SAME: Jan 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

AN ENGINEER’S VIEW
Identification of Engineering
Work (IDoEW)
The Council for the Built Environment (CBE) has recently issued a draft policy
document on the application of the reservation of work for registered engineering
categories. Commentary and suggested amendments have been requested from
ECSA (Engineering Council of SA) and the Voluntary Associations (VAs).
T
he essence of the policy lies in disciplines to all registered persons, the other,
the Acts issued by Parliament in favoured by ECSA, is to follow a process which
2000 governing the six profes- provides for a series of generic questions that need
Chris Reay sions that are considered to be to be asked about defined job functions. If these
Chairman of the Working
Committee: Communications
responsible for the activities that create conclude that the activities would have the need
(SA Institution of Mechanical and manage the built environment. One to comply with engineering competencies that
Engineering) of these is the Engineering Professions relate to public safety, then that role is reserved
Act which would apply to the various for registered persons.
categories of engineering activities. The selection of who is competent to carry out this
The implementation of registration is mandated to role is then done by normal evaluation of potential
ECSA which essentially provides an administration candidates by the responsible employer body. The
role and relies heavily on the input and support of ECSA model ensures compliance with the Act,
all the VAs, as well as from academia and industry. while that of the CBE introduces terms and roles
The bulk of the technical work is carried out by not contained in the Act, and which would lead to
the latter bodies in various committees hosted by enormous lists of competencies and disciplines that
ECSA. Overall it works well when one considers the would need massive administrative and technical
evolutionary challenges of setting and maintaining support bodies. It would require changes to the
standards for a profession. Act and the current registration process.
One hopes a constructive, collective solution to this
Could have literally reduced the profession to a low challenging process will result but one thing is for
standard free-for-all certain. It will have an enormous impact and per-
haps currently unknown effect on the employment
The key component of the process is the peer review of engineering resources. The VAs should evaluate
role played by the largely voluntary persons who how they can be relevant in this new order and
are appointed to the committees. provide employers of engineering resources with
Readers may recall the collective objections to the assistance.
recent SACBE Bill that got as far as the National Understanding the issues
Council of Provinces in Parliament before being It would be advisable for all mechanical engineering
withdrawn and effectively terminated. That fun- based companies to consider joining the SAIMechE
damental component of independent peer review as Affiliate Members as well as to encourage their
of applications for registration was to be removed qualifying resources to register with ECSA, and
and replaced by a ministerial appointment. It become members of the SAIMechE as well. It
would have lead to a disaster which could have costs the same to do both as it is to register with
literally reduced the profession to a low standard one only.
free-for-all. So much for the Act that focuses on
It will also benefit employers to form associations
the maintenance of public safety.
with those recruiting consultants who understand
Two views the implications of engineering qualifications and
However, we are now progressing to the stage where competence criteria. Too many job specifications
IDoEW may become a reality, and this depends on are issued by those who patently fail to understand
the CBE, ECSA and the VAs finding common ground these issues.
in the structuring of the policy and its practical
implementation. Currently there are two views on
how it should work.
One, favoured by the CBE, is to ascribe competency

Jan 2010 VOLUME 60 NUMBER 1
Featured on the Cover Contents

ESAB
Monthly Column Oils & Lubrication
Tel: (011) 240-4000
8 Naval Mine Warfare 21 Transforming the Market
Fax: (011) 240-4329
Email: chris.eibl@esab.co.za Power Transmission
Website: www.esabasia.com
Filters & Filtration
13 Co-Generation 25 No More Hassles
15 Controlling Drives 27 Clearing the Air
Exhibition & Conference Regulars
12 Focus on Cutting, Welding and
Copyright Fabrication 3 An Engineer’s View
All rights reserved. No editorial 6 Institution News
matter published in “SA Mechani- Automation & Robotics 11 Consulting Engineers SA
cal Engineer” may be reproduced 17 Look Ma, No Hands 23 SAIT
in any form or language without
Reducing Emissions 29 Nuclear Institute (SA Branch)
written permission of the publish-
20 Carbon Capture and Storage 30 Market Forum
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 there-
from. 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. The monthly circulation is 4 242
Produced by:
Official Publication of
PROMECH PUBLISHING, THE SA INSTITUTION OF MECHANICAL ENGINEERING
P O Box 373, Pinegowrie, 2123 and endorsed by:
Republic of South Africa
Tel: (011) 781-1401, Fax: (011) 781-1403  CORROSION INSTITUTE OF SA
Email: editorial@promech.co.za  SA PUMP MANUFACTURERS ASSOCIATION
Website: www.promech.co.za  SA VALVE AND ACTUATORS MANUFACTURERS ASSOCIATION
Managing Editor Susan Custers  THE SA INSTITUTE OF TRIBOLOGY
Editor Kowie Hamman  NUCLEAR INSTITUTE
Advertising Pauline Bouwer  SA INSTITUTE FOR NON-DESTRUCTIVE TESTING
Circulation Catherine Macdiva
 NATIONAL SOCIETY OF BLACK ENGINEERS
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 INSTITUTE FOR CERTIFICATED MECHANICAL AND
Disclaimer ELECTRICAL ENGINEERS
PROMECH Publishing and The South African Institution of Mechanical
 SOUTH AFRICAN ASSOCIATION OF CONSULTING ENGINEERS
Engineering as well as any other body do not take responsibility for
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THE SA INSTITUTION OF MECHANICAL ENGINEERING
2010 Challenge
2009 was another exciting and vibrant year
Council 2009/2010 for the Technology Olympiad. Not only is the
Office Bearers programme reaching more learners but it’s
President .................................................. G Barbic (George) also working closely with the educators and
President Elect ............................................. D Findeis (Dirk) the Department of Education to increase its
National Treasurer ................................. K Nyangoni (Kudzai)
footprint across South Africa.
Branch Chairpersons
S
Central ...................................................... M Cramer (Mike) AIMechE’s Technology Olympiad is fast
Eastern Cape ............................. Prof Dr DG Hattingh (Danie) becoming the only Technology awareness
KwaZulu/Natal ........................................... AG Fileczki (Alex) programme that schools can offer to learn-
Western Cape ......................... Prof B Collier-Reed (Brandon)
ers wishing to take technology subjects that
Portfolios: are free of charge to all participants.
Communications .............................................. CD Reay (Chris) Learners participating stand to gain a greater under-
Education - Universities................... Prof JL van Niekerk (Wikus) standing of the important underpinning principles
Education: Universities of Technology............... E Zawilska (Ewa) of mechanical engineering. At the same time,
Membership .................................................... E Zawilska (Ewa)
participants learn to co-operate as part of a team
Seminars and Workshops.................................. D Findeis (Dirk)
while they find a feasible solution to the challenge
Technology Programme ................................. SZ Hrabar (Steve)
set each year.
Chief Executive Officer: Vaughan Rimbault Encouraged to take up a career in one of
National Office Manager: Anisa Nanabhay the many disciplines of engineering
PO Box 511, Bruma, 2026
Tel: (011) 615-5660, Fax: (011) 388-5356 Advice to educators
Email: info@saimeche.org.za The Technology Olympiad provides workshops
Website: www.saimeche.org.za through appointed facilitators, at no charge.
Membership: Central, Eastern Cape & KZN: Guidance and advice to schools is also offered to
membership@saimeche.org.za educators. Through these workshops, the learn-
Membership: Western Cape: saimeche.wc@vodamail.co.za ers are instructed in presentation, report writing
Company Affiliates
Alstom Power Service SA
Babcock Africa Limited 2010 Challenge
Bateman Engineered Technologies Design and build a self-powered ball-shooter
Fluor SA that can travel from the start area to the shoot-
GEA Air-cooled Systems ing area and shoot a tennis ball at the goals
Hansen Transmissions SA without human intervention. The power source
Hatch Africa of the ball-shooter may be mechanical, gravity,
Howden Power pneumatic, hydraulic or any combination of
Industrial Water Cooling these.
KHD Humboldt Wedag SA
Megchem Eng & Drafting Services Invitations to par-
Osborn Engineered Products SA ticipate in the
Rotek Engineering 2010 chal-
RSD a division of DCD-Dorbyl lenge were
S.A.M.E Water mailed in
Sasol Technologies Januar y to
SEW Eurodrive approximate-
Siemens Ltd ly 8 000 high
SNC-Lavalin SA
schools offer-
Spicer Axle SA
Spirax Sarco SA ing Mathemat-
Thyssenkrupp Engineering ics, Science and
Transvaal Pressed Nuts & Bolts Technology at a grade
Ultra-Flow Engineering Services 10-12 level. We look forward to working closely
Vital Engineering with the donors, sponsors, schools, DST and
Weir Warman Africa Department of Education this year.
Winder Controls

THE SA INSTITUTION OF MECHANICAL ENGINEERING
and are encouraged to take up a career in one of

the many disciplines of engineering. It has been
proven beyond doubt that these workshops play an
essential role and add value to the overall learning
process.
Therefore, in an effort to increase awareness and
participation, the Technology Olympiad will place
a greater emphasis and focus on facilitators and
SAIMechE and
workshops in 2010.
Valid and relevant
Promech Publishing
Much thought and brainstorming has gone into
designing the challenge for 2010. Besides meeting
the stringent requirements of the current curriculum
wish all members and
it must appeal to learners as relevant, it must al-
low for a valid learning experience, it must be wide readers a memorable
enough to allow creativity in generating concepts
but specific enough that learners can understand
what is required. It must have an appeal of fun
2010
to learners from all communities and it must be
possible to adjudicate the result as objectively as
possible.
It is therefore with great excitement that we unveil
the next challenge (see alongside).
Training Events Calendar - JANUARY - MARCH 2010

Whilst every effort is made to ensure that events take place as scheduled, SAIMechE reserves the right to change the
sechedule as circumstances dictate. A registration form and full terms and conditions may be obtained from Carey Evans
on email: carey@saimeche.org.za 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: linda@saimeche.org.za or
Tel: (031) 764-7136.
Event Full Title Date Region
Code
C2110 The Management of Health & Safety Risks/Hazards 18-Feb-10 Cape Town
B1310 Structured Problem Solving Techniques 24-Feb-10 Port Elizabeth
A0210 Boiler House; Safety Valves 24 to 26-Feb-10 Durban
J0810 Finance for Engineers 3-Mar-10 Pretoria
D0210 Boiler House; Safety Valves 03 to 05-Mar-10 Vereeniging
C0210 Boiler House; Safety Valves 10 to 12-Mar-10 Cape Town
A1810 Materials- Selection Specification and Welding Technology 11-Mar-10 Durban
A3710 Pressure Vessel Design, Construction, Fitness for Service Assessment & Troubleshooting 12-Mar-10 Durban
E2610 Working in Confined 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 Distribution; Pipeline Ancillaries; Steam Flow Metering; Desuperheating 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 Distribution; Pipeline Ancillaries; Steam Flow Metering; Desuperheating 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

MONTHLY COLUMN
Naval Mine Warfare

In war movies, the
threat of naval mines
blowing the vessel
to smithereens any
second now, creates
suspense. A regular
‘ping’ adds to the
sinister ambiance as
the hull slowly drifts
past large spiky met-
al balls suspended
on a chain moored to
the sea floor.
A typical mine from WWII
A
lthough many Korea
of these mov- During the Korean War, for
ies play off instance, the North Kore-
during WWII ans failed to adequately
when U-boats were a defend against the Inchon
relatively new thing, Invasion in mid-September
the concept of min- 1950, but they were not to
ing rivers, harbours be caught out twice. Their
and bays to prevent Soviet supporters provided
access by the enemy thousands of sea mines,
dates back to the 17th plus technical advisors,
century, and is still very and very soon, several
USA and South Korean
Allowed countries without much Navy ships struck mines
of a navy to protect themselves off their east coast.
against invasion via their The threat of mines proved
waterways to be a serious problem for
the US Navy throughout
much general practice
the conflict. In mid-Oc-
today. The simplicity of
tober 1950, with winter
naval mine technology
fast approaching, they
has allowed countries
urgently needed supplies
without much of a
for their men and equip-
navy in terms of frig-
ment. Roads were in dis-
ates and submarines
What the first repair from heavy bombing
to protect themselves Naval mines against the retreating North
against invasion via looked like Korean Army, and rail links
their waterways.

MONTHLY COLUMN
were virtually unusable. Supply by sea through the under water. The water tamped the explosive, so
port city of Chinnampo was the only possibility. that the greatest force of the explosion was directed
The port’s approaches, however, were known to be against the boat.
heavily mined and opening the port became one
How it works
of the top military priorities. History has it that an
Sea mines are known to the general public as con-
US Navy admiral wired Washington: “We have lost
tact mines, those spiky balls moored just under the
control of the seas to a nation without a Navy, using
pre-World War I weapons, laid by vessels that were
Nobody can really account for exactly where all those
utilised at the time of the birth of Christ..”
mines are
Still a threat
Today, naval mines, whether they’re
built with sophisticated electronics or
simple ‘home-made’ technology, are still
one of the best ways of protecting shore
areas from invasion via the open sea.
To understand more about the domain
of underwater security, “SA Mechanical
Engineer” visits a division of Armscor
Business, the Institute for Maritime
Technology (IMT), in Simonstown to talk
to their development manager Mackenzie
Johnson.
“To build a missile and use it you need
expensive sophisticated technology and
equipment, but a naval anti-ship mine
can easily be built by anyone with ac-
cess to explosives and some electronics
knowledge” he says.
“The sea mine is still far and away one
of the most real threats across the world
today especially because of the large
numbers around,” Mackenzie says. “When
the Iron Curtain fell it was estimated that A fish-eye view of a mine field
Russia’s arsenal alone had between 250
000 and 425 000 naval mines. Today
nobody can really account for exactly
where all those mines are.“
History
Mine warfare as we know it today began
in 1776 when David Bushnell invented
the ‘Bushnell’s Keg’. This primitive mine
was composed of a watertight keg filled
with black powder and a flintlock detona-
tor which was suspended from a float.
These kegs were placed in the Delaware
River so that, it was hoped, they would
float into British ships downriver. These
early mines were called torpedoes as self-
propelled torpedoes as we know them
today had not yet been invented.
In 1829, a 14-year-old Yankee inventor
named Sam Colt demonstrated how an
underwater powder charge could be
set off by electricity. The demonstration
did not increase young Colt’s popularity
because onlookers were showered with
muddy water. However, Colt showed how
devastating a small explosive charge
could be when exploded against a boat A popular anti-ship mine

MONTHLY COLUMN
therefore have some detectable magnetic field and

are vulnerable to magnetic influence mines.
Even ships made out of wood or fibreglass are
not immune to magnetic detection as there are
numerous other components of a ship’s structure
that contribute to the magnetic ‘signature’ of the
vessel. Furthermore, the mine can be made to dif-
ferentiate between different types of targets on the
basis of their magnetic ‘signature’.
Mines can also detect targets by the pressure
(Bernoulli) effects caused by the forced water flow
beneath a vessel. This effect is related to the speed
of the vessel as well as the distance between the
vessel’s keel and the sea bottom. To counter this
effect, a “safe” speed for each vessel is determined
by measurement under controlled conditions. Lastly,
the mine may contain sonar equipment to detect
the acoustic ‘signature’ of the ship. This too allows
the mine to distinguish between many different
types of targets.
After 50 years
“The explosives in an old mine can still be effective
after 50 years. It’s also relatively easy to take an
old mine and fit it with modern electronic detection
and detonation technology such as ship signature
identification,” says Mackenzie.
“In the underwater security domain we focus on
capability maintenance and the development of
systems, by modelling the technologies related to
naval mine counter measures, sea mines, underwater
intruder detection and waterside security systems.
In support of the South African Navy, we keep a
close watch on mine counter measure systems the
rest of the world develops. During the Gulf War,
sea mines were used extensively and the United
Sweeping for mines with a helicopter States Navy were dealing with this problem on a
daily basis so they have a lot to teach us.”
water surface which explode on contact with a ship’s
hull. These still exist, but a modern mine is more Dolphins
likely to be one triggered at a distance. Convention- Among the ingenious solutions used to counter
ally these mines can detect the target’s presence mines is the use of dolphins to ‘hunt down’ the
through three methods: magnetic, pressure, and mines especially as 14 of the 19 USA Navy ships
acoustic influence. Many mines use any or all of destroyed or damaged since 1950 have been as
the combinations. Magnetic influence mines sense a result of mines. Dolphins have been trained to
the magnetic field caused by the iron in the ship’s receive a cue from their handler before they begin
hull. The magnetic field of a ship can be controlled to search a specific area using their biological sonar
by periodically degaussing (also called wiping) the called echolocation. When a dolphin echolocates, it
ship, or in the case of specialised naval vessels, emits a series of clicks which bounces off an object
by means of electric coils integrated in the ship and back to the dolphin, allowing it to construct a
structure and controlled in such a way to cancel mental image of the object.
the ship’s magnetic field. The dolphin reports back to its handler, giving one
response if a target object is detected and a dif-
Even ships made out of wood or fibreglass are not ferent response if no target object is detected. If
immune a mine-like target is detected, the handler sends
the dolphin to mark the location of the object so
However, wiping is a time-consuming process which it can be avoided by Navy vessels or dealt with by
involves wrapping the entire hull in large cables and Navy divers.
applying a magnetic field for several hours; control Mackenzie Johnson, IMT, Tel: (021) 786-8230, Email:
with coils is complex and expensive. Most ships jmj@imt.co.za
10 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

CONSULTING ENGINEERS SA
Not Just
Commodities
Newly-appointed President of Cesa (Consult-
ing Engineers SA), Zulch Lötter, says that the
presidency of Cesa is the most important office
he has held outside of UWP Consulting and he
regards it as a great honour to be able to plough
back into an industry in which he has been ac-
tive for close to 40 years.
I
n this role he aims
to focus on improv-
ing the business
environment for
consulting engineers.
It is important to him
that both Cesa mem-
bers as well as their
clients conduct busi-
ness with integrity
and in a professional
manner. He strongly
believes that consult-
ing engineers should
not be perceived by
clients and the public
as commodities, but
Zulch Lötter as their trusted advi-
sors.
To this end, Cesa and its members must engage with
politicians and decision makers to guide, advise and
assist them in creating a sustainable South Africa where
all our inhabitants work towards the common goal of
creating a future for our children.
Zulch was involved with the planning, design, rehabilita-
tion and construction of roads and runways, as well as
traffic engineering. Since 1984 Zulch has been a partner
and later a Director of UWP Consulting. In April 1999
he was appointed Managing Director of the company,
responsible for approximately 300 staff members situated
in 16 offices across South Africa, as well as subsidiary
offices in Zambia, Tanzania and Botswana. Zulch has
served on the CESA Council and EXCO since 2003.
He has been Chairman of CESA’s National Liaison, Finance
and Staff as well as Disciplinary committees. He is also
a Director of two of the Section 21 companies created
by CESA including the Project Development Facilitation
Alliance (PDFA) as well as the Built Environment Profes-
sionals Export Council (BEPEC).
Graham Pirie, Consulting Engineers South Africa (CESA), Tel:
(011) 463-2022, Email: gspirie@cesa.co.za
THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010 11

EXHIBITION AND CONFERENCE
Focus on
Cutting,
Welding, and
Fabrication
F
rom 16 - 18 March 2010, the 4th Subsahara Oil &
Gas and Petrochem exhibition and conference – Oil
& Gas Africa – will be co-located with the 13th Fish
& Marine Africa expo for the first time.
As both the offshore oil industry and the marine industry
are high users of welding, cutting, and fabrication technol-
ogy, these combined events are showcasing a pavilion of
relevant products and services called: “Focusing on cutting,
welding and fabrication”.
“SA Mechanical Engineer” has been appointed to pub-

lish an exclusive preview of the products and services of
companies making up the pavilion in the February 2010
edition. In addition to its normal circulation, 1000 extra
copies will be distributed to international visitors attend-
ing the event.
In 2008 the 3rd Oil Africa was attended by 3522 trade
visitors from 34 countries. 225 conference delegates came
from 25 countries.
For advertising bookings, contact Pauline Bouwer on Tel: (011)
781-1401, Fax: (011) 781-1403 or Email: editorial@promech.co.za.
For more info on the exhibition and conference contact Saki Magoxo,
Tel: (011) 783-7250 or Email: sales@exhibitionsafrica.com

POWER TRANSMISSION
Co-Generation
In a sugar processing plant there are hundreds of electric motors for fans, conveyors, compactors and pumps,
all using electricity. But sugarcane processing produces a high percentage of fibre waste called bagasse
which, in countries like Brazil, is widely used to generate the electricity used by these motors.
B
agasse fuel is renewable and the gases Using waste
it produces (essentially CO2) are more As a supplier of a large percentage of drives to the
than used up by the new cane growing sugarcane processing industry, Zest saw the Brazil-
in the fields. ian technology as an opportunity to offer the South
African sugar industry a similar solution.
Very flexible and can be adapted to
operate with other fuels as well
“SA Mechanical Engineer” speaks to Coenraad
Vrey, managing director of Zest Energy to learn
more. “Zest has traditionally supplied every-
thing from electric motors through to variable
speed drives, transformers, cabling and
electrical installation work, but we
did not have anything to offer on
the power generation side,” he
says. “We therefore established
Zest Energy and entered into an
agreement with a Brazilian com-
pany, TGM, to bring their technol-
ogy of co-generation, specifically
developed for the sugar industry
in Brazil over the past ten years,
to South Africa.
Total solution
“As a result, we can now sup-
ply everything from the drives
through to the complete power
generation plant to make a sugar
processing plant self-sufficient
and much more efficient from an
environmental point of view,” adds
Coenraad. “TGM manufactures a
complete power generation system
including the steam turbines and
planetary gearboxes which they
manufacture in-house. This means
that we will be able to ‘customise’
every installation to the exact
speed reduction and turbine
pressures for each individual
application, whether it is a sugar
processing plant, a steel mill or
a paper processing plant.
Coenraad elaborates, “One of
Zest’s technology suppliers, WEG,
has been supplying 90% of
TGM’s requirements in terms
of the alternator and electrical
reticulation equipment to support
the operation of the steam turbine

POWER TRANSMISSION
unit that they manufacture. graded to the higher pressure needed for turbine
This now gives Zest Energy power generation.”
access to this technology
Feeding the grid
and many years of expertise,
Essentially, the process involves the burning of
thereby allowing us to bring
bagasse to generate steam, which in turn generates
proven technology to South
electricity for all the plant equipment.
Africa.”
TGM’s steam power generation system is very
Electric motors flexible and can be adapted to operate with other
The steam turbine units TGM fuels as well. “Many sugar processing plants also
manufacture can generate produce ethanol which can be used as a fuel,”
up to 150 MW and for more says Coenraad. “Normally sugarcane estates only
power, units can easily be have accessible bagasse for about eight months of
combined to increase the the year. To deliver constant power, we can now
output. “In Brazil, the sugar install dual boilers that can also run on coal for
industry alone generates those short periods when no bagasse is available.
about 80% of the energy In Brazil this translates to 97% power generation
required by the industry,” availability throughout the year, which is what we
Coenraad Vrey, managing director of Zest
says Coenraad, “which is are now offering the local market.”
Energy why we are focussing on
the African sugar industry Other applications
Zest is not limited to providing equipment and
You cannot simply adjust a furnace to use less energy solutions for the sugar industry only. They are also
targeting industries that simply cannot scale down
as a start. In Brazil all the steam-driven mills and on the consumption of electricity. “You cannot sim-
centrifuges on the sugar processing plants have ply adjust a furnace to use less energy. For these
been converted to more effective electrical drives, industries, it will become more difficult to afford
while the steam generation plants have been up- electricity as the tariffs increase and high penalties
start being introduced in the future,” says Coenraad.
“In the case of a furnace, for
example, we can take the gas
from that furnace, clean it
and then use it as a fuel in
a co-generation configura-
tion. The gas from a 20MW
furnace could comfortably
generate between 5 to 7 MW
of electrical energy.”
Small steam power gen-
eration and co-generation
technology is not new to
South Africa, but it has
not been readily available
until now. “The advantage
of dealing with Zest is
that we now offer a total
in-house solution, where
we not only supply the mo-
tors, but all the mechanical
and electrical equipment
as well,” says Coenraad
in conclusion. “All these
systems are configurable to
specific industries and their
individual requirements and
are backed up by the expe-
rience and expertise of our
Brazilian counterparts.”
Coenraad Vrey, Zest Energy,
Tel: (011) 723-6000, Email:
coenraadv@zestenergy.co.za

POWER TRANSMISSION
Controlling
Drives
Lower cost variable speed units can be economically used to
replace mechanical damping units, manage air and fluid flows
with integrated PID, so reducing energy costs. It is however
necessary to look at the complete system in order to achieve
the required results.
S
A Mechanical Engineer” speaks to Marcus
Gericke, Gauteng branch manager at SA Marcus Gericke of SA Power
Power, a company that offers a full range of
mechanical and electrical products as well
we have Lenze gearboxes that cater for the smaller
as the design capability to optimise drive solutions
industry up to 45Kw. With Vogel we can cater for
for various applications. “On the mechanical side
medium sized applications ranging from bevel
gearboxes of 0.5 Nm to large planetary gearboxes
rated for 400kW,” he says.
The cheaper gearbox wastes a lot of

energy due to the losses within
Design
Drive systems are designed for each individual
application ranging from materials handling, bulk
conveying, factory automation, automated produc-
tion lines for the automotive industry to the high
precision drives used in precision-controlled robotic
applications. “Lenze as the second tier supplier just
completed a project at an automotive plant where
they supplied all the motors, drives, gearboxes,
brakes and soft-start systems integrated with
control systems such as Siemens for a complete
automotive assembly line,” Marcus says.
Control panel for a VSD system “Drive based safety is one of our strengths. The use
of safety engineering allowed us to save time and
money with fewer devices and less wiring, optimise
costs through the safety module’s scalability, and
achieve shorter machine clock cycles thanks to short
response times. The TÜV-certified safety satisfies
the requirements of up to category 4 of EN 954-1.
The cost savings achieved using these drives has
resulted in this client standardising on this system
for all their other factories around the world.”
Outlets
From the humble beginnings of a single office and
factory in Randburg in 1969, the company has
grown to today having two branches in Gauteng,
one in Durban, one in Port Elizabeth and two in
Cape Town. “Because we have such a wide range
of products covering applications in all industries,
we’re planning to expand even further in Gauteng
in order to cover the growing industries in the
Drives in a cable manufacturing plant

POWER TRANSMISSION
account the losses that occur both mechanically

and electrically to assist us in sizing the cor-
rect products for the application. This software
takes into account life cycles of the equipment,
energy consumption, wear and of course energy
saving,” Marcus explains.
Savings
The company is busy with a multi-stage project
where IP65 inverters are installed on motors at
a plant in KZN to improve the energy consump-
tion of the plant. This is being achieved by
replacing throttling valves used to regulate flow
by reducing motor speeds, This has resulted in
reduced mechanical wear on the pumps and less
strain on the motors caused by lower current
requirements. “Taking all of these actions into
account, the actual saving by the customer is
A complete drive installed not only in electricity but also in maintenance
costs as well,” adds Marcus.
area,” says Marcus.
“Energy saving is not as easy as just installing
“For many industries, we can design, engineer VSD’s. You need to take into account many factors
and supply all the drive systems they may need that change from company to company, application
including gearboxes, motors and control systems to application. Thinking about it, we have, in fact,
needed to improve efficiencies. We can integrate been doing energy saving for many years now by
with many control systems that are in the field designing our systems correctly, by using the best
today and work with customers to ensure energy suited products for the job, be it synchronous motors
efficient systems”. to soft starters. Each project has its unique design
features that must be taken into account and an
Obstacles can be overcome and these drives can be “energy saving drive solution” needs to be made.
replaced with VSD’s
Gearbox
VSD The overall energy efficiency of a drive train is,
In the past, variable speed drives were big and however, not only dependent on the motor efficiency
bulky, but with ever improving technology the and its control. The choice of gearbox used in the
components used have become smaller and in turn system is as important. Explains Marcus, “Usually
have resulted in smaller AC drives. people first ask after the price when it comes to
“We assist customers by doing a site analyses to the gearbox, but if you compare a low-cost worm
determine the exact power requirements for each gearbox with an efficiency of 50 to 60% to that of
application. We use Lenze software called “drive a moderately priced helical-bevel gearbox at 97%
solution designer” that incorporates and takes into efficiency, the cheaper gearbox wastes a lot of energy
due to the losses within.” Further improvements
in efficiency are achieved if a smaller motor and
gearbox can be used thanks to the improved
efficiency of the gearbox. In the end it all boils
down to designing the drive train optimally for
each specific application. For instance hydraulic
drives are well known for their comparatively
low efficiencies and hydraulic oil is hazardous
to the environment. Advances in electric drive
technology have meant that in many cases these
obstacles can be overcome and these drives can
be replaced with VSD’s.
“The crux of the matter is; design your drive
system correctly and incorporate energy saving
drive solutions from the start and your footprint
will be greener,” Marcus says in conclusion.
Marcus Gericke, SA Power, Tel: (011) 908-7060, Email:
marcus@sapower.co.za
Drive control

AUTOMATION & ROBOTICS
Look Ma, No Hands

In an automated manufacturing environment, the AGV (auto- Laser technology
matic guided vehicle) usually completes the loop in order to “Original technology ‘steered’ AGVs via circuitry built
make a particular production line fully automated. The AGV into the floors, but today we use laser technology.
does not become hungry, or tired, or prone to absenteeism. By simply working out routes on a CAD-type pro-
gramme and feeding this into the AGV’s system, the
vehicle’s routes are now easily managed,” explains
Willem. “Depending on the type of environment and
how many AGVs are operating in it, we fit certain
levels of sensors on each one in order to prevent
collisions with people or other moving objects that
may not be keyed into the system.
“If the AGV senses something in the distance, it
will slow down but not necessarily stop. As it gets
nearer the ‘unknown’ object, the second level of
sensing will slow the AGV down even more and a
third level of sensing will bring it to a stop if the
object does not move out the way at all,” Willem
elaborates.
Picking up loads at the production line
C
ompared with the rapid evolution of auto-
mated handling systems and robots, AGVs
seem to have lagged behind a bit in some
countries, but this does not mean the de-
velopment of technology has stagnated altogether.
While conveyors and lift trucks are the most com- Willem Prinsloo of Varic
mon handling solutions in warehousing as well as
in manufacturing plants, automatic guided vehicles The vehicle communicates with the main controlling
are increasingly becoming a viable alternative in PLC system on a continuous basis while continu-
both of these situations. ously reporting back to the system on, for example,
its battery condition.
Ultimate solution because it eliminates human presence
from high security areas Artificial intelligence
“In plain language, an AGV will, for instance, get to
In South Africa there have been a couple of AGV a station and tell the system: I am AGV 3, I have
installations in both the manufacturing and ware- completed my delivery to dispatch, my battery
housing environments. To learn more about these is still fine, standing by. The AGV will then wait
and the latest technology available, “SA Mechanical there until the system tasks it for the next job,”
Engineer” meets with Willem Prinsloo of Varic. explains Willem.
“Apart from our original installation at SA Mint’s “At the point when it reports that its battery is low,
plant, we also installed AGVs at an engine as- the system will instruct the AGV to go to the battery
sembly plant and some for the handling of large bay for either a recharge or a freshly-charged bat-
rolls of paper,” he says. “The installation at the SA tery replacement. Today we even have technology
Mint, in terms of security, is the ultimate solution which allows the battery to be recharged without
because it eliminates human presence from high attaching any cables. The AGV will simply park
security areas. on a spot where high induction coils are embed-

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18 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010Materials Today

Advanced September 2007 39
AUTOMATION & ROBOTICS
SGV Tugger with Optional

man Aboard platform
SGV2000 Side loaders have

handheld PCs which are used
to monitor and adjust the SGV
system by floor personnel
Simply park on a spot where high induction coils are

embedded in the floor
processes or high temperatures, an AGV system
can be engineered to fulfil the task much more
effectively. The technology has matured and it’s
available as a cost effective solution to complete
ded in the floor. Through this induction process, the automated production line of today.”
the battery is charged while the AGV is parked on Varic, Willem Prinsloo, Tel: (011) 918-4590, Email: wil-
that spot.” lem@varic.co.za
Four basic types
When it comes to traditional AGVs there are four
basic types of vehicles most commonly used. “Tow
vehicles, also known as tuggers, are simple and
inexpensive and they pull rail trailers or carts. By
adding multiple trailers you can move more loads at
one time than with a single lift truck. Tow vehicles
are used where you have a set path with distinct
pick up and deposit locations. They follow a route
and stop at stations for loading or unloading,”
explains Willem.
The second type are unit load vehicles that carry
pallets, slip-sheet, cartons or sub-assemblies on
their decks. These decks may be raised or lowered
with lifts, or have a conveyor to interface with other
equipment. Alternatively, the vehicle may have
multiple compartments to carry two, three or four
pallets at one time.
The third type is a forklift-type vehicle which op-
erates just like a lift truck, but without a driver.
Finally there are custom vehicles which can be
engineered to handle very large loads, like a twenty
ton steel roll, or unusual loads, like the whole body
of a school bus.
Conclusion
“South African industry has still not fully embraced
AGV technology, yet there are many instances where
they can benefit from it” says Willem in conclusion.
“In any manufacturing situation where the driver
of a vehicle is endangered, such as toxic chemical

REDUCING EMMISIONS
Carbon Capture and Storage

S
asol and Gassnova SF, a Norwegian state-owned demonstrate technology suitable for deployment at
enterprise responsible for managing governmental large scale CO2- capture facilities. The current TCM
interests related to Carbon Capture and Storage partners are Gassnova SF, A/S Norske Shell and Statoil
(CCS), signed a MoU in November last year at ASA, with Gassnova SF representing the Norwegian
the Union Buildings in Pretoria that will enable Sasol State in the project.
to explore the possibility of becoming a participant in
The technology centre is currently under construction
the European CO2 Technology Centre Mongstad (TCM)
at Mongstad on the west coast of Norway and will
currently under construction in Norway.
be in operation by the end of 2011. The test facili-
The signing of the MoU by Sasol CE, Pat Davies and Bjørn- ties are planned to capture 100 000 tons of CO2 per
Erik Haugan, CEO of Gassnova SF and chairman of TCM annum.
DA, took place in the presence of South African President,
Jacob Zuma and Sasol is proud that South Africa will soon be repre-
visiting Norwe- sented among the world’s leading nations in the fight
gian monarchs, against climate change. “The signing of this MoU is
King Harald V an important development that will support our com-
and Queen Son- mitment to reducing the company’s greenhouse gas
ja, during their emissions,” says Pat Davies.
state visit to Sasol aims to reduce its CO2 emissions by 15% by
South Africa. 2020 (based on 2005 as baseline) as well as lower
TCM is a unique targets at the absolute level for new CTL projects (30%
international down by 2030 on a 2005 baseline).
technology Sasol and Gassnova SF. For further information, please contact:
cooperation, Sasol, Jacqui O’Sullivan, Tel: (011) 441-3252, Email: jacqui.
established to osullivan@sasol.com. Nothemba Noruwana, Tel: (011) 441-
test, verify and 3295, Email: nothemba.noruwana@sasol.com.

OILS & LUBRICATION
Transforming
There are still many commodities that South
Africa has to import which makes us
vulnerable when there are shortfalls. A few
years ago, violent storms in the USA directly
affected the production of the base oils that
the Market
are used to make transformer oil, rapidly
leading to a serious shortage in South Africa at
a time when demand was particularly high in
the power distribution industry.
A
midst this shortage, Engen decided to
do something about it by investigating
the possibility of entering the market by
producing this precious commodity using
imported ingredients combined with the flexibility
of local blending to produce various grades.
Enough transformer oil to at least keep our existing

customers wet
Oil plant
“SA Mechanical Engineer” speaks to Anton Allner,
industrial lubricants strategy manager at Engen. “At
the time there were only two suppliers of transformer
oil in South Africa and when it became scarce, it was
really difficult for us to fulfil the demand from our
customers while at the same time competing with
these suppliers on the local market,” he explains.
One of our two lube oil blend plants in Durban had Anton Allner, industrial lubricants strategy manager
capacity to produce transformer oil on a small scale, at Engen
but lacked the technology and capacity to produce
higher volumes. “We partnered with Apar Industries The oil
in India and began the process two years ago to Transformer oil, or insulating oil, is a highly-refined
start producing enough transformer oil to at least mineral oil that is stable at high temperatures and
keep our existing customers wet”. has excellent electrical insulating properties. It is
used in oil-filled transformers, some types
of high voltage capacitors, fluorescent lamp
ballasts, and some types of high voltage
switches and circuit breakers.
It functions to insulate, suppress corona
and arcing. The oil also helps to cool the
transformer. Because it also provides
part of the electrical insulation between
internal live parts, transformer oil must
remain stable at high temperatures for
an extended period.
To improve cooling of large power trans-
formers, the oil-filled tank may have
external radiators through which the oil
circulates by natural convection. Very
large or high-power transformers may
also have cooling fans, oil pumps, and
even oil-to-water heat exchangers.
Growth
“When the expansion in the power gen-
eration industry started we decided to
address lubricant needs in this industry
The transformer oil plant sector specifically by establishing FluidLink

OILS & LUBRICATION
second biggest supplier of transformer oil in South

Africa, blending 6 million litres of transformer oil
per year.
“We spent 5 million on upgrading the old plant that
originally only produced uninhibited oil,” says Anton.
“After consulting with power generation companies
and transformer OEMs, we took it even further and
extended the plant to include a separate facility
that now also produces inhibited transformer oil.
The demand for both types has since continued to
grow by the day.”
The facility
Poweroil, Engen’s transformer oil brand, is one of
only two approved Eskom products. It is made from
carefully-selected Naphthenic base oils which are
produced using wax-free, low-sulphur naphthenic
crude, along with selected base stocks that are
refined to meet stringent international and local
specifications.
The dedicated facility in Durban is equipped for
bulk import, storage, blending of the various grades
The dedicated facility in Durban is equipped for bulk import, storage, blending of transformer oils as well as facilities to dispense
of the various grades of transformer oils for bulk distribution and a packaging line for 210L
drums and 20 L pails.
as a technical service that looks after all lubrication
requirements at power stations,” says Anton. “Set- “While our competitors only import finished
ting up a transformer oil production plant fitted in products, we have the flexibility to blend product
perfectly even though the intention originally was locally for different applications and customer or
manufacturer’s specific requirements,” says Anton.
Makes it difficult for them to quote years ahead To further enhance this service, Engen remodelled
the price structure around transformer oils.
purely to serve our existing customers. However, Price mechanism
the demand just kept on growing and systematically “The crude oil for transformers is totally different
others also started asking for transformer oil due from that of Brent and has a price mechanism of
to the general shortage.” its own,” explains Anton. “Most of our customers
The growing demand soon led to a decision to re- have long-term contracts to supply oil that extend
vamp the plant altogether and today Engen is the as far ahead as 2015, and with this market being
very volatile, it makes it difficult for them to quote
years ahead. The challenge for us was to develop
a price structure that considers the price of the
relevant crude oil, the exchange rate and other in-
dices such as fluctuating transport costs and labour
related costs. We now have a system whereby we
can quote a client for delivery in 2012. This price
adjustment mechanism is linked directly to the vari-
ous indices and as they fluctuate, so does the price
of our transformer oil which is clearly specified in
our client’s contract with the end-user. This system
was introduced over the past six months and has
been welcomed by all the players in the market.
“Our clients usually incur heavy penalties if they
don’t deliver on time, but now that they’re no longer
solely dependent on overseas suppliers, they can be
sure that the product complies with specifications,
is delivered on time and that it is available when
they need it,” Anton says in conclusion.
Engen’s Customer Service Centre at 08600-36436, Email:
1call@engenoil.com, www.engen.co.za. Your dedicated
sales contacts are Desmond Naidoo or Ashwin Perumal
Blending 6 million litres of transformer oil per year on Tel: (011) 480-6111

THE SA INSTITUTE OF TRIBOLOGY
Tackling Tribology
Greening Challenges
Tribology is an ancient science but was only recently defined
are aware of. Polychlorinated biphenyls (PCBs)
in the mid-sixties by Dr H Peter Jost. It’s the study of fric-
are a class of organic compounds with 1 to 10
tion and wear that goes well beyond lubrication to include chlorine atoms attached to biphenyl, which is a
the properties and nature of the surfaces that are rubbing to- molecule composed of two benzene rings. The
gether. We require friction – either increased or minimised– in chemical formula for PCBs is C12H10-xClx, where
every aspect of our lives, such as vehicle braking systems or x = 1-10. PCBs were widely used for many
the rolling resistance that a tyre pattern creates. Tribological applications, especially as dielectric fluids in
output is wear, heat and waste by-products. And a sound prin- transformers and capacitors and coolants. Due
ciple of well-applied tribology is that less is more. One litre of to PCB’s toxicity and classification as persistent
used oil has the potential to contaminate one million litres of organic pollutants, PCB production was banned
water. by the United States Congress in 1976 and by
W
the Stockholm Convention on Persistent Organic
ith the environment at the top of the Pollutants in 2001.
agenda, SAIT recently held a one-day It’s no wonder then that Eskom imposed a
seminar at Science Park entitled ‘Lubes trade ban on PCBs in 1977 and has a special-
& The Environment’. Expert subject ist program dealing with this poison. Note that
presenters dealt with topics ranging from managing PCBs are governed by SANS 0290 – a National
used oil in South Africa to micro-dosing lubricants, Standard on the management of polychlorinated
correct lubricant storage and handling, identify- biphenyls, mineral insulating oils. Recently
ing and management of Polychlorinated Biphenyl published in 2007, SANS 0290 provides a na-
(PCB) in insulating oils, low friction bearings and tional best practice guide on the management
energy-savings in hydraulic systems – to name a and phase-out of PCBs in dielectric fluids. This
few of the key issues. indicates the stuff is still out there and waiting
to contaminate unsuspecting handlers.
Only recover an estimated 70% of the 120 million litres
of used oil
MQL – it’s a ‘no-brainer’
ROSE foundation And if you like to believe that less can be more,
The Rose Foundation is Africa’s only used oil recov- then look no further than lubricant micro-dosing.
ery programme ‘ROSE’, which stands for Recycling This subject flies in the face of an African com-
Oil Saves the Environment, is a Section 21 (Non monplace practice of over-lubricating to prevent
profit) company established in 1994 consisting of excessive wear and failure. Micro-dosing is the
19 members from the lubricants Industry. In spite technique whereby minute quantities of lubricant
of their structured efforts at used lubricant recovery, are applied in an industrial operation, leaving an
the Foundation provides a sobering perspective for almost dry product and production environment.
Raj Lochen Micro-dosing is also referred to as “near dry” or
CEO of the ROSE used oil pollution in South Africa.
“Minimum Quantity Lubrication or MQL” or “mist
Foundation “Annually around 300 million litres of new lubri- lubrication”.
cants is sold into the South African market. This in
turn results in approximately 120 million litres of MQL requires special micro-pumps that can deliver
used oil becoming available. The Rose Foundation between 3 and 30 micro-litres per pulse – 30 mi-
through their partners NORA-SA only recover an cro-litres is an average volume of a drop. By adding
estimated 70% of the 120 million litres of used pumps, changing the pulse rate, dosing parameters
oil. 36 million litres of used oil remains to pollute can be established to meet the specific needs of
our waterways and underground water. This is the operation, ie, metalworking, lubrication of
a cumulative problem that will only grow and it bearings, chains, dies etc. Dosing is accompanied
concerns everyone.” by carefully-controlled air to disperse lubricant at
the exact point of lubrication, to blow away chips
PCB what? (metalworking) and to provide cooling of the tool.
On the green front, Polychlorinated Biphenyls
(PCBs) are a whole subject on their own that few Hydraulics – an unexplored frontier
Patrick Swan, CEO of Aswan Consulting, points out

THE SA INSTITUTE OF TRIBOLOGY
in a paper on hydraulic efficiency that ‘Hydraulic

fluids account for approximately 14% of all lubricants
marketed in South Africa, but over time hydraulic
fluids have entrenched themselves as commodity
fluids, generally sold on price, where a minimum
of technology is expected and received. Hydraulic
fluids are not only lubricants, but are also the prime
medium used to transfer energy in hydraulic sys-
tems, and over the past few years have become a
major research area to reduce energy losses when
transferring energy in a system.’
Careful attention to hydraulic fluid specification
can result in significant savings in the energy
required to move payload units.
In most cases these energy savings are combined low-friction bearings, effective storage of lubricants
with other performance benefits such as oxidation and becoming 14001 compliant – it’s for serious
stability, wear protection, corrosion resistance and minders of the planet.
improved air release. Case studies have proved that
SAIT has rubbed a vast knowledge surface that
modern, widely cross-graded hydraulic fluids are no
needs cascading into every aspect of life. How to
longer commodity items, but if used correctly, have
get these strong messages into the market – that’s
the capacity to contribute significantly to overall
the challenge!
energy efficiency.
Dave Scott, SAIT Member
Cascading Gill Fuller, Tel: (011) 802-5145, Fax: (011) 804-4972,
And then there are many other savings from using Email: secretary@sait.org.za, www.sait.org.za

FILTERS & FILTRATION
No
More
Hassles
Sales engineer Joe Pinheiro (left) and Philip Craig
Considering the cost of capital equipment and the demand for cleaner fuel, fuel suppliers are under pressure
to guarantee quality especially for remote locations where delivery trucks travel hundreds of miles on dirt
roads to the end user. The supply of clean fuel/oil is a problem of the past for many fuel/oil companies, as
they’re using a bulk fuel filtration system developed and built by Operational Marketing in Johannesburg.
S
A Mechanical Engineer” speaks to sales making contaminated diesel a huge problem that
engineers Philip Craig and Joe Pinheiro often affects plant availability,” they say.
about the comprehensive filtration solutions “End-users such as mining companies are increas-
they’re now offering into the fuel/oil industry. ingly demanding a cleaner supply of fuel/oils which
“Today’s engines are much more sophisticated presents a great opportunity for fuel/oil companies
Once water ingress occurs, bacterial growth within the to gain the edge by guaranteeing the delivery of
diesel forms clean product on site.
Dirt
“There are many ways that fuel/oil incurs contamina-
tion, particularly when it’s taken to remote mining
sites by road on rough roads, agitation loosens rust
inside the tank, while dust from the sand roads or
water condensation entering into the tanker is at
times unavoidable.
“For these reasons, we filter the
product on site before it goes
into the storage tanks and,
in some cases, we even filter
it again before it is delivered to
mining equipment or another source of
demand. Another option is to continuously
filter the product in storage through a kidney
circulation / multi-passing system to ensure
acceptable cleanliness levels.”
Know-how
“Each site, environment and system is different
requiring each filtration system to be adapted or
modified accordingly,” both Philip and Joe concur.
“As the sole agents in Africa for the Mahle range
of filters made in Germany, we use their complete
scope of supply on offer to us to provide best cost
The four-way filtration system effective filtration systems. In addition to these

systems is the inclusion of a pre-filter, sourced locally,

which extends the life of the fine Mahle filtrations ele-
ments. Other items such as the pumps and valves, are
supplied internally within the Omsa group, who are
agents for many other high quality products.
The system
Filtration for diesel starts with a simple manifold design,
incorporating very fine particulate filters followed by
a coalescer and separator filter for water in diesel. A
pre-filter was then included into the system and has
been developed further to a full-on self-containerised
filtration system that is tested and commissioned in
house before being supplied to the client. “This fil-
tration system incorporates a pre-filter that removes
all the coarse particles, followed by a filter manifold
or housing to remove the finer ingress of particles,”
explains Philip.
Can be isolated in order to change filters

without stopping the operation altogether
“The diesel then travels through a coalescer and

The pre-filter system separator filter housing to remove water, which at a
later stage is then drained from the housing through
lockable ball valves. To ensure that the coalescer and
separator system operates efficiently, the diesel flow
rate has to be regulated and controlled precisely. Once
water ingress occurs, bacterial growth within the diesel
forms. A jelly-like substance can then be formed in the
diesel that can only be treated with a chemical additive
which transforms the bacterial growth into a solid.
This jelly-like substance, which quickly blocks filters,
increases the cost of filter spares and poses huge prob-
lems downstream at point of delivery to equipment.
Enhancements
To ensure the system is more flexible, each filter
manifold is purposely designed to ensure that the inlet
and outlet pipes are symmetrical and can be rotated
180 degrees to accommodate the piping installation
on site. Isolating valves, which are critical, are fitted
to the manifold so the delivery line can be isolated in
order to change filters without stopping the operation
altogether.
A further enhancement is an in-line particle counter
which shows the level of contamination in fuel or oil.
There’s also an in-line filter with a magnetic cartridge
and aluminium housing available for thick oils which
cannot pass through a normal filter cartridge. The
magnetic filter cartridge is re-useable ensuring zero
cost on replacement of spares.
Understanding filters
“In our experience, most systems incorporating filtra-
tion are neglected with regards to maintenance. Filtra-
tion is merely the “kidney” or “liver” in the system,
without this, failure will eventually occur” says Philip
in conclusion.
Philip Craig, Tel: (011) 793-5562, Email: philipc@omsa.
co.za

Clearing the Air

ciency classes. “SA Mechanical Engineer” speaks
to Dr Daniel Schmitt, managing director of Freud-
Air ventilation systems often account for a large percent- enberg Filtration in South Africa.
age of a building’s energy consumption. Even more so if “Although mainly developed for ventilation systems,
the pressure drop in the air filters results in a larger total our classification also holds true for compressors
pressure drop in the ventilation system. Therefore, to op- and gas turbines,” he says. “Traditionally the fan
timise energy efficiency, the choice of air filters is vital in a ventilation system runs at a fixed speed and
without compromising filtration requirements. is specified according to the pressure drop in the
system. If a variable speed motor is used, we can
then regulate it to run at different speeds as the
pressure drop varies. This alone significantly reduces
H
energy consumption.”
owever, it’s not just a matter of choosing a
high efficiency filter. In fact, the pressure Study
drop of a higher efficiency filter is higher He elaborates, “We did a lifecycle cost (LCC) cal-
than a lower efficiency filter which means culation for an air filter and found that between
more energy is used to move the air against the 70 to 80% of the LCC of the filter is actually the
higher resistance of a high efficiency filter. Until now, energy it consumes when the fan has to overcome
there has only been an efficiency classification for its pressure drop. Only 20 to 30% of the cost is
filters, where the higher number indicates more par- related to purchase price, change-out, labour and
ticles being waste management. So, obviously, we tackled
taken out of the matter of filters. As mentioned, there is an
the air, but not efficiency classification for filters according to the
much about various European and American rating standards
optimising which we’ve cross-referenced with the performance
energy con- ratings,” explains Daniel.
sumption. You can select a filter according to
Filtration particle removal efficiency together with
Freudenberg its energy efficiency ratings
Filtration
recognised “Now you can select a filter according to particle
this dilemma removal efficiency together with its energy efficiency
and has come ratings. By selecting a specific energy efficiency
up with a rated filter and combining that with the energy
new system savings of a variable speed controlled fan instead
whereby fil- of the constant speed fans that are still being used
ters are not widely in South Africa, you can comfortably save
only classed between 15 to 20% in energy consumption. This
in pressure has been proven in various ventilation system
drop rang- installations in Europe.”
es, but also Mining
Dr Daniel Schmitt, managing director of Freudenberg Filtra- grouped into Daniel and his team of engineers are taking the
tion in South Africa energy effi- energy efficiency filtration
concept further in terms
of specific industrial ap-
plications in South Africa.
“We’re working closely with
end-users and compressor
OEMs to look at the air in-
take compressors on mines
which is a huge energy
item for them,” he says.
“Up here on the Highveld,
the air is thin to start with
which affects compressor
Energy efficiency for Viledon air filters of Filter Classes G3 to F9 in the first or second filter stage performance. If you also

The particularly energy-efficient Viledon Compact pocket filters and MaxiPleat cassette filters
have an air intake that has a high pressure drop can’t produce a standard reference grid like we did
because the filters are not properly selected, you’re for ventilation applications because each mine is
dramatically reducing the performance of the system different from the next one, so we’re analysing each
in terms of energy consumption. one individually. It depends what they have in place
“The mines, from the cost as well as availability as far as compressors, fans and filtration systems
point of view, are keen to reduce energy consump- are concerned. In these studies we consider all pos-
tion and have been very open to the discussions sibilities that will help to reduce the pressure drop
we’ve had so far,” says Daniel. “In this instance we such as simply making the intakes a little bigger at
the cost of a little bit of sheetmetal work.”
Not as common in South Africa yet as in Europe
New equipment
The very latest they’re working on at Freudenberg’s
workshop in Edenvale is actually building complete
energy-efficient pressurisation units designed for
local conditions. “Basically they are fan-filter units
equipped with variable speed fans, something
not as common in South Africa yet as in Europe,”
explains Daniel.
“We’re in the process of building the first one and
are working closely with a number of fan and electric
motor manufacturers to bring a ‘green’ pressurisation
unit to the market. The unit will come complete
with variable speed fans, the control unit built in
and already equipped with the best filters accord-
ing to the energy classification. It is a concept we
designed locally and each unit will be customised
for each individual application. The first one will
be completed for tests early in 2010.”
Although energy consumption is the hype right
now and shortages appear to have been resolved,
chances are there may very well be shortages again
when the economy picks up again. Daniel says in
conclusion. “Now is the time to familiarise yourself
with the technologies that are already available
to help you. Don’t wait until the crisis hits before
you react.”
Dr Daniel Schmitt, Feudenberg Filtration Technologies,
Tel: (011) 929-4500, Email: daniel.schmitt@freudenberg.
co.za

NUCLEAR INSTITUTE (SA BRANCH)
Travelling-wave Reactor
In Enrico Fermi’s New Piles Committee in the USA at the end by implication, available in quantity.
of WW2, Farrington Daniels, head of metallurgy in the Man- As far as I can gather, there are so far just two
hattan Project, advocated a power reactor system based on 50 MW plants in operation, both rather recently
spherical fuel elements cooled by helium. He later left nuclear commissioned in Spain. Others are on the way.
technology and became a prominent advocate of solar energy. The system is therefore still in the developmental
It’s therefore somehow neat to find Dieter Matzner, formerly stage.
chief engineer with PBMR, now extolling solar energy on be- For South Africa, without external back-up but with
half of Hatch. abundant sunshine and relatively abundant uranium
I
and thorium, solar (with storage) plus nuclear ap-
n Nov/Dec 09 issue, Matzner pear to be the obvious paths to pursue.
presented his vision of our electri-
cal future. Base-load (60%) is to January is a good month for crystal ball gazing and
be shared between coal, nuclear in respect of nuclear also, it seems to me that we
and imported hydro. Mid-merit (30%) are looking at a step change in the technology. As
is to be solar (with energy storage) a result of TMI and Chernobyl, nuclear plateaued
and closed-cycle gas turbines. Daily for some twenty years at around 16% of world
peaks are to be shared by pumped generation. We are now starting to move forward
storage fed possibly by wind genera- again – but there are issues. The safety record
tors, and by the present open cycle is excellent – apart from Chernobyl. But another
gas turbines. One may want to argue, Chernobyl must become inconceivable. Waste is
and the vision will certainly evolve an issue, at least in the public mind, as is the risk
as technologies mature and their of weapons proliferation. All can now be addressed
relative merits – and costs – become by advanced reactor and fuel cycle design. Uranium
apparent, but this surely is the type reserves are limited but, together with thorium, they
John Walmsley can be used vastly more efficiently in advanced
of picture that anyone interested in
energy should have in mind. It’s something tangible designs to the extent that the resource will become
to argue about. virtually infinite.
One of the components of the Matzner vision is Without refuelling

CSP, concentrated solar power, with energy stor- An entertaining example of the new concepts
age. This country has no external back-up from is the ‘travelling-wave’ reactor described in last
powerful neighbours and, in my book at least, September’s ‘Nuclear News’. To understand it you
intermittent solar energy and unreliable wind do not have to appreciate that in any reactor, uranium 238
have a place unless associated with some form of nuclei absorb some of the chain reaction neutrons
large-scale energy storage. Molten salt is evidently to become uranium 239. This immediately decays
flavour of the month. into neptunium 239 and, after two or three days,
into plutonium 239 - which is again fissionable. Up
Molten salt is, it seems, a well-known heat exchange to 40% of Koeberg’s output stems from fission of
medium second generation plutonium nuclei formed within
the fuel in this way.
In quantity
Molten salt is, it seems, a well-known heat exchange Now imagine a cylinder formed of natural or de-
medium. 40% potassium nitrate, 60% sodium ni- pleted uranium fuel assemblies with a uranium
trate, common names saltpetre and cubic saltpetre, 235 starter pack at one end. Fission neutrons
melting point 221 °C. In the power tower layout from the uranium 235 evidently penetrate up to
the salt operates between about 300 and 560°C 40 cm into the body of the cylinder, there in due
and, with the parabolic mirror system where there course to create plutonium 239. Sooner or later
has to be an intermediate oil loop, between about there is enough plutonium to become critical in its
300 and 370°C. Even with the higher temperature own right and to generate fission neutrons some of
system, a plant designed to give a steady 50 MW which travel another 40 cm into the cylinder, there
for 18 hours per day needs at least 25 000 tons to create still more plutonium. Waves of plutonium
of salt. creation and then fission thus travel slowly along
the cylinder – the heat being removed by molten
To replace Koeberg’s 1800 MW you would there- sodium. Evidently you can design the system to move
fore need over 600 000 tons, much more if your sufficiently slowly to generate, say, 1000 MWe for
mirrors are parabolic. But then it seems that both several decades - without refuelling. Cor!
constituents are fertilisers as well as, in the case
John Walmsley
of potassium nitrate, gunpowder and are therefore,

Market Forum
were able to demonstrate
that we have previously
executed large dust control
and gas-cleaning contracts.
This, among other key
factors, satisfied Alstom
Power that we have the
experience and expertise to
handle the project,” says
Woitek Liberda, MikroPul’s
general manager.
Alstom Power was also
impressed by the fact that
MikroPul was able to com-
mit to 88% local content for
all the primary equipment
involved, of which the bulk
is to be procured from BEE
sources, including black
women owned (BWO)
companies.
Des Tuck, MikroPul, Tel:
(011) 478-0456, Fax: (011)
478-0371, Email des.tuck@
mikropul.co.za
This schematic diagram shows the positioning of the various elements of one of the turbine hall ventila-
tion systems on any one of Medupi power station’s six generation units
Ventilation contracts
MikroPul of Johannesburg, a member of Actom, was re-
cently awarded its biggest ever HVAC (heating, ventilation
Fast first aid
The Quick Fix Clamp, available from Multotec Wear Linings,
& airconditioning) project by way of two contracts together
provides an appropriate and convenient solution for leaking
worth over R100m.
pipes which demand immediate attention. This innovative
The contracts, for the manufacture and supply of fans and product straps easily around the pipe with the minimum effort
auxiliary equipment for ventilation of all the turbine halls of sealing the leak for later long-term planned repair.
both of Eskom’s new six-
pack 4800 MW coal-fired
power stations, Medupi
and Kusile, were awarded
to MikroPul at the end of
July by Alstom Power, the
manufacturer and supplier
of the turbines for both
plants.
In bidding for these prized
contracts MikroPul faced
competition from a host of
other reputable companies,
including several interna-
tional contenders. However
Alstom Power found it to
have the requisite expertise
and track record for project
managing contracts of
similar magnitude.
“Although these are the
largest HVAC contracts The Quick Fix Clamp, available from Multotec Wear Linings, provides an appropriate and convenient
we have won to date, we solution for leaking pipes which demand immediate attention

Market Forum
Since its introduction several years ago, the Quick Fix Clamp 2011, with future orders on the cards.
has become popular in South African process plants as a no- This recent order follows on others to the United States Army,
fuss, low cost “band-aid” relieving maintenance personnel of United States Marine Corps and Canadian Forces, which since
crisis demands and providing the necessary stop-gap to keep 2005 total over 200 VMMD systems of varying configura-
production on the go until planned repairs can be done. tions. Prior to 2005, a total of 46 systems were supplied to
The red polyurethane pad with ceramic skeleton and its South Africa, France, Australia, the United Kingdom, Uganda
bright yellow belt is sufficiently conspicuous that it is not and the United States Armed Forces.
likely to be missed during maintenance reviews. Carl Rehder, executive director of RSD, says the original
Applying the Quick Fix Coupling is a simple procedure. Scaling VMMD system, known as the Chubby, was developed to solve
on the pipe external surface at the leak must be removed and South African land mine problems in the 1980’s during that
cleaned, and then the belt is placed around the pipe with country’s period of isolation. “The innovative design of this
the sealing pad covering the hole. The ratchet, which forms locally engineered and manufactured system has proven to
part of the coupling itself, is then used to tighten the clamp be a huge success story, both on the African continent and
so that it fits snuggly. No bonding or sealing compounds are internationally,” he adds.
required and the coupling is reusable. The VMMD system is a blast survivable, overpass capable,
Bernadette Wilson, Multotec Group, Tel: (011) 923-6193, Email: field repairable, mobile mine detection system. The innovative
marketing@multotec.co.za, www.multotec.com design protects the operator on encountering an explosive
device, the vehicle itself breaks apart in a predictable fashion.
It is the only such vehicle designed to provide this level of
protection to the operator.
Carl Rehder, RSD (A Division Of Dcd-Dorbyl (Pty) Ltd), Tel: (011)
914-1400, Fax: (011) 914-3885
Clearing the way

Combat-proven Vehicle Mounted Mine Detection (VMMD)
systems, engineered and manufactured by RSD (a division of
DCD-Dorbyl, have again been selected by the United States
Armed Forces for route clearance activities.
RSD, in partnership with Critical Solutions International Pipe handling system
Inc, has been successful in securing an order for 150 Hytec Marine and Offshore Services, a member of the Hytec
VMMD systems for supply to the United States Army Tank Group, has completed a project involving the redesign of the
and Automotive Command (Tacom). These vehicles will be pipe handling system and the construction of the control valve
supplied on a phased delivery programme through to April modules to be used on a drill ship. The vessel services the
petrochemical industry off
the west coast of Africa.
The project, valued at
R3.1 million, has been
completed under tight
deadlines and has demon-
strated Hytec Marine and
Offshore Services’ ability
to deliver high quality
solutions with maximum
speed and efficiency.
The control system for
the ship’s onboard robotic
pipe handling system was
redesigned, supplied and
constructed by Hytec Ma-
rine and Offshore Services.
The system supplies the
ship’s drilling rig with the
riser pipes necessary for
reaching the ocean floor.
Riser pipes are stored on
the stern of the vessel, while
The VMMD system is a blast survivable, overpass capable, field repairable, mobile mine detection the drilling rig is located
system.

Market Forum
amidships. The supplied solution
is capable of forward and reverse
movement as well as articulation
on a vertical plane.
The system has been designed
using Bosch Rexroth components
throughout to ensure maximum
precision and reliability under harsh
conditions. The new pipe handling
system affords two advantages
over the previous system, namely
improved stability at sea and the
elimination of damage to riser pipes
during the handling process. The
new system has resulted in a safer,
more efficient vessel from which
to conduct marine drilling.
Hytec Marine and Offshore Services
also supplied 189 litre Hydac hy-
draulic accumulators to be used
on the ship’s blow out preventor
(BOP) systems.
Clynton Sutherland, Hytec Marine
and Offshore Services, Tel: (021) 551-
4747, Fax: (021) 551-2575, E-mail:
Hytec Marine and Offshore Services recently fitted a drill ship, servicing the petrochemical clyntons@hytec.co.za
industry, with an improved pipe handling system

Market Forum
Varies with demand More Performance
Lowara has developed a number of products that Since energy costs account up to 70% of the compressor’s
play a key role in managing lifecycle cost (LCC), it is Atlas Copco’s commitment to
water delivery through all ele- reduce this cost drastically with every new compres-
ments of the HVAC cycle. sor generation. Their engineers have succeeded
in lowering SER (Specific Energy Requirements)
Lowara Pumps are manu-
by up to 8% by integrating the new screw
factured from fabricated
compressor element in an enhanced packaging.
stainless steel or cast iron
At the same time, FAD (Free Air Delivery) is
depending on the range
increased with up to 8%, resulting in
and application. Use of
remarkable savings on electricity.
laser welding technology
in the case of stain- When the compressed air demand is
less steel fabrication fluctuating, the advanced control
ensures pumps that algorithms of VSD create average
c l ive t s
c y el u c
ry
are resistant to ag- energy savings of 35%. The
C er d r o d
gressive chemicals entire range has been equipped
VA t p
e
H wa f
e g ro
and guarantees that with new saver cycles on both fan
t h gin b e
o f na u m
the production process and dryer, increasing the average
ts a n
energy savings even further.
en m a
respects the natural en-
m in e d
vironment. l e ole o p More Flexibility
l e r el
a l ey v
h a k de
Examples in the Lowara port- Installation flexibility is characteristic for this

ug y as
folio of pumps for HVAC include GA 5-11/GA 5-15 VSD Premium-range. The GA
r o la h
th t p ra
the FC Series pumps used mostly in Workplace Concept is reinforced with noise levels
th o w a
commercial HVAC applications which starting from 60 dB(A)*. This GA-range is the most
L
a
incorporate the Hydrovar. silent in the complete Atlas Copco GA-portfolio, allowing
Lowara can provide a wide range of pumps for installation close to the point of use. Installation cost
that create an end-to-end water solution not only for HVAC is further minimized by extending the standard operating
building services, but all applications including water sup- range to up to 46° Celcius, making a dedicated compressor
ply, wastewater pumps, borehole or submersible pumps, room unnecessary.
and fire-fighting systems. More VSD models, including a tank-mounted GA 15 VSD
The Hydrovar variable speed controller is a great example
of realising energy efficiency. By varying pump speed
with demand, savings in pump power usage combine
with longer pump reliability for a lower life cost across
commercial and domestic HVAC applications.
Lanelle Wheeler, ITT Water & Wastewater, Tel: (011) 966-
9300, www.flygt.co.za
Small but More

Driven by a future generation element and using the
most advanced development techniques, Atlas Copco
has redesigned its smallest oil-injected screw compres-
sor range GA 5-11/GA 5-15 kW Variable Speed Drive
(VSD). This new range sets a new industry standard
in the 5 to 15 kW compressor range. An 8% increase
of air delivery, noise levels as low as 60dB(A), new
VSD voltage variants, an extended operating range,
a new Elektronikon controller and an additional tank-
mounted GA 15 VSD model, boost the possibilities
of this new range.
This range is used in a variety of applications as general
assembly and manufacturing and in a broad range of
industries including automotive, water treatment, air
segmentation, construction and many others.

Market Forum
and new standard Voltage 200/575 variants, reduce instal- ensuring an improvement in the work environment.
lation costs even more, extending the VSD offer towards “Reduction of noise generated by machines and equipment
our customers. significantly improves efficiency in the overall workplace,”
Atlas Copco South Africa Pty Ltd, Tel: (011) 821-9000, Telefax: (011) says Scott Larson, general manager for BMG’s chain division.
821-9106, Website: www.atlascopco.co.za “Belts were considered a counter measure to noise, but with
limitations in terms of application, strength and overall costs,
low noise chains provides the perfect solution.”
Noise levels of Tsubaki’s new SN roller chain are 6 ~8 dB
lower compared with the standard pre-lubricated RS roller
chain. When SN roller chain engages with the sprocket, the
new spring roller absorbs the force of the impact. This lower
Noise reduction impact force results in lower noise levels. Another advantage
BMG’s comprehensive range of Tsubaki chain products in- is that the SN series is fully interchangeable with standard
cludes low noise drive chains that combat noise pollution, roller chains.
Tsubaki high performance chains with special materi-
als, coatings and lubrications, undergo an immacu-
late manufacturing process to ensure dimensional
accuracy, constant geometry, high surface quality
and extended service life.
Scott Larson, BMG, Tel: (031) 576-6200, Fax: (031) 576-
6582, Email: scottl@bmgworld.net, Web: www.bmgworld.
net
Hands-free
SKF’s laser-based and wireless shaft alignment tool,
Fixturlaser Upad, is the first tool of its kind that is
truly portable.
“The wireless display unit is worn on the arm; the
user therefore has his hands free and can work in
complete freedom,” explains David Ramnath, SKF
South Africa’s Business Development Manger, Reli-
ability Systems.
David continues, “It may be small in size, but it can
handle everything that its big brother, the award-
winning shaft alignment tool Fixturlaser XA, can do,
ranging from advanced shaft alignment applications
to geometric measurements. The user interface guides
the user during the entire measurement and align-
ment process by using color-coded measurement
values, icons, and arrows. These units also have a
touch screen, which makes it easier for the user to
navigate through functions.”
“The consumer market for electronics has long been
driven by making products smaller and portable. Elos
Fixturlaser, with 25 years of experience in developing
laser-based system for alignment of rotating machinery,
considers it is high time that the maintenance sector
benefits from this development, and SKF South Africa
BMG’s comprehensive range of Tsubaki chain products includes low noise is in full agreement,” elaborates David.
drive chain that combats noise pollution, ensuring an improvement in the work Elos Fixturlaser are also proud to be the only manu-
environment. SN roller chain can be used in applications where the strength
of a roller chain is required, without the accompanying noise. The low noise
facturer of laser based shaft alignment tools with
SN series is fully interchangeable with standard roller chain a measurement method for Fixturlaser UPAD that

Market Forum
the process control of liquid products at a prominent local
liquid product processing plant.
The order, estimated at R1m, specified Martin Lohse water
knife gate valves: valve type CDSP/G with through going
plate fitted with a double acting pneumatic actuator, flanged,
drilled to ASA 150 and a 316 stainless steel body and blade.
A maximum pressure of 6 Bar and maximum temperature
at 120 degrees C were also specified.
The Martin Lohse range of superior quality valves
is, apart from successful utilisation in water
treatment applications, also used extensively
in the paper and pulp industries and Voith
Paper was actively involved in finalising the
order to customer specification because
is based on the of this division’s extensive experience
CCD technology, with the product application.
recently awarded with the Subsequent to the initial order, Voith
Nobel Prize. Paper received an enquiry for an ad-
Samantha Joubert, SKF South Africa (Pty) Ltd, Tel: (011) ditional 32 smaller Martin Lohse valves,
821-3500, Fax: (011) 821-3501, Email: samantha.joubert@skf. from the processing plant. A Voith Paper
com, www.skf.co.za spokesperson says that product superiority,
a good business relationship and excellent after
sales service undoubtedly led to the enquiry,
which will, when ordered and delivered, be worth an ap-
proximate R2m.
Voith Turbo, Roy Webster, Tel: (011) 418-4036, Email: roy.webster@
voith.com, www.voith.com, www.rsa.voithturbo.com
Large valve order

Voith Turbo South Africa (VTZA), the South African represen-
tative of the Martin Lohse GmbH range of valves, recently
secured an order for six large 400mm diameter valves for
Water loss manage-
ment
Munitech, which focuses on
municipal operations and
maintenance management,
has recently established a
specialist leak detection
department in response
to heightened awareness
of water loss management
in this country.
Muinitech has initiated
an innovative GIS based
management system for
leak detection and repair.
By using GIS to manage the
process, a strong platform
from which to analyse data
from subsequent sweeps
of an area, has been es-
tablished.
Active leak detection
encompasses activities
ranging from walking the
reticulation lines and ob-

Market Forum
serving visible leaks, to the
deployment of sophisticated
acoustic sensing equipment
that “listens” for leak noises
on submerged pipes.
The company has recently
completed a contract for leak
detection and repair services in
the southern operational area
of eThekwini. Field teams,
which have undertaken numer-
ous leak detection sweeps of
rural, peri-urban, suburban
and industrial areas, have
contributed to a reduction in
real loss as part of eThekwini’s
Non-Revenue Water Reduction
Programme.
George Iliev, Munitech, The B & A
Group, Email: illievg@munitech.
co.za
Ndumiso Kubeka and George Iliev from Munitech interpret a filed correlation as part of Munitech’s
leak detection programme, which is designed to improve water loss management throughout South-
ern Africa

Market Forum
Early warning
Festo has supplied FEC 440 PLCs to PT Bernama Infor-
matika Nusantara, a Bandung-based IT company. The
company is using the PLCs in the construction of tsunami
early warning modules used in Padang, Sumatra.
On 26 December 2004, a seaquake 150 km west of
Sumatra triggered a devastating tsunami and fears of
another catastrophe still run high. For this reason, the
government in Padang has developed a tsunami early
warning system in which numerous systems are inte-
grated. The system includes tide gauges, wave sensors
and network communications to the media, which can
quickly spread confirmed details about approaching
tsunamis.
The electronic modules for the network and control sys-
tem are installed at nine locations in Padang City. Each
module contains a Festo FEC 440 PLC which acts as
the module’s controller. One of the modules acts as the
Master Operation Control & Monitoring Unit, monitor-
ing system components in other locations. Its ability
to communicate with other devices using the TCP/IP
protocol is a large benefit. The PLC also has the key task
of controlling the activation of warning sirens.
Joanne Dix, Festo (Pty) Ltd, Tel: (011) 971-5560, Fax: (011)
974-4203, Email: info_za@festo.com
Set and sealed
The Spirax Sarco SV615 range of high performance
safety valves for over pressure protection in steam, gas
and liquid applications has been upgraded to achieve
even higher setting accuracy and greater reliability.
Furthermore, SV615 valves are set and sealed to the
customer’s pressure specification with the same day
dispatch on urgent orders.
The upgrades include reduced friction of the valve
movement, flatter seats and less spring relaxation,
resulting in more accurate setting, extremely predict-
able opening and crisper closing.
To ensure reliability and continuing good performance,
valves are randomly chosen and independently tested
on a fully instrumented test rig. The SV615 range
meets European Pressure Directive requirements and
the integrity of shut-off complies with ANSI/API STD
527-2002. Unique serial numbers and traceable set
pressure certificates are issued with every valve.
Spirax Sarco SV615 safety valves have a high dis-
charge capacity and can be used to protect steam
boilers, pipeline and pressure vessels, compressors
and receivers and most general industrial service
applications.
Emily Heath, Spirax Sarco, Tel: (011) 230-1300, Fax: (011)
393-1922, E-mail: info@za.spiraxsarco.com, www.spirax-
sarco.com/za
Log onto www.promech.co.za

to read back issues of The tsunami early warning system includes tide gauges, wave sen-
“SA Mechanical Engineer” sors and network communications to the media, which can quickly
spread confirmed details about approaching tsunamis

On the Move
Sincere Apologies
The “On the Move” section of the August
2009 issue mistakenly had McCarthy
Heavy Equipment’s Materials Handling
Division appointing Brand Pretorius as
CEO of McCarthy Ltd. Mr Pretorius has,
in fact, been CEO of McCarthy Ltd since
1999 with McCarthy Heavy Equipment
Andy Church Deric Dignon Mzingaye Mthethwa as one of their divisions.
Brand Pretorius
We regret the error
Subscription
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PROMECH PUBLISHING Fax No: (011) 781-1403
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Ltd, part of the B & From:......................................................................................
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(insert your name)
the following ap-
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Church is business
manager, agricul- Company: ..............................................................................
Christo van Rooyen Gert van den Berg ture; Deric Dignon
is process engineer; Address: ...............................................................................
and Mzingaye Mthethwa is senior mechanical engineer.
...............................................................................................
Gavin Phillips has joined Metric Automotive Engineering
as the company’s IPD parts specialist. IPD products are ...................................................................Code: ..................
Caterpillar replacement parts which are manufactured in a
quality controlled environment. Telephone: ( ) ....................................................................
The Omsa Group of companies has appointed Jacky Wilson Fax: ( ) ................................................................................
as their internal sales representative specifically to handle
the valve sector of the group. Email:.....................................................................................
The following new staff have joined SEW Eurodrive: Sabelo
Shabalala as internal sales engineer (Pinetown branch),
Christo van Rooyen as sales engineer for the Pietersburg Index to Advertisers
area as well as Gert van den Berg as sales engineer for the
Northern Cape region. Association of Arbitrators 19
AST Inside Front Cover
There, I fixed it! Bearings International

BMG
Inside Back Cover
20
Donaldson 24
EMS 4
Engineer Placement 12
Engen 36
Esab Outside Front Cover
Eskom Outside Back Cover
Feeling at Home 26
SAID 18
Tegnon 32
WCNDT 11


SAME: Jan 2010

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THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010 

 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010 

Featured on the Cover Contents

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010 

 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

and are encouraged to take up a career in one of

Training Events Calendar - JANUARY - MARCH 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010 

Naval Mine Warfare

A typical mine from WWII

 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010 

therefore have some detectable magnetic field and

10 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010 11

“SA Mechanical Engineer” has been appointed to pub-

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The cheaper gearbox wastes a lot of

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account the losses that occur both mechanically

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Look Ma, No Hands

Picking up loads at the production line

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010 17

CARING FOR DISADVANTAGED ANIMALS SINCE 1958

DEBIT ORDER DONATION INSTRUCTION

POSTAL ADDRESS :____________________________________________________________________________________

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BRANCH CODE : ACCOUNT NO :

TYPE OF ACCOUNT : CURRENT SAVINGS TRANSMISSION

DATE OF FIRST PAYMENT : MONTHLY DONATION AMOUNT : R

18 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010Materials Today

SGV Tugger with Optional

SGV2000 Side loaders have

Simply park on a spot where high induction coils are

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Carbon Capture and Storage

20 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

Enough transformer oil to at least keep our existing

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second biggest supplier of transformer oil in South

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in a paper on hydraulic efficiency that ‘Hydraulic

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systems is the inclusion of a pre-filter, sourced locally,

Can be isolated in order to change filters

“The diesel then travels through a coalescer and

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Clearing the Air

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One of the components of the Matzner vision is Without refuelling

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Clearing the way

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Examples in the Lowara port- Installation flexibility is characteristic for this

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 January 2010

E-MAIL : TELEPHONE : ____

BANK : _ BRANCH : _______