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1/48 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 1

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2/482 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

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Chris ReayChairman of the Working

Committee: Communications

(SA Institution of Mechanical

Engineering)

AN ENGINEERS VIEW

For three eras in a row, the state has advisedthat they are to spend large amounts onprojects to support infrastructure. The firstin about 2003 was R400 billion to be spent

in three years, the second R787 billion announcedin February 2009 to be spent in four years, and

now we have another even greater sum to be spentstarting 2010. The problem I have with theseenormous projections which sound very admirableis that do we ever get a reconciliation of the actualspend, and what has been created for it?

If one surveys the likes of the municipal infrastruc-ture, for example, it appears more evident that theassets have deteriorated significantly, and this isshowing its effects with service delivery violence,shocking water status reports with video evidenceof the state of the rivers, wet lands, water andsewage plants.

Concealed from the publicThe extent of breakdowns and accidents in thedistribution network is generally concealed fromthe public as the safety investigation routines havealso declined. The recent 250MVA transformer firein De Aar was too big however to avoid the emailrounds.

The great pothole saga is of course very evidentto the public, with the consequent damage tosuspensions and noticeable increase in new tyresales. Low cost housing has not done much withthe need to destroy and rebuild R3 billion worthof previously built houses. It is not as thoughthe current building technology is rocket science they are simple constructs that any reasonablecontractor should be able to build to last.

Clearly the management or lack of it is responsible,so where has the training spend via say the SETAsgone that one would have thought would have aneffect on this part of the infrastructure? We all knowthe actual situation, but are all too PC to admit it inpublic forums. It probably personifies the massivestate of misused funds for personal gain.

Overall then, how much of this big spend is reallycreating the built environment?

Growing obstacleI recently took another look at the Dinokeng Sce-

narios that were published and debated in 2009.It is hard not to believe that the basics currently inplace are not those to precipitate the walk apartscenario. Many efforts to try and contribute to thesolutions that would assist us to achieve the walktogether scenario are ignored.

In technical skills development alone, we face agrowing obstacle to meet anything near the projectedinfrastructure spend. Government is able to findR140 million for fancy ministerial cars and manyother millions for parties and trips, but try to get afew million to train Engineers for municipalities.

Perhaps one plus will emerge from our misplacedand misused empowerment monster; those arecurrently disempowered and have to struggle tomake the grade will eventually, when the freehandouts are no longer possible and the energyin the flywheel has been depleted, have gainedstreet-wise skills and survival mechanisms to haveactually benefitted from the policy.

It may just be that such characteristics becomeengrained in the genes. And those who lived byentitlement will have regretted not understandingthe implications of the second law of thermody-namics.

State of the NationI have to say that after listen-

ing to the state of the nation

address by the President, it

only illustrates that either

politicians just keep on be-

lieving we are all uninformed

morons or that they are sim-

ply living in the blissful state

of ignorance, accompanied by

a good dose of self preserva-tion. I have a feeling that it is

the latter.

When the free handouts are no longer possible

8/7/2019 SAME: Feb 2010


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Monthly Column8 Skiing Without a Boat

Cover Story11 A Bulk Filtration Solutions Offering

Oil & Gas12 Oil & Gas Conference Exhibition

2010

15 Fabrication in Saldanha

18 New Kid on the Block

Compressors and Vacuum Pumps21 Filling the Vacuum

25 Whats in a Name?

Produced by:

PROMECH PUBLISHING,

P O Box 373, Pinegowrie, 2123

Republic of South Africa

Tel: (011) 781-1401, Fax: (011) 781-1403

Email: [email protected]

Website: www.promech.co.za

Managing EditorSusan Custers

EditorKowie Hamman

Advertising Pauline Bouwer

Circulation Catherine Macdiva

DTP Zinobia Docrat/Sanette Lehanie

Disclaimer

PROMECH Publishing and The South African Institution of Mechanical

Engineering as well as any other body do not take responsibility for

the opinions expressed by individuals.

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

Ofcial Publication ofTHE SA INSTITUTION OF MECHANICAL ENGINEERINGand endorsed by:

CORROSION INSTITUTE OF SA

SA PUMP MANUFACTURERS ASSOCIATION

SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION

THE SA INSTITUTE OF TRIBOLOGY

NUCLEAR INSTITUTE

SA INSTITUTE FOR NON-DESTRUCTIVE TESTING

NATIONAL SOCIETY OF BLACK ENGINEERS

INSTITUTE FOR CERTIFICATED MECHANICAL ANDELECTRICAL ENGINEERS

SOUTH AFRICAN ASSOCIATION OF CONSULTING ENGINEERS

ASSOCIATION OF SOCIETIES FOR OCCUPATIONAL SAFETY

AND HEALTH

Pipes, Pumps & Valves27 Nowhere to Stick

31 Riding Outthe Storm

Material Selection35 Catching the Eye

Regulars

3 An Engineers View

6 Institution News

33 Nuclear Institute (SA Branch)

34 INCOSE

39 Market Forum

46 On the Move

Contents

The monthly circulation is 4 242

CopyrightAll rights reserved. No editorialmatter published in SA Mechani-cal Engineer may be reproducedin any form or language without

written permission of the publish-ers. While every effort is made toensure accurate reproduction, theeditor, authors, publishers andtheir employees or agents shallnot be responsible or in any wayliable for any errors, omissions orinaccuracies in the publication,whether arising from negligence orotherwise or for any consequencesarising therefrom. The inclusionor exclusion of any product doesnot mean that the publisher oreditorial board advocates or rejects

its use either generally or in anyparticular field or fields.

Feb 2010 VOLUME 60 NUMBER 2

Featured on the Cover

Donaldson Filtration Systems

Tel: (011) 997-6000Fax: (011) 608-0021

Email:

[email protected]:

www.donaldson.co.za

8/7/2019 SAME: Feb 2010


SAIMechE Boardroom for hireThe comfortable and spacious boardroomat our Bruma offices is currently under-utilised, and offers an opportunity to providea service to both Institute members and thegreater mechanical engineering community.The newly-renovated and air-conditionedboardroom with modern furniture can com-fortably seat 12, and has abundant poweroutlets for laptops. A remote-controlledceiling-mounted data projector as well asa flip-chart with pens are provided.

This facility would suit those looking for acentrally-located professional meeting venue,easily accessible from OR Tambo InternationalAirport and Gilloolys Interchange.

Hire rates (excl. VAT):

MembersBrief ad-hoc meetings (depending onavailability): no charge.

Booked meetings: R100 for morning/

afternoon; R150 for the whole day.

Non-membersBrief ad-hoc meetings: not offered tonon-members

R400 for morning or afternoon; R700for whole day

Tea, coffee and biscuits will be provided aswell as water and mints.

Free wireless secured internet access alsoavailable.

We do not provide other snacks and drinks

and these would be for own account andarrangement.

Anisa, Tel: (011) 615-5660, Email: info@saimeche.

org.za.

THE SA INSTITUTION OF MECHANICAL ENGINEERING

Council 2009/2010

Office BearersPresident .................................................. G Barbic (George)

President Elect ............................................. D Findeis (Dirk)

National Treasurer ................................. K Nyangoni (Kudzai)

Branch ChairpersonsCentral ...................................................... M Cramer (Mike)

Eastern Cape ............................. Prof Dr DG Hattingh (Danie)

KwaZulu/Natal ........................................... AG Fileczki (Alex)

Western Cape ................. ....... . Prof B Collier-Reed (Brandon)

Portfolios:Communications .............................................. CD Reay (Chris)

Education - Universities................... Prof JL van Niekerk (Wikus)

Education: Universities of Technology............... E Zawilska (Ewa)

Membership .................................................... E Zawilska (Ewa)

Seminars and Workshops.................................. D Finde is ( Dirk)

Technology Programme ................................. SZ Hrabar (Steve)

Chief Executive Officer: Vaughan Rimbault

National Office Manager: Anisa NanabhayPO Box 11, Bruma, 2026Tel: (011) 61-660, Fax: (011) 88-6

Ema il: [email protected]

Website: www.saimeche.org.za

Membership: Central, Eastern Cape & KZN:

[email protected]

Membership: Western Cape: [email protected]

Company AffiliatesAinsworth Engineering (Pty) LtdAlstom Power Service SABabcock Africa LimitedBateman Engineered TechnologiesFluor SAGEA Air-cooled SystemsHansen Transmissions SAHatch AfricaHowden PowerIndustrial Water CoolingMegchem Eng & Drafting ServicesOsborn Engineered Products SARotek EngineeringRSD a division of DCD-DorbylS.A.M.E WaterSasol TechnologiesSEW EurodriveSiemens LtdSNC-Lavalin SASpicer Axle SASpirax Sarco SA

Thyssenkrupp EngineeringTransvaal Pressed Nuts & BoltsVital EngineeringWeir Warman AfricaWinder Controls

Whats Happening?

8/7/2019 SAME: Feb 2010


THE SA INSTITUTION OF MECHANICAL ENGINEERING

Training Events Calendar - 2010

Whilst every effort is made to ensure that events take place as scheduled, SAIMechE reserves the right to change thesechedule as circumstances dictate. A registration form and full terms and conditions may be obtained from Carey Evans

on email: [email protected] or Tel. (031) 764-7136. Detailed individual event programmes are available from Carey.Corporations wishing to book In-House Workshops may contact Linda Robinson on email: [email protected] or

Tel: (031) 764-7136.

EventCode

Full Title Date Region

E2610 Working in Conned Spaces - Safety Requirements & Guidelines 17-Mar-10 East Rand

F0210 Boiler House; Safety Valves 17 to 19-Mar-10 Secunda

A1310 Structured Problem Solving Techniques 18-Mar-10 Durban

B3610 Project Management - A Review of Essentials 24-Mar-10 Port Elizabeth

D3010 Root Cause Failure Analysis 24 to 25-Mar-10 Vereeniging

B4710 Capital Budgeting for Projects 25-Mar-10 Port Elizabeth

C4610 Value Engineering & Value Management 31-Mar-10 Cape Town

D0310 Steam Distribution; Pipeline Ancillaries; Steam Flow Metering; Desuperheating 7-Apr-10 Vereeniging

A2110 The Management of Health & Safety Risks/Hazards 8-Apr-10 Durban

F0310 Steam Distr ibution; Pipel ine Ancil laries; Steam Flow Metering; Desuperheat ing 14 to 15-Apr-10 Secunda

A3310 Stainless Steel - Complete Overview for Engineers Including Design with Stainless Steel 20-Apr-10 Durban

A3410 Aluminium - A Complete Overview for Engineers Including Design with Aluminium 21-Apr-10 Durban

C0310 Steam Distr ibution; Pipel ine Ancil laries; Steam Flow Metering; Desuperheat ing 21 to 22-Apr-10 Cape Town

A3510 Plastics - A Complete Overview for Engineers Including Design with Plastics 22-Apr-10 Durban

F1310 Structured Problem Solving Techniques 28-Apr-10 Secunda

J0610 The Engineer As Manager 28-Apr-10 Pretoria

SAIMechE Saldanha BranchSAIMechE Council is considering a branch in Saldanha, andneeds to know whether there are sufficient SAIMechE membersin the area who would benefit from a local branch. Member Ken

Vaughan (who works in Saldanha) has volunteered to managethis initial phase.

Judging from the responses sent to Ken, we will set up an initialmeeting in Saldanha to discuss the implications of a local branch,and then move to establish a committee. From then on it willbe up to the committee to drive things. Although the branchis a members initiative, it will hopefully also help to increaseSAIMechE membership in the area.

We ask that you contact Ken with comments or suggestions via our National

ofce on email [email protected].

Geoff Alder - Consultant, author, publisher and

SAIMechEs Refrigeration course developer

Captivated delegates at a recent Cape Town workshop led by Geoff Alder on Psychrometrics and Psychrometric

Principles

8/7/2019 SAME: Feb 2010


MONTHLY COLUMN

Welcome to cable skiing! Cable skiing isa way to water ski or ride a wakeboard,where the skiers rope and handle arepulled by an electrically-driven cable,

whereas traditionally a water skier is pulled by amotorboat. The ski mechanism consists of twocables running parallel to one another with carri-ers between them, allowing several skiers on thewater at the same time.

The carriers are metal plates with hooks onthem which allow the tow rope to be attachedand detached easily without shutting the system

down. The cable is generally suspended above

the water from fixed pylons erected on a coursearound the dam.

The differenceAccording to the skiers, the feel on a cable ski isslightly different from riding behind a boat. Thehigher angle of pull on the cable ski makes biggerair jumps and sharper turns possible. Generallythere are ramps and sliders for the riders to use,but wake boarders also have a trick whereby theyload the line by putting tension on the rope and,using the water as a spring, fling themselves intothe air in order to carry out somersaults or similarroutines.

Though it is possible to do this behind a boat,the higher angle of pull and the slight jerk on thecorners of the course, allows good riders to attainmuch higher jumps. We speak to Nic Malton whoregularly goes on the cable ski. I do i t for fun anddepending on the mood Ill either use a surfboardor the wakeboard, he says.

The main difference between skiing behind a boatand the cable ski is that the you dont have theboats wake on the cable. Behind a boat you canuse the wake to launch and get into the air for a

trick, but on the cable you have to create momen-

SkiingWithout a BoatOn a perfect summers day SA Mechanical Engineer set off

to do a story on waterskiing at a dam in Midrand. Coming over

the last ridge we could clearly see some skiers skimming the

smooth surface, others flying through the air off ramps and yet

more negotiating wide turns at the other end of the dam. But

as we come closer to the water, there is something distinctly

missing, not a single roaring power boat ploughing through the

water in sight.

You have to create momentum from the cable thats

running at a constant speed

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A typical cable ski course from the air

MONTHLY COLUMN

tum from the cable thats running ata constant speed.

You go wide to pick up speed andthen, when the cable picks up theslack this creates, it gives you a f irmpull and sudden momentum thathelps you to get into the air. Theother thing you have to learn is to dotricks near the base station becauseunlike a boat which is able to turnaround to come and pick you up, ona cable system you have a long swimback to shore if you fall on the otherside of the dam.

How it worksOn our visit to Base 3 Leisure Lakes

in Midrand, we quickly learn how thesystem works mechanically. At thebase station, an operator manuallyhooks the ski rope onto the main cable carriermechanism. The operator then asks the skierwhether he or she is ready and passes the ski ropehandle to him where hes waiting on the jetty. Asthe carrier approaches, the operator simply throwsa lever to engage the ski rope and seconds later,the skier is gently pulled onto the water to do histhing around the 800 metre course.

If the skier falls, he simply lets go of the ski ropeand has to work his way back to the shore while

the rope continues on back to the base stationwhere its manually dislodged from the carrier tobe readied for the next skier. The cable travelsat a speed similar to that of a boats speed intournament water-skiing, with a top speed of 58kilometres per hour.

South AfricaA far-sighted Allen Louw of Aventura installed thefirst South African cable ski at the Warmbaths Spain 1993. The South African Cable Ski Association

was formed in the same year as a steering com-mittee and has held a number of very successfulcompetitions over the years. At the beginning ofthe season in 1996, the association held its firstrecognised national competition and together, withthe formation of two clubs, gained recognition withinthe South African Water Ski Federation.

The association in conjunction with Aventura heldthe hugely successful championship in 1998 atthe Aventura Spa where two world records werebroken.

A few years later, Mike OConnell opened LeisureLakes in Midrand which is a very well-supportedsite that holds regular events.

Mike OConnell, XS Promotions, Tel: (011) 314-3589,


Have a long swim back to shore if you fall on the other

side of the dam

Skiing on a cable ski is only slightly different from skiing behind a boat

8/7/2019 SAME: Feb 2010


Excellent

Minerals

Solutions

WARMAN

Centriugal Slurry Pumps

www.weirminerals.com

PerormanceNot promises

Mines dont make money when they

arent running.

Weir Minerals Arica is committed to

ensuring that your mine and mineral

processing plant continue to operate with

maximum availability.

With over 100 years o experience and

expertise producing some o the industrysmost recognised pumps, cyclones, valves

and linings, Weir Minerals Arica ensures

your productivity by maximising ours. With

our lean manuacturing principles and

acilities on every continent, we can ll your

needs quickly and efciently saving your

operation time and money.

Weir Minerals Arica providing the

productivity perormance you demand.

8/7/2019 SAME: Feb 2010


DFSPL designs and sells bulk filtrationsystems. Currently, their focus is inAfrica, having provided solutions forclients in over 15 countries, including

South Africa, Mali, Ghana, Niger, Guinea, CoteDIvoire and Zambia. In the near future, three ad-

ditional regions will be supported: South America,the Carribean and Asia.

Once an inquiry is received, Donaldsons bulkfiltration technical division evaluates the project,informs the client of what is required and designsand sells the filtration system. This system is theninstalled on site by a local engineering company,after which, a Donaldson technician travels tocommission the site.

Driving down TCOMost recently, Donaldson worked on a project forBonikro Mine, a diesel site, in Cote D Ivoire. Oncethe filtration system had been installed, Deon Cilliers,technical support engineer, travelled to the site forinspection of the installation and commissioning.

Deon states, In these modern times of high pres-sure fuel injector systems, it is imperative to havecleaner fuel in order to save downtime and main-tenance costs and therefore drive down TCO (totalcost of ownership).

A set of filters was installed on the downloadingside with a water separator and particle removalfilters. The same set of filters, were installed onthe transfer pump to the day tanks and to the dis-pensing hose reels for the dump trucks and smallvehicles respectively. Breathers were also installed

to complete the process.

Two samplesA sample was taken before the filters on downloading and one from the hose reel for the dumptrucks. These two samples were compared.

Sample from down loading: ISO 26/23/18

Sample from hose reel: ISO 16/14/11

The Worldwide Fuel Charter requires an ISO 4406particulate cleanliness specification of 18/16/13.Bearing this in mind, it is clear Donaldson is settinga superior standard for bulk filtration cleanliness.

Donaldson provides a value-added service to clientsthrough assistance with design, commissioning andthe selection of a bulk filtration system. A com-prehensive after sales support structure providesadvice, recommendations, technical assistanceand spares.

Donaldson Filtration Systems provides solutionsfor all bulk fuel and oil filtration. It is committedin providing industry with superior filtration solu-tions.

Donaldson Filtration Systems (Pty) Ltd, Mariette Venter;

Tel: (011) 997-6000, Fax: (011) 608-0021, Email: marketing.

[email protected], Website: www.donaldson.co.za

COVER STORY

A Bulk Filtration

Solutions Offering

Donaldson Filtration

Systems (Pty) Ltd

(DFSPL) has signed

contracts withnumerous oil

companies to provide

bulk filtration for

mining sites.

Sample comparison

Setting a superior standard for bulk filtration cleanliness

8/7/2019 SAME: Feb 2010


With key international and local plenaryspeakers in the line-up, the 2010conference retains its ranking as oneof the top events on the African Oil

and Gas calendar and Southern Africas leadingindustry interface globally.

With a wide range of topics covering everythingfrom Upstream Developments in Africa to TechnicalPapers on Rig & Platform Design, the mix of plenaryconference, seminars, briefings and workshops isexpected to attract in the region of 750 delegates

from throughout the African continent.

Great interestAs the fourth iteration of this event, Oil & Gas Africa2010 seeks to explore the challenges faced by thesub-Saharan and African Oil & Gas markets duringeconomically uncertain times. The previous threesaw the presence of 10 000 visitors, 800 delegatesand in excess of 500 exhibitors.

The event comprises both a conference (16-17March) and exhibition component (16-18 March). Theexhibition, for its part, will prove of great interestfor suppliers to oil refineries, petrochemical plants,oil and gas installations and pipelines.

Oil & Gas 2010Billed as being Bigger, Better and Busier than everbefore, the conference and exhibition was previ-ously known as Oil Africa and has been updated toemphasise the increasing role that gas productionis playing in the industry.

Typically, delegates and exhibitors hail from the likesof Angola, Botswana, Burkina Faso, Cote dIvoire,Canada, China, DRC, Egypt, France, Ghana, India,Italy, Kenya, Korea, Madagascar, Monaco, Mozam-bique, Namibia, Netherlands, Nigeria, Portugal,Russia , South Africa, UAE, UK, USA, West Indiesand Zimbabwe.

Confirmed speakersConfirmed speakers include:

Ebbie Haan Managing Director: Sasol SPI. [Basedin Johannesburg, South Africa]

Dr Martyn Davies CEO: Frontier Advisory. [Basedin Johannesburg, South Africa]

Kamal Dorabawila Head of Oil and Gas in Africa:International Finance Corporation (IFC). [Basedin Washington, DC, USA]

Advocate Barrisford Petersen Head Oil & Gas:Bowman Gilfillan. [Based in Cape Town, SouthAfrica]

Chris Bredenhann Advisory / Partner: Price-WaterhouseCoopers. [Based in Cape Town,South Africa]

Stuart Griffin Schlumberger. [Based in Lon-don, UK]

Eduardo Lopez Senior Oil Demand Analyst:International Energy Agency (IEA). [Based inParis, France]

Says John Thomson, managing director of co-or-ganisers, Exhibition Management Services: "While

ExhibitorsWelding Alloys SA (WASA)

Afrox

Techtra

Renttech SA

Esab

TranscapeTechnoswitch

Zulfi Welding Electrodes

De-Tect Unit Inspection

Messer-Eutectic SA

All

sectors of

the Oil, Gas, Petrochemical

and related industries are set to converge

on the Cape Town International Convention Centre

(CTICC) between Tuesday 16 and Thursday 18 March 2010,

when OIL & GAS AFRICA 2010 the continents leading

Oil, Gas and Petrochemical Engineering Supply Chain event

takes place daily between 10h00 and 18h00.

Opportunity to interact with African national

independent oil companies from Ghana, Nigeria and

elsewhere

Oil & Gas Africa 2010 is sponsored by SasolSPI (Gold sponsor) and the Petroleum AgencySouth Africa (Bronze sponsor). The event isendorsed by Provincial Government WesternCape, City of Cape Town, the South AfricanOil and Gas Alliance (SAOGA), the WesternCape Investment & Trade Promotion Agency(WESGRO), the South African Supplier De-velopment Agency (SASDA), the South Africa Angola Chamber of Commerce, OffshorePetroleum Association of South Africa, SA

Capital Equipment Export Council, the SouthAfrican Petroleum Industry Association (SA-PIA), and the Cape Town Regional Chamberof Commerce and Industry.

OIL & GAS 2010

8/7/2019 SAME: Feb 2010


the continent's growing importance as a new sourceof crude oil is attracting an increasing number ofAfro-centric oil industry meetings and conferences,our event, Oil & Gas Africa, now in its fourth edi-

tion, is still the largest and only Engineering SupplyChain exhibition.

At the last event we had 3 522 visitors attendingfrom 34 countries. With the ongoing discoveriesbeing made on Africa's West Coast Oilfields andincreasing numbers of operators working there, weexpect the attendance to increase significantly atour 2010 event."

Active participantPetroleum Agency SA has been an active par-ticipant in Oil & Gas Africa since its inception,both as exhibitor and sponsor, says Dave van der

Spuy, Manager Petroleum Resource Evaluation atPetroleum Agency SA, which is the South Africanagency for the promotion of petroleum explorationand exploitation. We are proud to announce thatwe will once again be exhibiting. In addition, we willbe sponsoring the attendance of ten representativesof entry level HDSA owned companies, allowingthem to attend at half price.

This will afford them the opportunity to network withothers in the industry, giving them the opportunityto publicise their capabilities, form synergies withproviders of related services and make themselvesknown to the primary users of services: the explora-

tion companies.

Modalities for financing projectsPaul Runge, Conference Director and ManagingDirector of Africa Project Access, has the follow-ing to say: This, the 4th Oil & Gas Africa Expoand Conference, is of particular significance inthat it will provide an opportunity to interact withAfrican national independent oil companies fromGhana, Nigeria and elsewhere. The rise of theseprivate African oil companies in the upstream andmidstream sectors is a new and interesting phe-nomenon providing an important new client base

for suppliers.Another important aspect is the events emphasison modalities for financing African oil and gas proj-ects. The keynote address by Kamal Dorabawil, oilspecialist at the International Finance Corporationin Washington, is especially appropriate withinthis context.

Working in conjunction with their respective SouthAfrican Business Chambers and Economic Counsellorsfrom the Department of Trade & Industry, organisershave scheduled inbound buyer/delegate groups fromthe various African oil producing countries.

In addition, industry related associations andorganizations are planning various complimentarytechnical workshops, seminars and briefings tosupplement the main conference. The African Refin-ers Association, for example, has scheduled their

Designed to educate and inform, the SAIMechE Technical Seminarwill once again run alongside the Oil & Gas Africa Conference.With a number of key industry specialists. Confirmed topics willinclude:

Offshore Engineering Developments over the past 30 years

Design of Jacket Structures

Selection of Steels

The Design and Installation of Near-Shore Subsea Pipelines

Pressure Vessels

Rotating Equipment

Offshore Power Generation

Environmental Regulations in Off-Shore Industry

Design for Lifting Operations and TransportationWelding of Offshore Structures

Structural Design of Topsides

Corrosion Protection

Project Quality Assurance

Design of Piling Systems

OIL & GAS 2010

Please make a point of visiting

SA Mechanical Engineers

stand atOil & Gas Africa 2010.

Wed love to see you!

AGM and two days of Downstream Workshops forthe week leading up to exhibition.

Friday 19 March has been set aside for the South

African Oil & Gas Alliance (SAOGA) golf day.

Admission to the Oil & Gas Africa 2010 Trade Ex-hibition is open to all South African businesses.

Says Warwick Blyth, Executive Director, South AfricanOil & Gas Alliance: We look forward to building onthe solid foundation of the previous three years aswe continue with the development of the WesternCape & South African Oil, Gas & Energy Industriesand strengthen its international ties. We confirmour support for this initiative and look forward tomeeting many new international participants andwelcoming them to the Mother City of South Africa

as well as those who have been working with usbefore and not forgetting our regionally-based col-leagues, clients and suppliers.

To register for the conference, visit www.

fairconsultants.com. To register as a visitor

to the exhibition, visit www.exhibitionsaf-

rica.com.

8/7/2019 SAME: Feb 2010


8/7/2019 SAME: Feb 2010


The port of Saldanha is best known for

its iron export facilities, but over the past

couple of years, long-term infrastructure

developments have progressed to include

the establishment of a fabrication facility to

serve the oil and gas industry off the African

west coast. This steel fabrication facility is

built on the same site where the fabrication

and construction of the 14 500 tonne fixed-

leg platform jacket for the Mossgas offshore

platform took place in the 1980s.

SA Mechanical Engineerspeaks to Steve Hrabar,immediate Past Presidentof SAIMechE and directorof the South African Oil &Gas Alliance, who has formany years been activelyinvolved in promoting thedevelopment of such afacility at Saldanha. Gri-naker LTA has now beenappointed as the operator

of this facility and theyhope to get the ball rolling with projects this year,he says. The company is familiar with this typeof heavy fabrication work as they had a similaryard in Nigeria.

Offshore projectsThe fabrication site is well equipped for the con-struction of offshore oil and gas projects with thefirst phase of the centre consisting of a fabricationyard of 220 000 m2 that includes an open weld-ing area, high bay fabrication workshops with 15and 25 tonne capacity gantry cranes, a blastingand priming workshop, a pipe spool fabricationworkshop and an electrical and instrumentationworkshop.

Other facilities include material warehouses, cus-

Fabrication in Saldanha

OIL & GAS 2010

Steve Hrabar

8/7/2019 SAME: Feb 2010


toms control and a bonded warehouse, a 35 metreload-out quay, high mast flood lighting as well asmedical and first aid facilities.

Serviced by a fleet of mobile cranes, fabrication ca-pacity will focus on the fabrication and constructionof jackets, process topside modules, decks, booms,bridges and sub-sea infrastructure.

BackgroundOriginally, after the Mossgas project, it was hoped

that future offshore projects would be available inSouth Africa and internationally, however this wasnot possible and the site lay fallow until 2006, ex-plains Steve. Due to the offshore activity on the WestCoast of Africa, the National Ports Authority formeda committee to see what infrastructure changes theywould have to implement to support the oil and gasactivities on the West Coast.

The committee was made up of representatives ofbusinesses in engineering and project management,fabrication and construction, ship repair, upstreamdevelopment and logistics.

Base to operate fromJoining this committee was the Provincial Governmentof the Western Cape, National Ports Authority, IndustrialDevelopment Corporation, the Department of Tradeand Industry, South African Revenue Service, Chamberof Commerce, Petroleum Agency of South Africa andthe West Coast Business Development Centre.

An interim report was issued in August 2003 and afinal report in September 2004, adds Steve. Thereport recommended that the Saldanha fabricationfacility be re-commissioned and a dry-dock be con-structed to support the activities in Saldanha Bay. Inaddition, a dedicated berth should be allocated for

repairs to rigs and oil and gas vessels in Cape Townso that the ship repair industry would have a baseto operate from.

OffsetMAN Ferrostaal, who supplied three submarines

OIL & GAS 2010

More suitable for the manufacture of the

various components for offshore platforms

8/7/2019 SAME: Feb 2010


There have been discussions whether to locate theoffshore oil and gas business in Saldanha Bay orkeep certain activities in Cape Town, says Stevein conclusion. Cape Town has an existing dry-dockbut is not suitable for semi-submersible rigs asthey are too wide to fit into the facility. There areongoing talks between the Provincial Governmentof the Western Cape, Transnet National Ports Au-thority and the Saldanha Municipality to plan theroad ahead, but this has been an arduous processthat will take some time to resolve.

Steve Hrabar, Tel: 082 558 8656, Email: stefanzh@iafrica.

com

to the South African Navy, hadan offset obligation to the SouthAfrican Government and theybecame interested in the recom-

mendations of the NPA report andcommissioned an Investment Op-portunity Analysis in the MarineSector, adds Steve.

This analysis was examined byMAN Ferrostaal who targeted twoopportunities on which a DueDiligence was performed. Onceapproval had been given by the dti,to these opportunities, a businessplan was developed, including lo-cal business to participate in theventure. In 2006 new buildingswere erected and the fabricationsite was re-commissioned.

When the NPA Oil & Gas Com-mittee submitted their report,the Provincial Government of theWestern Cape created a Section21 Company called the SouthAfrican Oil & Gas Alliance, wherebusiness and government mar-keted the abilities of South African industry to theoffshore oil and gas market. This company wasformed in 2004 with the strategy of creating the

infrastructure so that businesses could cooperateand compete with other countries for the WestAfrican market, Steve elaborates.

The plan for the infrastructure was to have a fab-rication site in Saldanha Bay, a dedicated berth inCape Town harbour for repairs and maintenanceto rigs, the building of a dry-dock and establishingan onshore base to support offshore activities, headds. Two of these plans have come to fruitionwith the dry-dock and the onshore base being fol-lowed up as funds become available.

ComponentsAlthough Saldanha Bay is thedeepest and largest natural portin Southern Africa, and hasthe capacity to build completeplatforms, fabrication work for acomplete platform may very well,like the Mossgas project, also bedistributed to other harbours suchas Cape Town and Durban.

As theyre currently doing, CapeTown harbours repair facility canwork on complete rigs and there-fore we foresee that Saldanha will

initially be more suitable for themanufacture of the various com-ponents for offshore platforms,explains Steve. These includejackets, bridges, outriggers, decksand modules.

OIL & GAS 2010

Arduous process that will take some time to resolve

8/7/2019 SAME: Feb 2010


New Kid On The BlockTheres a new player in the South African welding industry

and all indications are that this firm is rapidly following

in the footsteps of its mother company, a global leader in

welding supplies and associated services. In light of a man-

ufacturing industry that can only grow, the South African

industry has welcomed the influx of new technology which

this company is bringing to the table.

SA Mechanical Engineer speaks to Chris Eibl,

the managing director of Esab Africa Welding& Cutting, who elaborates on the companyshistory and the advantages of the product

range offered to the local market. Esab is a worldleader in advanced welding and cutting solutions

with a product and geographical spread that isunrivalled in the majority of the worlds markets,

he says. Our global representation coversfive continents and has 35 manufacturing

locations to serve customers throughoutthe world.

From the companysfoundation in

Sweden

in 1904 and the development of the worlds firstwelding electrode, Esab has contributed to the weldingmarket with a continual stream of innovations. Thisincludes submerged arc welding in 1937, gravitywelding the year after, TIG-welding in 1944 andthen in 1947 MIG/MAG welding.

More milestonesOther technological milestones in the companyshistory are plasma cutt ing in 1955, cored wires in1956, robot arc welding and narrow gap weldingin the seventies, low moisture electrode coating,bulk pack of wire and high speed cored wire in the80s. In the nineties they brought out friction stirwelding technology called SuperStir and in 2001introduced the first modular platform for weldingequipment.

Most recently they came up with AristoRod, andadvanced surface coating wire which was followedby the Qset function in 2005. In 2008 Esab wasthe recipient of the Frost & Sullivan Global WeldingConsumables Customer Excellence Award.

ServicesThe companys services and product range is ex-tensive, ranging from cutting systems, to welding

equipment, accessories and consumables. Seventy

OIL & GAS 2010

Seventy years of cutting experience and a constant keen

ear for our customers needs

8/7/2019 SAME: Feb 2010


years of cutting experience and a constant keenear for our customers needs have resulted in anextensive range of products, from thermal cuttingtechnologies such as plasma, oxy-fuel and lasercutting systems, to new waterjet cutting technolo-gies, says Chris.

One of our specialities, welding automation, hasadvantages such as high quality, capacity and

much better productivity. We develop and producea wide range of mechanised and automated weldingsystems to meet any need, tailored specifically toeach users special requirements and needs.

As far as welding equipment is concerned, Esabssystems are based on solid-state technology. Thelatest generation of welding equipment can beprogrammed with specific process preferences forindividual needs or for the actual welding processes,explains Chris. State-of-the-art plasma cuttingequipment is available in manual, mechanisedand precision mechanised formats. This range isrounded off with our highest quality welding PPEand accessories.

ConsumablesEsab is one of the worlds leading manufacturersof consumables with a vast array of approvals on

most products. Our range includes covered elec-trodes, cored wires, solid wires, TIG rods, stripsand fluxes, covering all customers needs for everytype of welding, says Chris. The company hastailored its range of consumables to the requirementsof the South African market with the introductionof consumables that conform to ASME II, Part CSFA 5.01, Schedule H, I, J, K, Class S3, C3, C5

and T3.

The invention of advanced surface coating (ASC) onMIG wires has proved to deliver significant savingsto welders across the globe. This next generationof MIG wires will replace the old technology ofcopper-coated wires within the next decade, Chrispredicts. Already over 50% of Europe has movedaway from old copper-coated wires.

Esab packaging solutions for consumables combineproduction efficiency with environmental responsi-bility. The Marathon Pac wire delivery system canoffer truly non-stop production in robot applica-tions, meaning zero downtime for spool changesand zero downtime for drum changes when usingthe endless wire set-up.

OIL & GAS 2010

Replace the old technology of copper-coated wires

within the next decade

8/7/2019 SAME: Feb 2010


OIL & GAS 2010

premium alternative that is unrivalled in terms ofproduct quality and worldwide acceptance. Fabrica-tors now have access to this leading global weldingand cutting brand.

Weve acquired the best people in the industryboth in terms of technical and business compe-tence to the extent that our local personnel havea combined experience in the welding market ofover 150 years, he adds proudly.

Slick supply chainFor enhanced customer service, the entire supplychain has been outsourced to specialists in thisfield, namely Hellmann Worldwide Logistics, aglobal company that has extensive coverage ofthe southern African market. Hellmann has ware-houses in Johannesburg, Durban, Port Elizabeth,

East London, Cape Town and many other Africancountries.

This unique distribution network enables us to reactquickly to changing market demands and offers aseamless supply of products to the market. With ourbusiness partners, often referred to as distributors,we have the geographical coverage and presenceto support all the needs of all southern Africanfabricators, says Chris in conclusion.

Chris Eibl, Esab Africa Welding & Cutting, Tel: (011) 240-

4000, Email: [email protected]

Weve acquired the best people in the industry both in

terms of technical and business competence

CommitmentEsab has committed itself to the southern Afri-can market with the establishment of Esab AfricaWelding & Cutting, says Chris. For the first timewere now a part of the welding and cutting marketin southern Africa, bringing customers a viable

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Just because the pump is turning does notmean its actually pumping effectively,he says. The gap between the vanes andthe housing gets bigger over time due too

wear which reduces the pumps performancesignificantly.

A simple vacuum test will immediately reveal thisor other faults such as an air leak in the systemwhich forms part of the service that Horma Pumpsoffers vacuum pump users. We dont charge to

test a vacuum pump system, provided the pumpcomes to us for repair, says sales manager, RyanBaptista. Sometimes its not the pump itself, butrather a poor installation which causes the systemto leak air.

How it worksThe liquid ring principle used in a vacuum pumpcompresses gas by rotating a vaned impeller withinan eccentric space in a cylindrical casing. Liquid,usually water, is fed into the pump and, by centrifugalacceleration, forms a moving cylindrical ring againstthe inside of the casing. This liquid ring creates aseries of seals in the space between the impellervanes to form compression chambers.

The eccentricity between the impellers axis ofrotation and the casings geometric axis results ina cyclic variation of the volume enclosed by thevanes and the ring, creating a vacuum at the inletport of the pump. Gas, often air, is drawn into thepump via the inlet port and is trapped in the com-pression chambers formed by the impeller vanesand the liquid ring. The reduction in volume causedby the impeller rotation compresses the gas beforeit goes to the discharge port at the other end ofthe pump casing.

Doing it rightAlthough the principle of a vacuum pump is simple,many dont fully understand its workings and theyjust dont get it right, Ryan says. Calls come in

regularly for us to help out in such instances. We goto site, do a complete test of all the vacuum pumpsystems and draw up a comprehensive report toindicate the performance of each pump and whetherit needs to be serviced, repaired or replaced.

Apart from repairs and service to all makes ofvacuum pumps, Horma Pumps also locally manu-factures their own series used in the sugar, mining,pulp and paper and petrochemical industries. Weservice the platinum mining industry extensivelyand therefore Rustenburg is the one area where wehave appointed an agency, adds Ryan. The factthat we manufacture locally allows a delivery time

for a new pump, built from scratch, of six weeksas opposed to an import that usually takes aroundthree months to deliver.

TestingWeve also invested in an in-house test facilityin order to apply the necessary ISO certificationstandards as well as the different specificationsthat are required by each client, says Andr. Ourdoor is always open for customers to come in andwitness the tests we do on their specific pumps.This gives them the confidence that theyre gettingwhat theyre paying for, he adds.

In addition, we keep data packs for our regularcustomers containing site inspection reports,specification and repair records, says Andr.Through this we can see when a trend developsand be prepared with the necessary stock when a

COMPRESSORS AND VACUUM PUMPS

Filling theVacuumAlthough the

operation of a vacuum pump

is straightforward, its easily installed

incorrectly and then even the slightest air leak

in the feed system to the pump will cause it to run

inefficiently. For a closer look at vacuum pumps SA

Mechanical Engineer speaks to Andr Vorster, director of

Horma Pumps in Edenvale.

Andr Vorster, director of Horma Pumps (left) and sales manager, Ryan

Baptista

We apply a Monarch coating on all the wet-end

components to reduce wear

8/7/2019 SAME: Feb 2010


pump has to be replaced instead of waiting for itto break down.

Bearings and chemicalsAlthough vacuum pumps do not have many moving

A complete vacuum pump, ready for delivery

parts, regular maintenance and supervision by aproperly trained operator is crucial for a full pumplife. The first thing that usually fails on a vacuumpump is the bearing, explains Andr. The sealstarts leaking due to a lack of maintenance and


8/7/2019 SAME: Feb 2010


water gets to the bearing, contaminating it. Its thenjust a matter of time before it fails.

To prevent this from happening, weve made improve-ments in our design to reduce the risk of neglectedmaintenance. The bearing cover is machined andfitted with extra high quality seals to make sure nowater gets to the bearing.

A unique feature of the Horma Pump series is aspecial coating that can be applied to the inside thepump housing to reduce chemical wear. In chemicalprocessing, the acids eat away at the pump hous-ing very quickly. As a counter measure, we applya Monarch coating on all the wet-end componentsto reduce wear, says Ryan. We have instanceswhere a pump used to last six months in a chemicalapplication, but since weve coated it, it lasts over

two years.

OverloadingAnother unique feature found only on Horma pumps

is a vacuum relief valve. Through plant design, orignorance, operators often feed too much water intothe system which creates a very high vacuum thateither breaks the shaf t or the second stage impeller,explains Andr. Weve come up with a vacuum reliefvalve that will open in such a case to suck more airand not water, thereby preventing the shaft of thepump from being overloaded. Since fitting these, wevehad no failures due to overloading of the system.

Vacuum pumping is not a complex concept, but ifyou dont know enough about it, mistakes can costyou a lot of money, says Andr in a final comment.Make use of reputable companies that are certified

to provide you with the right equipment from the startand then its simply a matter of proper maintenanceto get the optimum life out of your pump.

Ryan Baptista, Horma Pumps, Tel: (011) 452-4300, Email:

[email protected]

A vacuum pump for refurbishment

Since fitting these, weve had no failures

due to overloading of the system


8/7/2019 SAME: Feb 2010


8/7/2019 SAME: Feb 2010


Whats in a

Name?

As much as everyone wants a premium

brand along with the technology, service and

longevity associated with it, not everyone

can afford it. However, if the premium brand

incorporates its technology and support intolower end products, end-users can rest as-

sured theyre getting value for money.

Chris Makume of Multibrands

A Worthington compressor

Ringing bells and whistles

The portfolio offers an extensive product rangeincluding professional and industrial reciprocatingpiston compressors, oil lubricated screw compres-sors with fixed or variable speed technology, oil-freeunits, compressor management systems, qualityair products that include dryers and air receiversand spares. In piston compressors the range, fromboth the Worthington and Ceccato brands, starts atsmall units of 1.5kW and goes up to 11kW, saysChris. The rotary screw compressors range from11kW up to 160kW.

To distinguish between the two, Chris explains thatWorthington compressors fit into the higher end of

the low-end market while the Ceccato range catersfor low-end users who are looking for machine reli-ability but cant afford all the bells and whistles ofa premium brand.

Serious supportAll the products feature low noise level technol-ogy, reliability, energy efficiency and they re easy toinstall supported by service commitments from our

distributors across the country, says Chris.

We have established long-term business rela-tionships with some of the reputable compressedair companies in major provinces to market our

Multibrands products locally, he elaborates.Maintenance and after sales service is sustainedat the Atlas Copco service levels that customershave come to expect. Our distribution channelsenjoy 100% committed and dedicated product

This is what the company Multibrands isall about. It offers a range of compressorproducts that complement the high-endrange of compressors of its mother company,

Atlas Copco. SA Mechanical Engineer meetswith Chris Makume, manager of Multibrands inSouth Africa, to talk about the Worthington and

Ceccato range of compressor products that arenow available on the local market.

Reaching the goalRecognising the market requirements, Atlas Copcoacquired Worthington Creyssensac and Ceccato,both well respected international manufacturersand suppliers of compressors and quality air prod-ucts, he explains. In South Africa we establishedMultibrands as an independent business unit to

market these products.

The main objectiveis to complement andenhance the well en-trenched and highlyrecognisable premiumbrand, adds Chris.

Cant afford all the bells and whistles of a premium

brand


8/7/2019 SAME: Feb 2010


products before the acquisition, but havesince been improved by applying someof the premium brands technology andknow-how to this range of air products.

Explains Chris, Aspects like better en-ergy efficiency and reliable availability,for example, were incorporated in ourrange of no-nonsense machines.

Just because the Multibrands range isaimed at the low-end market does notmean the product is inferior in terms oftechnology, it just means the end-user isgetting a machine with the basic essentialsof a reliable product, adds Chris.

How it worksA typical Mutibrand customer is looking

for quality and reliability, while the AtlasCopco customer looks for more, such asLAN connectivity, remote monitoring andcontrol, etc.

Big brother is watchingOver five hundred Multibrands units have

already been sold through the fifteen distributorscurrently in the local market. This indicates thatwere filling a niche requirement, Chris states.This business concept has also been implementedin other parts of the world, but the South Africansetup, with Atlas Copco Compressor Technique(South Africa) as the big brother, has proved to be

particularly successful.

Even now, with the global financial crisis, there arestill lots of opportunit ies and we are confident thatMultibrands will continue to grow from strength tostrength in the South African market, concludesChris. Were currently working on expanding thelocal distribution network and intend to take the

concept up into Africa through suitable distributorsin the SADEC countries.

Chris Makume, Multibrands, Tel: (011) 821-9141, Email:

[email protected]

marketing and after market support to ensure thenecessary backup for customers.

Top-of-the-range technologyBoth Worthington and Ceccato were well-established

Energy efficiency and reliable

availability in our range of no-nonsense

machines


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There are clear pollution guidelines for deal-ing with effluent in industry, but complyingwith these regulations can be hinderedby the unreliability of the types of pumps

traditionally used in the industrial waste disposalprocess. SA Mechanical Engineer speaks to Nicovan Schalkwyk, general manager at Watson-MarlowBredel South Africa about this age-old problem.

ProblemsThe sump provides an unglamorous yet essentialfunction in any industrial process or facility, becausethe removal of wastewater and process liquidsmaintains a clean and safe working environmentas well as allowing plants to comply with pollutionlaws, explains Nico.

However, the capacity of industries to comply withthese regulations can be limited by the reliabilityof their equipment. The sump pump that transferssite effluent from the sump where it collects, tothe foul sewer where it is transported to a sewagetreatment works for decontamination, is notoriously

unreliable.

The lowest pointUnfortunately, problems occur far too frequently

due to the challenging nature of the effluent asthe sump is usually situated at the lowest point

Industrial sites like mining plants have sumps in

the form of pits in the ground at the

lowest points on the site. Wastewater and debris

is collected there so that it can controllably be

pumped from these sumps to specific

treatment areas like slimes dams or waste

disposal systems. This wastewater not only

contains large abrasive objects, but also

chemicals, oil and other spills from all over the

site.

Nico van Schalkwyk of Watson-Marlow Bredel, South

Africa

Nowhere to

Stick

This means there is an absolutely clear

path of flow with no valves, seals or

glands

8/7/2019 SAME: Feb 2010


PIPES, PUMPS & VALVES

of a process to allow waste to flow in freely andtherefore it is also the place where other itemswill inevitably end their journey, Nico adds. Theliquid in the sump therefore often contains grit, oil,

rags and various items of debris. For many pumptypes, such abrasive effluent causes severe wearon the pump, while certain debris may block italtogether and has the potential to cause the sumpto overflow.

Equally vulnerableMany site managers have overcome this issue byinstalling secondary pumps that can take over op-eration should the primary pump become disabled.

The secondary pump can also run in unison duringpeak times. However, as these pumps are usuallyof the same type, they are equally vulnerable toblocking and therefore cant provide a long- termsolution to the issue.

The submersible is just one type of pump that canbe used for this application, explains Nico. Othertypes include diaphragm pumps and progressivecavity pumps. These are often the first choice simplybecause operators know how to handle them, but

they are less than satisfactory for sump applicationsdue to the challenging conditions.

In fact, they are particularly ill-suited to the taskas the dust and grit causes wear in all three pumptypes, while debris can build up on the impellerof the submersible and on the valves of the dia-phragm pump, obstructing the flow and causingthe pumps to block.

A solutionAn increasingly popular solution to the problemis the peristaltic pump, due to its reliability andcapacity to cope with debris without blocking.Peristaltic technology is designed to handle dif-ficult applications where its non-contacting pumpmechanism wins over other pump types, saysNico. Where conventional pumps use valves to

push liquid through them, peristaltic technologyemploys pressing shoes to compress and releasea hose. This means there is an absolutely clearpath of flow with no valves, seals or glands, andtherefore nowhere for debris such as rags andstones to get stuck.

Watson-Marlow Bredel SPX peristaltic hose pumpsare increasingly finding favour in demanding effluentdisposal applications. Unlike the submersible pump,the peristaltic self-primes and can be mounted at

Has no difficulty handling thickened slurries up to

concentrates of 80 percent solids

8/7/2019 SAME: Feb 2010


ground level. This makes it much easier to accessfor maintenance as opposed to the submersiblewhich has to be kept under the fluid level preciselybecause it wont self-prime.

PortableThe SPXs ability to achieve and maintain the

specified flow rate is crucial to efficient flocculation.This and the fact that it has no difficulty handlingthickened slurries up to concentrates of 80 percentsolids, makes it the ideal pump for these duties,Nico says emphatically. Though not as cheap asyour everyday submersible, it does, at the endof the day, provide a much more cost-effectivesolution.

In addition, an occasional blockage caused bya particularly large solid can usually be clearedsimply by reversing the pump. Flow can be re-directed easily by changing the rotation of thepressing shoes, and the sludge often found at thebottom of a sump is no problem to pump straightthrough. Above all, the peristaltic pump is easilymounted on wheels, giving it the flexibility of justone portable pump system that can be used on allthe sumps on a site.


Moving waste water with a peristaltic pump

Extremely pleasedMaintenance is also as easy as replacing the hosewhich is the only part of the pump to get worn,and its relatively cheap to replace too. Chemicallyresistant hoses can be changed quickly while thepump itself is not affected by the substance, ensur-

ing long-term reliability and endurance.

With sumps performing such an important func-tion in any process, plants simply cannot afford forthem to fail, concludes Nico. So all our custom-ers have been extremely pleased and relieved tohave finally found a reliable solution to their sumpproblems.

Nico van Schalkwyk, Watson-Marlow Bredel South Africa,

Tel: (011) 796-2960, Email: [email protected]

Maintenance is also as easy as replacing the hose

Log onto www.promech.co.za to

read back issues of SA Mechanical Engineer

8/7/2019 SAME: Feb 2010


Customers in the fluid power and hydraulicsindustry can soon expect a major upgradein the quality of hose assembly and hoseproducts. For several years, the industry hasbeen plagued with sub-standard materials

and inadequate knowledge of assembly and maintenancetechniques by poorly qualified staff.

Considering the negative consequences that affect numerousapplications in which hose and couplings are an integralpart, the council of the South African Fluid Power Associa-tion (SAFPA) has resolved to remedy the situation by issuing

Long-awaited Development

formal guidelines. In future, all customers serviced by accred-ited and certified SAFPA members will be assured of qualitycomponents and assemblies that meet the standards set bythe SAFPA Hose Assembly Accreditation Scheme.

Approved productsThe comprehensive guidelines

based on Standards set by theBritish Fluid Power Associationcover a number of relevant issuesin hydraulic engineering, includ-ing safety, especially relating tocompatibility of components usedin hydraulics systems. Specifica-tions for assembly, testing and useof recognised, approved productswill prevent the use of unmatchedhose and end couplings, the mixingof inserts and ferrules from differ-ent or unknown manufacturers,

and unbranded or reworked hoseend couplings all potentiallydangerous.

Come on boardFurther specifications relating tohealth, training, quality control,testing, storage, maintenance etc.are contained in the guidelines andare expected to streamline plantoperations and reduce excessivedowntime.

It is anticipated that the majority

of manufacturers and hydraulicssuppliers will come on board.This scheme is a long-awaiteddevelopment and will bring SouthAfrica up to standard with globaloperations.

Brian Rogers, SAFPA, Tel: (011) 888-

7163, Fax: 086-503-4524, Email:

[email protected], Website: www.

safpa.org.za

8/7/2019 SAME: Feb 2010



Riding Out

the StormEquipment manufac-

turers really have a

rough ride during a

recession. Raw materi-

als cost more, labour

wants their usual

increases, utilities goup, customers want

better prices because

theyre struggling, yet

manufacturers have to

remain competitive in

a market that gener-

ally has less money to

spread around.

In addition to the recent major economicdownturn, equipment manufacturer,Weir Minerals Africa, had to cope withthe long-term merger of CH Warman

and Weir Envirotech to establish thecompanys new identity while retaining

customer confidence in their products.Also, the extensive product range result-ing from the merger brought its own setof challenges. SA Mechanical Engineerspeaks to Rob Fawcett, operations directorof Weir Minerals Africa, about the chal-lenges of the past 18 months.

TrendsIts been a very difficult time for us becausewere caught between our customers whoneed price relief and the market inflationary

pressures on our business, he says. Weve hadto look very hard at our businesses and how we

can assist customers by absorbing price increases.Looking ahead, there may be tougher challenges interms of increased labour and utility costs.

In spite of this we have not really experienced adownturn in business over the past year, Rob adds.

Although weve sold fewer pump units, the trendis toward bigger ones and therefore weve madethe necessary changes to extend our range of pumpproducts to cater for this development. We haveundertaken an unprecedented number of product

developments over the last 18 months which hasrequired significant capital investment. Weve alsoinvested heavily in our manufacturing facilities toensure that the required efficiencies are achievedto remain competitive in a global market.

IssuesApart from extending certain equipment ranges and

improving designs, weve alsolooked at total cost of ownershipon some of the products out inthe field, says Rob. Customerrequirements are changing in

terms of labour becoming moreexpensive and it being difficult tosecure skilled labour to operateequipment. Therefore custom-ers are expecting equipment tolast longer with fewer serviceintervals.

UpgradesWeve made a conscious deci-sion to change the rubber com-pound used in our products toR55, a premium brand rubberwhich dramatically increases

wear characteristics and avail-ability in pumps and cyclones.The R55 material is particularlysuitable for large particle erosiveslurry applications such as millView of new pump assembly facility with its in-line spray capability

Rob Fawcett, operations director, Weir MineralsAfrica

Although weve sold fewer pump units, the trend is

toward bigger ones

8/7/2019 SAME: Feb 2010


discharge applications, adds Rob. The compoundand the manufacturing process are more expen-sive, but this cost was entirely absorbed by us.This change alone has resulted in an approximatetwenty percent improvement in wear performance

of the pump unit.

Upgrade kits have been developed to increase theperformance of our older tried-and-tested pumptechnology. Improvements have been made to theimpeller design and the sealing arrangements.The improved dry gland expeller sealing systemcan be fitted during a single maintenance serviceor fitted as components wear and require replace-ment. For a heavy duty environment, there is a

whole new range of mill pumps with options ofunlined metal or a rubber lined unit, adds Rob.These will be produced locally and released tothe market soon.

In addition, health, safety and environmental is-

Front view of Weir Minerals Africas Alrode manufacturing facility incorporating pump as-

sembly, distribution and rubber manufacture

The new designated area for pulse line assembly of smaller units

sues relating to the servicing ofa pump in terms of disposal ofthe parts every time the pump isserviced, are a lot more onerous

than they were five years ago,explains Rob. So, the less thepump has to be stripped for aservice, the less risk there isfor injury or disposing of partsthat may be hazardous to theenvironment.

The company is focusing itsexpertise on providing millcircuit solutions with the sup-ply of premium quality valves,hydrocyclones and mill linerswhere applications typically

involve heavy abrasive and/orcorrosive slurries that makesevere demands on the equip-ment used.

EfficiencyAll this adds to operation costsand we therefore addressed theefficiencies of our products andthe processes within our twomanufacturing plants, saysRob. Every product has a setefficiency when its first installed,but the question is, is this ef-ficiency sustainable throughoutthe life of the equipment? Fromour side, new designs will ensurethat customers are optimisingefficiency over the lifespan of aproduct.

In general over the last 18months, the pump ranges available from WeirMinerals have been upgraded to the latest Weirstandards and technology. These have been ap-plied to achieve extended life and performance.The pump might run a little better in terms of

throughput, but improvements will be noticeablein terms of power consumption and extended wearperformance.

NewAlready on offer is Weirs new SLR pump, a rub-ber-lined, medium-to-light duty pump that has anumber of significant benefits. Rob elaborates, Itis equipped with a double adjustment system thatallows for the pump to be adjusted while running,reduced time to overhaul, and requiring a minimumnumber of replacement parts. The design optimisesthe critical balance between wear performance andpump performance efficiency. These improvements

all contribute to end-user assurance that theyvegot the best possible option in terms of total costof ownership.

Rob Fawcett, Weir Minerals Africa, Tel: (011) 617-0809,



Whole new range of mill pumps with options of unlined

metal or a rubber lined unit

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NUCLEAR INSTITUTE (SA BRANCH)

He addresses the question of how theUK is to support itself energy-wise withminimal recourse to fossil fuels. He sayshes not necessarily pro-nuclear but he

is vigorously pro arithmetic.

The book is full of revealing back-of-envelope calculations. Did you know,for example, that the embedded

energy of an average motor car isaround 76 000 kWh, perhaps 14kWh for every day that you ownit? Goods imported into Britainhave an energy content of around48 kWh per day for every man,woman and child plus 12 kWhfor transportation into the UK.

The three main primary energygobblers in Britain are indeedtransportation and space heating(both estimated at 40 kWh/d per

person) and electricity generation(18 kWh/d per person). The author begins byinsisting that energy consumption must be cut,transportation being a prime target. He calculatesthat with widespread electrification, principally theuse of battery-power, the transportation energy billcould be halved.

Heat pumpsSpace heating energy use could be reduced by 25%by better insulation and, particularly, by replacingconventional heaters with heat pumps. He is muchmore interested at this stage of the book in techni-cal feasibility than in cost implications.

He then sets out to discover where the requiredenergy is to come from - concentrating on UK re-newables, clean coal (perhaps), nuclear (perhaps)and on solar energy from the Sahara. He defines asustainable energy source as one that will last at

least a thousand years. The question mark over cleancoal stems from the fact that even if sequestrationworks, coal will not last that long.

Breeder technologyThe reservation concerning nuclear is that to besustainable we must use breeder technology. Hedeclares himself insufficiently qualified to commenton the safety of breeder reactor systems. Nuclearindustry, please note the concern, its widespread.Finally, even with all sources tapped, Britain willnot be able to find enough truly renewable energy.He therefore envisages solar energy imported fromthe Sahara, referencing the recently announcedGerman-led Desertec scheme.

He comes up with five alternative plans for provid-ing the 1,1 million GWh per year needed. Thatsabout four times the current South African usage.The various plans cater respectively for those whodont like the idea of importing energy, for those whoobject to renewables sources cluttering the Englishcountryside, for those who dont like nuclear, forthose who dont want either nuclear or coal, andfor those who just want cheap energy.

Rough costsNuclear looms largest in the last of these provid-ing over 60% of electr icity generation. Finally, fora brief discussion of rough costs, he produces amedian Plan M and an astonishing diagram show-ing how much of the British Isles would have to begiven over to biomass and other energy generationactivities to meet it.

Plan M foresees respectively 23 and 29GW ofon- and off-shore wind backed up by 30GW ofpumped storage. We also have 48GW of photovol-taic panels, 40GW of imported solar energy and45GW of nuclear.

Move the debate forwardThe numbers he uses for nuclear capex translate toabout $2300 per kW installed which, after recentescalation, is probably too low by a factor of two.That said, his capex estimate per unit delivered forwind power (including pumped-storage back-up asper Plan M) is 2,7 times greater than nuclear, im-ported solar is six times more expensive and PV 25times. The small contribution of clean coal in PlanM comes in at 1,4 times the estimated nuclear cost but subsequent fuel costs would militate heavilyagainst using coal, clean or otherwise.

This is an entirely inadequate account of a mar-vellously informative effort to move the debateforward. The hope must be that someone will havethe energy to produce something similar for thiscountry and quickly.

John Walmsley

Without the Hot AirBy now, hopefully, everyone has heard of David MacKays

marvellously informative and readable book Sustainable en-

ergy without the hot air. It should be required reading for

everyone with an interest in energy. David J C Mackay is a

professor in the Department of Physics at Cambridge and, as

of November 2009, Chief Scientific Advisor to the UK Ministry

of Energy and Climate Change. The 350-page book is a free

download - except that its full of coloured diagrams and cost

me R295 to have printed. Prof Mackay is clearly trying hard

to get his message across. There are presentations of vari-

ous lengths available, presumably on video, and there is a ten

page abstract on the web.

John Walmsley

Hes not necessarily pro-nuclear but he is vigorously pro

arithmetic

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INCOSE

Is the concept of a configura-tion item still valid once theitem is in operation? Duringthe operations and support

phase, a configuration itemis determined by the selectedlevel of management. It is thatlevel where the user organises,assigns responsibility for andcontrols maintenance, supply,

procurement and modificationactivities.

Any item needing maintenance,or that has been designated forseparate procurement, is bydefinition a configuration item.Note that this is the same concept

as used during development and production, butthe nature of the contract is of course completelydifferent.

During development and production, all deliverableitems contractually referred to are configurationitems. During operations and support, an end itemand all its subassemblies right down to items ofsupply (those items that populate the supply sys-tem), are configuration items. Management occursat the level of items of supply, but it would not bepossible to contract development and productionfor those items of supply since they will only beidentified late in development.

Computer software, since it controls functionality,is almost always designated a configuration item.

Operational software should always be designatedas a configuration item but separate from supportsoftware.

Fewer is betterThe essential starting point for selecting a configu-

ration item is a contractor, since

different items from a single contractor potentiallyform a single configuration item, and

items from different contractors are by defini-tion different configuration items.

A configuration item should be designable andproducible by one contractor, and should be test-able as an entity not as part of its next-higherassembly.

The selection of configuration items is a crucialtrade-off decision. Dividing a complex item intoseparate configuration items to create more vis-ibility and easier control is self defeating. It resultsin more management effort, more paperwork andmore coordination problems. It is similar to break-ing down a large contract into a few smaller ones.Neither size nor visibility is a valid criterion forselecting a configuration item. In general, fewerconfiguration items are better.

The limit of resolutionA configuration item is not the level where configu-

ration management starts, neither is it the levelwhere it stops. Configuration management occursthroughout the product breakdown structure rightdown to the lowest level. But at the configurationitem level the customer transfers configurationmanagement implementation responsibility to thecontractor. The customer controls lower-level itemsindirectly, since their specifications are derivedfrom the configuration items specification, andconfiguration management responsibility is recur-sively enforced by contract.

Configuration items are the basic building blocksfor configuration management. A configuration itemmay be viewed as the limit of resolution sinceit is the lowest level of assembly that is visible tothe customer.

Ad Sparrius, 082-574-0266, Email: ad_sparr@iafrica.

com

Configuration items are the basic building blocks for

configuration management

What is a

Configuration Item?A configuration item is defined as a deliverable item in terms of a development or a manufacturing contract.

There are additional criteria for designating an item as a configuration item. To continue with the previous ex-

ample: the customer has contracted a prime contractor to develop and construct a Spacecraft, and the Space-

craft is the configuration item in terms of that contract. One of the lower-assemblies is a Battery that is to be

reused in another spacecraft. That means that the customer, who has contracted to receive the Spacecraft,

needs to keep specification control over the Battery. The Battery is thus designated as a configuration item

even though it is not a deliverable. Similarly, items that have been standardised, or that need to be operation-

ally reprogrammed, or that are likely to be changed after initial deployment, should also become configuration

items.

Ad Sparrius

8/7/2019 SAME: Feb 2010


Of course, there are always the extrem-ists. SA Mechanical Engineer founda Bugatti, a Lamborghini, Mercedesand BMWs on the internet that have

been chrome plated completely, from the grille rightthrough to the tailpipe including all the body panels.The all-chrome 2009 Bugatti Veyron is the onlyone in the world, but no word on how much it costfor the whole chrome treatment,considering the car itself costs

about twenty million rand.

How to do itThere are several ways of chromeplating a whole car. By far theeasiest and cheapest is to takea series of digital photographs ofyour car from various spectacularangles and then, using Photoshop,turn your weather-beaten faded

old jalopy into a chrome lustrethat will dazzle all your friendson Facebook. Another way isto paint the car with a specialchrome-finish paint.

We found a DIY kit to give your Hummer a chrome-look for just over R10 000. Another option is topolish the raw aluminium panels on your Audi TTuntil it has the shine of a chrome finish and thenlacquer it to protect it from the elements.

The real thing

To do the real thing by chrome plating all the panelson a car is by far the most expensive and tedious ofall. To find out whether its possible and how youdgo about it, we speak to Laurence Segal directorof Edison Electroplating in Johannesburg. It canbe done, but it will cost an arm and leg, he says.If you can get the car in its raw metal state allthe better because then you forego the huge taskof stripping off the paint first, then smoothing themetal surfaces of the various metals on the car toa highly polished state before chrome plating.

Youd need special tanks and anodes to accom-

modate the size of body panels over and above thefact that the different metals making up a car haveto go through different processes for chrome plating,adds Mario Beltrame, the automotive specialist atEdison. In electroplating, the preparation of thesurface is crucial as even the slightest scratch can-not be filled with electroplating, its just too thin.So all surfaces would have to be polished to a verysmooth finish before you even start plating.

PolishingThe process consists of first plating the polished

Catching

the Eye

Not all that glitters is gold. For centuries chrome plating

has given vehicles that extra bit of sparkle. Bumpers, door

handles, side mirrors, trimmings, rims and exhaust tail pipes

are the parts that are usually chromed on standard cars while

hobbyists go a bit further to chrome tappet covers, gear le-

vers, oil caps and engine nuts and bolts.

Mario Beltrame (left) and Laurence Segal of Edison Electroplating

Is this BMW real chrome or just painted?

MATERIAL SELECTION

Turn your weather-beaten faded old jalopy

into a chrome lustre

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surface of the raw metal with a layer of copper aboutas thick as a human hair, then its polished beforeits covered with a layer of nickel plating. In turnthis layer is polished to a fine finish before finally

A chromed Lexus

chrome plating onto the layer of nickel. Consideringthat youre doing an expensive sports car the finalfinish cant have any flaws, so all the layers, one ata time, have to be well-polished.This would take alot of time and very special care, but for the rightmoney, Id do it, says gung-ho Laurence.

MATERIAL SELECTION

Even something for the ladies which they would not

elaborate on

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The polishing process consists of aseries of buffing wheels, coarse firstand then progressing on to finer andfiner buffing wheels. The trick is to

remove small nicks and scratches onthe surface of the metal to be platedas you go along as the quality of thefinal finish depends on the previousplating layers which are so thin thatthey follow the contour of the surfaceand wont fill even very fine scratchesor indents in the surface.

PlatingThe actual plating isnt long, however.The base coat of copper acts as aprimer for the nickel metal to follow

and fills any minor imperfections inthe part. Generally, depending on thesize of the part, it will remain in thecopper tank anywhere from 20 to 45minutes. Next is the nickel tank. Thisis the beginning of a bright, qualitychrome job. Depending on the sizeand shape of the part, a stay of around 30 min-utes in the nickel tank results in about a 1/1000to 1/2000 of an inch thick coating. Then finallyit goes to the chrome tank where it takes under aminute for a layer of chrome to deposit.

Laurence and Mario have electroplated platedmany weird things in their time, even somethingfor the ladies which they would not elaborate on.But baby booties, cowboy hats, running shoesand cutlery, apart from car and motorbike parts,are by far the most popular items. Silver plating,brass, copper and chrome can all be done on non-metallic objects, says Laurence. In fact, wevejust done the nickel plating on the headlamps of avintage Rolls Royce according to the original Rolls

specifications.

Preserving the itemThen, the owner of a Lear jet comes to us theother day to have all the fittings and ashtrays inhis jet gold plated, adds Mario. The only thingweve stopped doing is to chrome mags rims forcars as there is a risk involved. Chrome is a slug-gish compound and to get it into all the gaps of adeep rim requires the rim to be cut in half and thenre-welded after the plating. Were just not preparedto take the risk of guaranteeing such a weld.

People often confuse brass and gold plating or silver

and chrome plating as the difference in appearancewhen these surfaces are polished is subtle, but theexperts at Edison will guide you in the right direc-tion. Gold and silver costs more because it is thereal thing, but when it comes to heirlooms most

MATERIAL SELECTION

Were just not prepared to take the riskof guaranteeing such a weld

people dont mind the expense, they simply want topreserve the item, says Laurence in conclusion.

Laurence Segal, Edison Electroplating, Tel: (011) 607-2011,


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S

outh Africas biggest supplier of UnmannedAerial Vehicles (UAVs) systems, Denel (theother being ATE) is respected for developingand producing some of the most rugged andreliable tactical UAV surveillance systems

in the world. While the US and Israel dominate the globalmarket, there is scope for South Africa to use local skillsto create market-leading UAVs to developing nations - amarket estimated at R2bn per annum. The South AfricanUAV industry aims to capture in excess of 20% of this endof the market at an estimated value of R400m a year.

The global increase in operational use of UAVs is a directresult of lessons learnt by allied forces in Iraq and Afghanistan.The surveillance benefits in the defence world of being ableto survey borders and enter war zones without a pilot are

extensive. The availability of capable and affordable SouthAfrican UAVs of various sizes will trigger the enhancement ofnot only national security, but crime fighting, disaster man-agement, election monitoring and search and rescue. UAVseven provide benefits to the agricultural, mining, health and

environmental sectors.Within the next five years UAVs will be used by a diversity ofindustries from policing poachers on coastlines, carrying testspecimens from remote clinics to laboratories for analysis, tokeeping an eye on livestock on farms, and will prove to be alucrative parallel market for international UAV players.

South Africa has an enviable edge in comparison with themany international (including European) countries intendingto enter the booming world-wide UAV market which is at-tracting an estimated R50 billion a year.

UAVs are not generally allowed to access civilian airspacebecause current regulations were originally drafted for manned

flight. This is changing, with regulatory bodies across the globe,including SAs Civil Aviation Authority driving the process ofdrafting internationally compliant, UAV friendly regulations.International competition is fierce to master what is termedsense and avoid technology aimed at enhancing the safeuse of UAVs in controlled airspace. Once this capability hasbeen perfected, the opportunities will lead to an explosionin UAV demand.

Denel Dynamics, Shantall Tshoshane, Tel: (012) 671-1555, Email:

[email protected], www.deneldynamics.co.zaSKUA, High-speed Target Drone

Unmanned Flying Machines

8/7/2019 SAME: Feb 2010


Market ForumStopping blockagesThe new generation Flygt F pump has been engineered toput an end to costly clog

same: feb 2010

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