the customer to test the effectiveness of Loesche’s grinding technology and its influence on the total material flow of the existing processing plant. The degree of mineral liberation, particle size distribution,

Significant Advantages

energy consumption and throughput can be optimised individually for each deposit and each treatment process, depending on the ore characteristics.

Past experience shows that considerable benefits are achievable on various ore types with differing characteristics, such as lead/zinc and nickel. The OGPmobile is a fully functional grinding plant, which is comparable with the test circuits in the Loesche Test Centre in Neuss Germany. The flexible circuit allows operation in

an airflow as well as in overflow mode without gas sweeping.

Large samples of milled material – 200-300 tons for further direct processing in subsequent process steps – can be produced. The quality of the milled products is checked by analysis in the integrated laboratory.

Loesche South Africa, Alana Ridley, Tel: (011) 482-2933, Fax: (011) 482-2940Email: [email protected], Web: www.loesche.com

A continuous r ise in the demand for scarce water resources is resulting in an increased need to develop more water intake

systems in South Africa, and new

process equipment company Ludowici Meshcape

stocks a comprehensive range of environmentally-

friendly wedge wire screens that

perfectly complement these systems.

Ludowici Meshcape technical consultant David Owen points out that water intake systems are designed for use in seawater and freshwater applications, specifically to remove any debris and particles from the water, before it is transported for its final use.

“A water intake system is a pump that draws in water at low velocity, while solids such as marine life, sand and seaweed are prevented from entering the intake system by the Ludowici Meshcape wedge wire screen, which consists of two wedge-shaped woven wires, spirally

w o u n d to create

s m a l l apertures that typically allow for fine separation of between 300 microns (μ) to 1 mm,” he explains.

Ludowici Meshcape manufactures wedge wire to ISO 9001-2008 standards, thanks to the company’s R15-million Euroslot manufacturing machine, imported from France in 2009, which ensures that the quality of the aperture finish is world class.

Ludowici Meshcape, David Sibley, Tel: (011) 609-1120, Fax: (011) 452-2545Email:[email protected], Web: www.ludowicimeshcape.co.za

Local Water Intake Projects


http://www.loesche.com


http://www.ludowicimeshcape.co.za


Recycling

Major Order in Record Time

KEW Foundries supplied Gunric Valves with seven DN2500 valve bodies and discs, weighing five tonnes and six and a half tonnes each respectively, to be used on isolation duty

MARKET FORUM

Scrap metal merchant and recycling specialist Envirocycle has become rec-ognised as an nationwide-leader in the disposal of ferrous metal, non-ferrous metal and industrial waste, by making use of a range of specially-modified Hyundai excavators supplied by HPE Africa – the sole distributor of Hyundai earthmoving equipment in Southern Africa.

Envirocycle executive director Stefan Pretorius stresses that recycling is a critical and essential part of modern life in South Africa and worldwide. Enviro-cycle’s fleet of 40 heavy-duty transport vehicles currently consists of one Hyundai R360LC-7 tracked excavator, a Hyundai R220LC-9 excavator and two Hyundai R210LC-7 tracked excavators. The machines, the company also placed an order for an additional two R220LC-9 excavators and a second-hand HL740-7 wheel loader, which were delivered in March 2012.

All Hyundai excavators can very easily be fitted with auxiliary piping, which

ensures that Envirocycle is able to eas-ily fit the claws for picking up scrap. “Thanks to the option of auxiliary piping on the entire Hyundai range, the user simply has to change the attachment, fit the piping, and finally set the pressure of the pipe for the claw. An HPE Africa technical team can complete this simple

Industrial Recycling

process in a short period of time,” says HPE Africa national service manager Hein Stander.

HPE Africa, Kirsty Denholm Tel: (011) 397-4670, Email: [email protected] Web: www.hpeafrica.co.za

KEW Foundries supppliedd GuValves with seven DNDN25000 vbodies and discs, weieighhing tonnes and six and a haallf toneach respectively, to be ususedisolation duty

KEW Foundries has just completed a multi-million rand order for Gunric Valves, to cast seven valve body and disc sets for use by a large water utility.

The biggest butterfly valves that this manufacturer of high quality valves has supplied to the local market to date comprised DN2500 valve bodies and discs, weighing five tonnes and six and a half tonnes each respectively, to be used on isolation duty.

KEW Foundries, John Bryson, Tel: (053) 841-0474, Fax: (053) 841-0473E-mail: [email protected], Web: www.kewfoundries.co.za


http://www.hpeafrica.co.za


http://www.kewfoundries.co.za


Alien Systems & Technologies (Pty) Ltd (AST Africa) is proud to announce the launch of the Astex range of vehicle fire suppression systems. The company offers an array of suppression and protection products including the award winning Pyroshield total flooding system.

Managing director Paul Wright says, "There is very little AST Africa cannot protect, from gas fire extinguishing sys-tems, enhanced detection to conventional fire protection. Our highly experienced and industry respected engineers are able to tailor make the best possible

solution for business operating in almost any industry."

Pyroshield currently protects the build-ings and server rooms of some of South Africa's biggest industry players while the Pyrogen in-cabinet fire extinguish-ing system features in substations in mines all over the African continent. Paul says vehicle systems were simply the next step.

The protection offered by the Astex systems encompasses everything from small vehicles to large non-road equip-ment. The likes of excavators, drag

lines, dozers, graders, underground mining equipment, buses, forklifts, medium-sized commercial vehicles and four-wheel drive vehicles for mine sites are all afforded the option to utilise the Astex system for maximum fire suppression and protection.

Three systems are now available to the African market and specifically designed to cope with the extremes of the African mining industry.

Alien Systems & Technologies, Sam Wright, Tel: (011) 949-1157, Web: www.astafrica.comEmail: [email protected]

Actom Mechanical Equipment has produced its largest-ever centrifugal fan to date for a mine vent system to serve the expansion of local copper producer Palabora Mining Company’s underground mining operations at Phalaborwa, Limpopo Province.

At 4 m diameter the new fan is sub-stantially larger than the largest the company has previously produced, which had a diameter of 3,4 m.

The new mining operations will be at a depth of 1600 m below surface, 400 m deeper than the present workings. “Production is due to start in 2016 and will be increased over the subsequent three years as production in the exist-ing mine tapers off,” explaines Gavin Meredith, Palabora Mining Company’s

Senior Advisor Engineering.

The new fan has been installed near the existing main vent fans halfway down the old open pit at a depth of about 300 m below surface. “The two exist-ing 1,25 MW ventilation fans running in parallel have a combined output capacity of 600 m3/sec at 2000 Pa pressure. The new 3 MW power fan will have an initial output of 500 m3/sec at 2700 Pa pressure, ramping up to 400 m3/sec at 5500 Pa pressure as the mine develops,” explaines Mike van Oerle, Actom’s Product Manager, Mining Fans.

Actom Mechanical Equipment, Craig Johnston, Tel (011) 871-6789, E-mail [email protected], Web: www.actom.co.za

Seen here close to completion in ACTOM Mechanical Equipment’s Germiston plant is the 4 m diameter centrifugal mine vent fan for Palabora Mining Company’s expansion project.

Largest Centrifugal Fan

More Powerful Solutions

HP has launched new, more power-ful cloud-based solutions, allowing architecture, engineering and con-struction (AEC) professionals to print where the job takes them. Users are connected to HP’s web-connected, large-format Designjet ePrinters and eMFPs for printing on the go, whether at a partner’s office, in a taxi or at the construction site. An expansion of HP’s partnership with Autodesk enables remote printing from the highly popular AutoCAD WS. By registering for HP ePrint & Share, AutoCAD WS users can use the new Plot to Print function to print their designs and automatically archive a copy on any web-connected HP Designjet or HP ePrinter. This new feature provides full control over plot styles, paper sizes, layouts and more.

Additional capabilities for the HP ePrint & Share mobile application, HP’s free, cloud-based printing and sharing tool for Designjet users, in-clude full functionality for the iPad and the ability to send PDF e-mail attachments to print. Previously, all documents printed from the mobile app were selected from the user’s HP ePrint & Share library. Now, users can print PDFs received via e-mail as well, providing access to more documents when and where they need them.

HP, Hedy Gorton, Tel: 086 000 1030, Email: [email protected]

MARKET FORUM

http://www.astafrica.com



http://www.actom.co.za



An innovative new floating dredge system for the removal of slurry from process water is poised to forever change the way local companies approach the removal of mineral sediments from process ponds, dams and storage tanks.

Incorporating Flygt slurry pumps, the SlurryRat, developed by UAT in Australia and distributed throughout sub-Saharan Africa exclusively by Xylem (formerly known as ITT Water & Wastewater South Africa), is an industrial strength pond cleaner, providing a robust and efficient means of dealing with slimes and slurries produced from a range of mining industries.

Without requiring cutter heads, the electrically powered and remotely controlled SlurryRat operates via a unique combination of suction and

The innovative SlurryRat floating dredge system is ideal for the removal of slurry from process water and according to local distributor, Xylem, is set to change the way companies approach the removal of sediments from process water

Atlas Copco has received one of its largest orders ever in South Africa, to deliver Pit Viper 351 blasthole drilling rigs for around R 290 million to Kumba Iron Ore, a unit of Anglo American, one of the world’s largest mining companies.

The equipment will be supplied to the Sishen Mine in Kathu, northwest South Africa. The units are scheduled to be delivered from July 2012, and the last unit should be introduced into productivity in March 2013. The order was received during the first quarter.

Atlas Copco was recently identified by Anglo American as one of two preferred suppliers of surface drills with a drill diameter bigger than 165 mm. Sishen, one of the seven largest open-pit mines in the world, already has an existing fleet of ten Pit Viper 351s.

“We are proud to have been chosen as a strategic long-term partner to Anglo American and we look forward to building the relationship further in the future,” says Bob Fassl, business area president, Atlas Copco Mining and Rock Excavation Technique. “The Pit Viper 351 has a good reputation among our customers and we see great interest in this product from mining companies around the world.”

Atlas Copco, Bob Fassl, Tel: (011) 821-9000,Web: www.atlascopco.com

Very LARGE order

Pit Viper 351 blasthole drilling rigs

Consistancy is Vital

Two pass direct expansion dryer, Artic Driers style

Removing Min e

Almost all refrigeration air dryers only show the actual physical gas or compressed air temperature within the dryer itself. The temperature shown on the dryer’s fascia panel is not a dew point, it’s merely a temperature indicator. When, or if a drain valve fails, the condensing of water vapor to a liquid contamination still continues, thereby flooding the airline with liquid water.

In similar vein, if the refrigeration Freon compressor trips on internal thermal overload the majority of air dryers will not display this fault on the fascia panel, so again the air line is flooded with water contamination. Many engineering staff do not realise that that when a dryer fails or an automatic drain malfunctions, that the water injected into the ring main will take anything up to 30 days to be re-adsorbed by dry air for a (rectified or repaired) air dryer.

To prevent these occurrences regular maintenance of dryers should be undertaken by trained staff familiar with a dryer’s operating systems. Routine planned service maintenance should be undertaken by trained outsource engineers to check gas loads, switching hysteresis and hot gas valve set-ups etc.

Tel: (011) 425-3484, www.articdriers.co.za

MARKET FORUM

http://www.articdriers.co.za

http://www.atlascopco.com


agitation that protects valuable plastic liners, while extracting most high density sediments for re-processing.

“No downtime is necessary while the slurry is being removed, because the SlurryRat is able to operate while the pond remains online,” Xylem SA’s application engineer: mining and minerals, Lee Vine, says. “Companies who have already made use of this technology have been impressed by its efficiency and cost effectiveness, as well as the fact that the system can be customised to suit the specific conditions at each site.

Xylem, Lee Vine, Tel : (011) 966-9300, Fax: (0 11) 552-87421, Web: www.xylemwatersolutions.com/za

MARKET FORUM

in eral Sediments

Afrox’s Project Execution and the Ecovar team has successfully relocated a fully-fledged hydrogen plant from an existing site in Atlantis in the Western Cape, to a customer site 130 km from central Cape Town.

Ecovar stands for ECOnomical and VARiable and is a concept developed by Afrox’s parent company, The Linde Group, for supplying standardised oxygen, nitrogen and hydrogen via on-site production plants dedicated to supplying a single customer.

Due to the site security, risks, and equipment pilferage, a decision was taken to dismantle and relocate this plant onto the Afrox site at Duferco Steel Processing, a longstanding customer located 5 km away from the Port of Saldanha. Duferco, also a major Afrox LPG customer, produces in excess of 600 000 tons per annum

of steel products, including hot rolled pickled and oiled, galvanised and cold rolled products, using state-of-the-art technology.

The plant was dismantled at Atlantis, containerised and transported to Sal-danha on a flatbed truck. All pipework was re-used and replicated

Says Ecovar manager, Busty du Preez, “Apart from ensuring Durferco had an uninterrupted supply of hydrogen during the relocation, another of our Western Cape clients, a leading manufacturer and exporter of metal powder precision components, was reliant on us in this period to provide sufficient hydrogen to fulfil a large contract for the European motor industry.”

Afrox, Busty du Preez, Tel: (011) 490-0400 Email: [email protected] Web: www.afrox.co.za

Security of Supply

MARKET FORUM

Book now for 2012

SeptemberOils and lubrication

Compressors, air motors and vacuum pumps

Mills

Power Generation - wind

OctoberPower transmission

Computers in engineering

Pipes, pumps and valves

Power Generation

Materials and Machine Tools

Contact Mark Bennett on Tel: (011) 781-1401 Fax: (011) 781-1403

or E-mail: [email protected]

for further details

http://www.xylemwatersolutions.com/za


http://www.afrox.co.za



MARKET FORUM

Concept StoreBMG Fasteners has recently opened a new concept store in New Germany, Durban.This specialist fasteners store stocks a wide range of fasteners, tooling and abrasive products for all industrial requirements, as well as to satisfy demand from the DIY enthusiast

BMG Fasteners has recently opened a new concept store in New Germany, Durban. This specialist fasteners store stocks a wide range of fasteners, tool-ing and abrasive products for all industrial requirements.

“What’s unique about this spe-cialist store is we offer our customers a unique self-service, ‘touch and feel’ shopping experi-ence, whether they need a single fastener or have bulk require-ments,” says Darryl Campbell, general manager, BMG Fasten-ers. “We have had very positive feedback from our customers who appreciate their one-stop shopping experience for the exact product they require.

“A full technical advisory and sup-port service at the store ensures the correct product is selected for each specific application.”

Included in the range available from the concept store are hand,

air and power tools, abrasives, tapes, silicones, as well as weld-ing and safety wear. Premium fastener brands include Huck fasteners and Nord-Lock bolt securing products, washers and truck wheel nuts. Other well-known brands are Gedore, Somta, Klingspor, Pferd, Matabo, Bosch, Black & Decker and Gearwrench.

BMG Fasteners plans to open more concept stores in other key regions.

BMG Fasteners, which boasts the largest stockholding in the Southern hemisphere, sup-plies diverse industries with a comprehensive range of quality branded of fasteners, bolts, nuts and related products.

BMG Fasteners, Darryl Campbell, Tel: (031) 576-6200, Email: [email protected]: www.bmgworld.net

MARKET FORUM

Engineer Placementswww.engineerplacements.com


http://www.bmgworld.net

http://www.engineerplacements.com

www.garnettcross.com


MARKET FORUM

Shortened delivery periodsPan Mixers South Africa (PMSA) has improved control over the supply chain of its critical steel parts, after entering into a service agreement with newly-established steel merchant, TWR Steel Service Centre.

TWR Steel is based in Graniet Street in Jet Park, Boksburg, and consists of a 2 800 m2 manufacturing facility. It is a wholly-independent company that serves as a preferential supplier of steel products to PMSA.

TWR Steel, which officially began production in March 2012 after being established in late 2011, sets itself apart from the competition due to the fact that it specifically-focuses on improving the predominantly prolonged and delayed service delivery periods that currently dominate the local steel market. PMSA director Walter Ebeling notes that since its inception, TWR Steel has already made a measurable improvement to their turnaround times.

“PMSA manufactures between 60 to 70 percent of the components for its machinery in-house. In the past, we would outsource the profiling, bending, laser cutting and rolling functions to

outside companies,” he explains. “Due to long lead times; however, we were often forced to wait for several weeks before receiving certain materials, and resorted to overstocking of certain items to reduce the impact of delays for customers.”

Walter adds that the establishment of TWR Steel now ensures that PMSA has full control of all of the components of its manufactured machinery.

PMSA, Quintin Booysen, Tel: 086 100 7672, Email: [email protected] , Web: www.pmsa.com

Oxy-fuel cutting

The Institute for Advanced Tooling (IAT) at Stellenbosch University (SU), has commissioned a M2 laser cusing machine

The highly advanced laser can build any 3D object by simultaneously fusing and micro-welding fine metal powder. Therefore, there is huge opportunity for design freedom and production of com-ponents without the use of any tools, stimulating innovation and leading to product development time reduction, productivity improvement and mass customisation

A further major advantage is the large variety of processed materials it can handle such as aluminium, stainless steel, various hot-work steels, titanium, cobalt-chrome, nickel-based alloys and other. This allows a large utilisation of the equipment in demanding applica-tions from the aerospace (critical hollow parts made out of titanium), automotive, medical and dental industries (various implants), beyond its primary use for production tooling.

First-of-its-kind LaserMARKET FORUM

in collaboration with postgraduate students at SU.

Stellenbosch University, Tel: (021) 808-9184,E-mail: [email protected]

This high-tech system is the only one of its kind in South Africa and is a result of intensive research and development work conducted by the IAT engineers



http://www.pmsa.com

http://www.pmsa.com



Index to Advertisers

Artic Driers 18

Atlas Copco 16, Outside Back Cover

Axiom Hydraulics 4

Chem Systems 16

Compressed-Air 27

Electra Mining Africa 10

Engen 34

Chris Spencer

SEW Eurodrive has announced the launch of a repair service for servo motors at their Cape Town branch in Montague Gardens.

“The maintenance requirements of SEW servo motors are generally relatively low. However, breakdowns can happen to any product, and when it does happen, the motor needs to be re-paired as fast as possible to ensure minimum loss in productivity and maximum factory avail-abil-ity” comments Paul Strzalkowski, Electronics product manager.

In the past these units were sent to the headquarters in Germany for repairs and most often cus-tomers would replace the unit to minimise their downtime. Since the launch of the new service, custom-ers now have the option of sending their motors to the servo specialists at the

Local repair centre

Servo motor

Cape Town branch of SEW Eurodrive, for a rapid repair.

“Not only does this new initiative save the customer time, it also saves money. Servo drives are relatively expensive as a result of the high quality permanent magnets which are used in their con-struction. It is quite a complex product to work on as it requires specialised tooling and dedi-cated software, to align the motor feedback components. The Cape Town branch is now fully equipped to handle all of these repairs in house” adds Paul. The current turnaround time is ap-proximately 1 to 2 working days subject to spares availability.

Sew-Eurodrive, René Rose, Tel: (011) 248 7000, Email: [email protected], Web: www.sew.co.za

Linda Brown

The OMSA Group has appoined Linda Brown as their new Engineering Manager and Chris Spencer to the newly-created position of Thermoplastic Valve Specialist.

Richard Rudling has been appointed general manager at Ecochem Pumps, while Floris Pretorius has been appointed sales representative, Vaal Triangle, and

Hugo Pretorius is sales representative, Secunda’

Transnet National Ports Authority has annouced the appointment of Herbert Msagala as General Manager: Port Operations effective

June 2012.

Richard RudlingFloris PretoriusHerbert Msagala Hugo Pretorius

MARKET FORUM

Engineer Placements 44

Europair Inside Back Cover

Festo 14

Garnet Cross 44

Horne SA 25

Hytec 36

Interbuild Africa 29

KDP Services 21

Munters Outside Front Cover

Nkosi’s Haven Inside Front Cover

PPS 11

Rodecon 28

SAEEC 22

SAID 30


http://www.sew.co.za


www.europair-africa.com


www.atlascopco.com

sa mechanical engineer july 2012

Documents

giant scheme

small business

exchange of money

giant pyramid scheme

credit crisis

pyramid scheme collapses

irate investors

police services