SAME: Feb 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

AN ENGINEER’S VIEW
State of the Nation

I have to say that after listen- Clearly the management or lack of it is responsible,
ing to the state of the nation so where has the training spend via say the SETA’s
gone that one would have thought would have an
address by the President, it effect on this part of the infrastructure? We all know
only illustrates that either the actual situation, but are all too PC to admit it in
politicians just keep on be- public forums. It probably personifies the massive
state of misused funds for personal gain.
lieving we are all uninformed
Overall then, how much of this big spend is really
morons or that they are sim-
creating the built environment?
ply living in the blissful state
Growing obstacle
of ignorance, accompanied by I recently took another look at the Dinokeng Sce-
a good dose of self preserva- narios that were published and debated in 2009.
tion. I have a feeling that it is It is hard not to believe that the basics currently in
Chris Reay place are not those to precipitate the “walk apart”
Chairman of the Working the latter.
Committee: Communications scenario. Many efforts to try and contribute to the
(SA Institution of Mechanical solutions that would assist us to achieve the “walk
Engineering) together” scenario are ignored.
F
In technical skills development alone, we face a
or three eras in a row, the state has advised growing obstacle to meet anything near the projected
that they are to spend large amounts on infrastructure spend. Government is able to find
projects to support infrastructure. The first R140 million for fancy ministerial cars and many
in about 2003 was R400 billion to be spent other millions for parties and trips, but try to get a
in three years, the second R787 billion announced few million to train Engineers for municipalities.
in February 2009 to be spent in four years, and
Perhaps one plus will emerge from our misplaced
now we have another even greater sum to be spent
and misused empowerment monster; those are
starting 2010. The problem I have with these
currently disempowered and have to struggle to
enormous projections which sound very admirable
make the grade will eventually, when the free
is that do we ever get a reconciliation of the actual
handouts are no longer possible and the energy
spend, and what has been created for it?
in the flywheel has been depleted, have gained
If one surveys the likes of the municipal infrastruc- street-wise skills and survival mechanisms to have
ture, for example, it appears more evident that the actually benefitted from the policy.
assets have deteriorated significantly, and this is
It may just be that such characteristics become
showing its effects with service delivery violence,
engrained in the genes. And those who lived by
shocking water status reports with video evidence
entitlement will have regretted not understanding
of the state of the rivers, wet lands, water and
the implications of the second law of thermody-
sewage plants.
namics.
When the free handouts are no longer possible
Concealed from the public
The extent of breakdowns and accidents in the
distribution network is generally concealed from
the public as the safety investigation routines have
also declined. The recent 250MVA transformer fire
in De Aar was too big however to avoid the email
rounds.
The great pothole saga is of course very evident
to the public, with the consequent damage to
suspensions and noticeable increase in new tyre
sales. Low cost housing has not done much with
the need to destroy and rebuild R3 billion worth
of previously “built” houses. It is not as though
the current building technology is rocket science
– they are simple constructs that any reasonable
contractor should be able to build to last.

Feb 2010 VOLUME 60 NUMBER 2
Featured on the Cover Contents

Donaldson Filtration Systems
Tel: (011) 997-6000 Monthly Column Pipes, Pumps & Valves
Fax: (011) 608-0021 8 Skiing Without a Boat 27 Nowhere to Stick
Email: 31 Riding Out the Storm
marketing.sa@donaldson.com
Cover Story
11 A Bulk Filtration Solutions Offering
Website: Material Selection
www.donaldson.co.za 35 Catching the Eye
Oil & Gas
12 Oil & Gas Conference Exhibition
2010 Regulars
15 Fabrication in Saldanha 3 An Engineer’s View
18 New Kid on the Block 6 Institution News
Copyright 33 Nuclear Institute (SA Branch)
All rights reserved. No editorial
matter published in “SA Mechani-
Compressors and Vacuum Pumps 34 INCOSE
cal Engineer” may be reproduced 21 Filling the Vacuum 39 Market Forum
in any form or language without 25 What’s in a Name? 46 On the Move
written permission of the publish-
ers. While every effort is made to
ensure accurate reproduction, the
editor, authors, publishers and
their employees or agents shall
not be responsible or in any way
liable for any errors, omissions or
inaccuracies in the publication,
whether arising from negligence or
otherwise or for any consequences
arising therefrom. The inclusion
or exclusion of any product does
not mean that the publisher or
editorial board advocates or rejects
its use either generally or in any
The monthly circulation is 4 242
particular field or fields.
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
DTP Zinobia Docrat/Sanette Lehanie
 INSTITUTE FOR CERTIFICATED MECHANICAL AND
Disclaimer ELECTRICAL ENGINEERS
PROMECH Publishing and The South African Institution of Mechanical
 SOUTH AFRICAN ASSOCIATION OF CONSULTING ENGINEERS
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the opinions expressed by individuals.  ASSOCIATION OF SOCIETIES FOR OCCUPATIONAL SAFETY
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THE SA INSTITUTION OF MECHANICAL ENGINEERING
What’s Happening?
Council 2009/2010
SAIMechE Boardroom for hire
Office Bearers The comfortable and spacious boardroom
President .................................................. G Barbic (George) at our Bruma offices is currently under-
President Elect ............................................. D Findeis (Dirk) utilised, and offers an opportunity to provide
National Treasurer ................................. K Nyangoni (Kudzai) a service to both Institute members and the
greater mechanical engineering community.
Branch Chairpersons The newly-renovated and air-conditioned
Central ...................................................... M Cramer (Mike) boardroom with modern furniture can com-
Eastern Cape ............................. Prof Dr DG Hattingh (Danie)
fortably seat 12, and has abundant power
KwaZulu/Natal ........................................... AG Fileczki (Alex)
outlets for laptops. A remote-controlled
Western Cape ......................... Prof B Collier-Reed (Brandon)
ceiling-mounted data projector as well as
Portfolios: a flip-chart with pens are provided.
Communications .............................................. CD Reay (Chris) This facility would suit those looking for a
Education - Universities................... Prof JL van Niekerk (Wikus)
centrally-located professional meeting venue,
Education: Universities of Technology............... E Zawilska (Ewa)
easily accessible from OR Tambo International
Membership .................................................... E Zawilska (Ewa)
Airport and Gillooly’s Interchange.
Seminars and Workshops.................................. D Findeis (Dirk)
Technology Programme ................................. SZ Hrabar (Steve)
Chief Executive Officer: Vaughan Rimbault

National Office Manager: Anisa Nanabhay
PO Box 511, Bruma, 2026
Tel: (011) 615-5660, Fax: (011) 388-5356
Email: info@saimeche.org.za
Website: www.saimeche.org.za
Membership: Central, Eastern Cape & KZN:
membership@saimeche.org.za
Membership: Western Cape: saimeche.wc@vodamail.co.za
Company Affiliates
Ainsworth Engineering (Pty) Ltd Hire rates (excl. VAT):
Alstom Power Service SA
Babcock Africa Limited Members
Bateman Engineered Technologies • Brief ad-hoc meetings (depending on
Fluor SA availability): no charge.
GEA Air-cooled Systems
• Booked meetings: R100 for morning/
Hansen Transmissions SA
Hatch Africa afternoon; R150 for the whole day.
Howden Power Non-members
Industrial Water Cooling • Brief ad-hoc meetings: not offered to
Megchem Eng & Drafting Services non-members
Osborn Engineered Products SA
Rotek Engineering • R400 for morning or afternoon; R700
RSD a division of DCD-Dorbyl for whole day
S.A.M.E Water
Tea, coffee and biscuits will be provided as
Sasol Technologies
well as water and mints.
SEW Eurodrive
Siemens Ltd Free wireless secured internet access also
SNC-Lavalin SA available.
Spicer Axle SA
Spirax Sarco SA
We do not provide other snacks and drinks
Thyssenkrupp Engineering and these would be for own account and
Transvaal Pressed Nuts & Bolts arrangement.
Vital Engineering Anisa, Tel: (011) 615-5660, Email: info@saimeche.
Weir Warman Africa org.za.
Winder Controls

THE SA INSTITUTION OF MECHANICAL ENGINEERING
SAIMechE Saldanha Branch

SAIMechE Council is considering a branch in Saldanha, and
needs to know whether there are sufficient SAIMechE members
in the area who would benefit from a local branch. Member Ken
Vaughan (who works in Saldanha) has volunteered to manage
this initial phase.
Judging from the responses sent to Ken, we will set up an initial
meeting in Saldanha to discuss the implications of a local branch,
and then move to establish a committee. From then on it will
be up to the committee to drive things. Although the branch
is a members’ initiative, it will hopefully also help to increase
SAIMechE membership in the area.
We ask that you contact Ken with comments or suggestions via our National
office on email info@saimeche.org.za.
Geoff Alder - Consultant, author, publisher and

SAIMechE’s Refrigeration course developer
Captivated delegates at a recent Cape Town workshop led by Geoff Alder on “Psychrometrics and Psychrometric
Principles”
Training Events Calendar - 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
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
Skiing Without a Boat

On a perfect summer’s day “SA Mechanical Engineer” set off the water from fixed pylons erected on a course
to do a story on waterskiing at a dam in Midrand. Coming over around the dam.
the last ridge we could clearly see some skiers skimming the The difference
smooth surface, others flying through the air off ramps and yet According to the skiers, the feel on a cable ski is
more negotiating wide turns at the other end of the dam. But slightly different from riding behind a boat. The
as we come closer to the water, there is something distinctly higher angle of pull on the cable ski makes bigger
missing, not a single roaring power boat ploughing through the air jumps and sharper turns possible. Generally
water in sight. there are ramps and sliders for the riders to use,
W
but wake boarders also have a trick whereby they
elcome to cable skiing! Cable skiing is ‘load the line’ by putting tension on the rope and,
a way to water ski or ride a wakeboard, using the water as a spring, fling themselves into
where the skier’s rope and handle are the air in order to carry out somersaults or similar
pulled by an electrically-driven cable, routines.
whereas traditionally a water skier is pulled by a Though it is possible to do this behind a boat,
motorboat. The ski mechanism consists of two the higher angle of pull and the slight jerk on the
cables running parallel to one another with carri- corners of the course, allows good riders to attain
ers between them, allowing several skiers on the much higher jumps. We speak to Nic Malton who
water at the same time. regularly goes on the cable ski. “I do it for fun and
You have to create momentum from the cable that’s depending on the mood I’ll either use a surfboard
running at a constant speed or the wakeboard,” he says.
“The main difference between skiing behind a boat
The carriers are metal plates with hooks on and the cable ski is that the you don’t have the
them which allow the tow rope to be attached boat’s wake on the cable. Behind a boat you can
and detached easily without shutting the system use the wake to launch and get into the air for a
down. The cable is generally suspended above trick, but on the cable you have to create momen-

MONTHLY COLUMN
tum from the cable that’s running at

a constant speed.
“You go wide to pick up speed and
then, when the cable picks up the
slack this creates, it gives you a firm
pull and sudden momentum that
helps you to get into the air. The
other thing you have to learn is to do
tricks near the base station because
unlike a boat which is able to turn
around to come and pick you up, on
a cable system you have a long swim
back to shore if you fall on the other
side of the dam.”
How it works
On our visit to Base 3 Leisure Lakes
in Midrand, we quickly learn how the
system works mechanically. At the A typical cable ski course from the air
base station, an operator manually
hooks the ski rope onto the main cable carrier was formed in the same year as a steering com-
mechanism. The operator then asks the skier mittee and has held a number of very successful
whether he or she is ready and passes the ski rope competitions over the years. At the beginning of
handle to him where he’s waiting on the jetty. As the season in 1996, the association held its first
the carrier approaches, the operator simply throws recognised national competition and together, with
a lever to engage the ski rope and seconds later, the formation of two clubs, gained recognition within
the skier is gently pulled onto the water to do his the South African Water Ski Federation.
thing around the 800 metre course.
If the skier falls, he simply lets go of the ski rope Have a long swim back to shore if you fall on the other
and has to work his way back to the shore while side of the dam
the rope continues on back to the base station
where it’s manually dislodged from the carrier to The association in conjunction with Aventura held
be readied for the next skier. The cable travels the hugely successful championship in 1998 at
at a speed similar to that of a boat’s speed in the Aventura Spa where two world records were
tournament water-skiing, with a top speed of 58 broken.
kilometres per hour. A few years later, Mike O’Connell opened Leisure
South Africa Lakes in Midrand which is a very well-supported
A far-sighted Allen Louw of Aventura installed the site that holds regular events.
first South African cable ski at the Warmbaths Spa Mike O’Connell, XS Promotions, Tel: (011) 314-3589,
in 1993. The South African Cable Ski Association Email: info@xspromotions.co.za
Skiing on a cable ski is only slightly different from skiing behind a boat

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10 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

COVER STORY
A Bulk Filtration
Donaldson Filtration
Systems (Pty) Ltd
(DFSPL) has signed
contracts with
Solutions Offering
numerous oil
companies to provide
bulk filtration for
mining sites.
D
FSPL designs and sells bulk filtration A set of filters was installed on the downloading
systems. Currently, their focus is in side with a water separator and particle removal
Africa, having provided solutions for filters. The same set of filters, were installed on
clients in over 15 countries, including the transfer pump to the day tanks and to the dis-
South Africa, Mali, Ghana, Niger, Guinea, Cote pensing hose reels for the dump trucks and small
D’Ivoire and Zambia. In the near future, three ad- vehicles respectively. Breathers were also installed
ditional regions will be supported: South America, to complete the process.
the Carribean and Asia.
Two samples
Once an inquiry is received, Donaldson’s bulk A sample was taken before the filters on down
filtration technical division evaluates the project, loading and one from the hose reel for the dump
informs the client of what is required and designs trucks. These two samples were compared.
and sells the filtration system. This system is then
• Sample from down loading: ISO 26/23/18
installed on site by a local engineering company,
after which, a Donaldson technician travels to • Sample from hose reel: ISO 16/14/11
commission the site.
Setting a superior standard for bulk filtration cleanliness
Driving down TCO

Most recently, Donaldson worked on a project for
Bonikro Mine, a diesel site, in Cote D’ Ivoire. Once
the filtration system had been installed, Deon Cilliers,
technical support engineer, travelled to the site for
inspection of the installation and commissioning.
Deon states, “In these modern times of high pres-
sure fuel injector systems, it is imperative to have
cleaner fuel in order to save downtime and main-
tenance costs and therefore drive down TCO (total
cost of ownership)”.
The Worldwide Fuel Charter requires an ISO 4406

particulate cleanliness specification of 18/16/13.
Bearing this in mind, it is clear Donaldson is setting
a superior standard for bulk filtration cleanliness.
Donaldson provides a value-added service to clients
through assistance with design, commissioning and
the selection of a bulk filtration system. A com-
prehensive after sales support structure provides
advice, recommendations, technical assistance
and spares.
Donaldson Filtration Systems provides solutions
for all bulk fuel and oil filtration. It is committed
in providing industry with superior filtration solu-
tions.
Donaldson Filtration Systems (Pty) Ltd, Mariette Venter;
Tel: (011) 997-6000, Fax: (011) 608-0021, Email: marketing.
Sample comparison sa@donaldson.com, Website: www.donaldson.co.za
THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 11

OIL & GAS 2010
Oil & Gas 2010

Billed as being “Bigger, Better and Busier than ever
All before”, the conference and exhibition was previ-
ously known as Oil Africa and has been updated to
sectors of
emphasise the increasing role that gas production
the Oil, Gas, Petrochemical
is playing in the industry.
and related industries are set to converge
on the Cape Town International Convention Centre Typically, delegates and exhibitors hail from the likes
(CTICC) between Tuesday 16 and Thursday 18 March 2010, of Angola, Botswana, Burkina Faso, Cote d’Ivoire,
when OIL & GAS AFRICA 2010 – the continent’s leading Canada, China, DRC, Egypt, France, Ghana, India,
Oil, Gas and Petrochemical Engineering Supply Chain event Italy, Kenya, Korea, Madagascar, Monaco, Mozam-
– takes place daily between 10h00 and 18h00. bique, Namibia, Netherlands, Nigeria, Portugal,
Russia , South Africa, UAE, UK, USA, West Indies
and Zimbabwe.
W
ith key international and local plenary Oil & Gas Africa 2010 is sponsored by Sasol
speakers in the line-up, the 2010 SPI (Gold sponsor) and the Petroleum Agency
conference retains its ranking as one South Africa (Bronze sponsor). The event is
of the top events on the African Oil endorsed by Provincial Government Western
and Gas calendar and Southern Africa’s leading Cape, City of Cape Town, the South African
industry interface globally. Oil and Gas Alliance (SAOGA), the Western
With a wide range of topics covering everything Cape Investment & Trade Promotion Agency
from Upstream Developments in Africa to Technical (WESGRO), the South African Supplier De-
Papers on Rig & Platform Design, the mix of plenary velopment Agency (SASDA), the South Africa
conference, seminars, briefings and workshops is – Angola Chamber of Commerce, Offshore
expected to attract in the region of 750 delegates Petroleum Association of South Africa, SA
from throughout the African continent. Capital Equipment Export Council, the South
African Petroleum Industry Association (SA-
Opportunity to interact with African national PIA), and the Cape Town Regional Chamber
independent oil companies from Ghana, Nigeria and of Commerce and Industry.
elsewhere
Great interest Confirmed speakers

As the fourth iteration of this event, Oil & Gas Africa Confirmed speakers include:
2010 seeks to explore the challenges faced by the • Ebbie Haan – Managing Director: Sasol SPI. [Based
sub-Saharan and African Oil & Gas markets during in Johannesburg, South Africa]
economically uncertain times. The previous three
• Dr Martyn Davies – CEO: Frontier Advisory. [Based
saw the presence of 10 000 visitors, 800 delegates
in Johannesburg, South Africa]
and in excess of 500 exhibitors.
• Kamal Dorabawila – Head of Oil and Gas in Africa:
The event comprises both a conference (16-17
International Finance Corporation (IFC). [Based
March) and exhibition component (16-18 March). The
in Washington, DC, USA]
exhibition, for its part, will prove of great interest
for suppliers to oil refineries, petrochemical plants, • Advocate Barrisford Petersen – Head Oil & Gas:
oil and gas installations and pipelines. Bowman Gilfillan. [Based in Cape Town, South
Africa]
• Chris Bredenhann – Advisory / Partner: Price-
Exhibitors WaterhouseCoopers. [Based in Cape Town,
• Welding Alloys SA (WASA) South Africa]
• Afrox
• Techtra • Stuart Griffin – Schlumberger. [Based in Lon-
• Renttech SA don, UK]
• Esab
• Transcape
• Eduardo Lopez – Senior Oil Demand Analyst:
• Technoswitch International Energy Agency (IEA). [Based in
• Zulfi Welding Electrodes Paris, France]
• De-Tect Unit Inspection
• Messer-Eutectic SA
Says John Thomson, managing director of co-or-
ganisers, Exhibition Management Services: "While

OIL & GAS 2010
the continent's growing importance as a new source

of crude oil is attracting an increasing number of Designed to educate and inform, the SAIMechE Technical Seminar
Afro-centric oil industry meetings and conferences, will once again run alongside the Oil & Gas Africa Conference.
our event, Oil & Gas Africa, now in its fourth edi- With a number of key industry specialists. Confirmed topics will
tion, is still the largest and only Engineering Supply include:
Chain exhibition.
• Offshore Engineering Developments over the past 30 years
“At the last event we had 3 522 visitors attending
from 34 countries. With the ongoing discoveries • Design of Jacket Structures
being made on Africa's West Coast Oilfields and • Selection of Steels
increasing numbers of operators working there, we
• The Design and Installation of Near-Shore Subsea Pipelines
expect the attendance to increase significantly at
our 2010 event." • Pressure Vessels
Active participant • Rotating Equipment
“Petroleum Agency SA has been an active par- • Offshore Power Generation
ticipant in Oil & Gas Africa since its inception,
• Environmental Regulations in Off-Shore Industry
both as exhibitor and sponsor,” says Dave van der
Spuy, Manager Petroleum Resource Evaluation at • Design for Lifting Operations and Transportation
Petroleum Agency SA, which is the South African • Welding of Offshore Structures
agency for the promotion of petroleum exploration
and exploitation. “We are proud to announce that • Structural Design of Topsides
we will once again be exhibiting. In addition, we will • Corrosion Protection
be sponsoring the attendance of ten representatives • Project Quality Assurance
of entry level HDSA owned companies, allowing
them to attend at half price. • Design of Piling Systems
“This will afford them the opportunity to network with
others in the industry, giving them the opportunity
to publicise their capabilities, form synergies with AGM and two days of Downstream Workshops for
providers of related services and make themselves the week leading up to exhibition.
known to the primary users of services: the explora- Friday 19 March has been set aside for the South
tion companies.” African Oil & Gas Alliance (SAOGA) golf day.
Modalities for financing projects Admission to the Oil & Gas Africa 2010 Trade Ex-
Paul Runge, Conference Director and Managing hibition is open to all South African businesses.
Director of Africa Project Access, has the follow- Says Warwick Blyth, Executive Director, South African
ing to say: “This, the 4th Oil & Gas Africa Expo Oil & Gas Alliance: “We look forward to building on
and Conference, is of particular significance in the solid foundation of the previous three years as
that it will provide an opportunity to interact with we continue with the development of the Western
African national independent oil companies from Cape & South African Oil, Gas & Energy Industries
Ghana, Nigeria and elsewhere. The rise of these and strengthen its international ties. We confirm
private African oil companies in the upstream and our support for this initiative and look forward to
midstream sectors is a new and interesting phe- meeting many new international participants and
nomenon providing an important new client base welcoming them to the Mother City of South Africa
for suppliers. as well as those who have been working with us
“Another important aspect is the event’s emphasis before and not forgetting our regionally-based col-
on modalities for financing African oil and gas proj- leagues, clients and suppliers.”
ects. The keynote address by Kamal Dorabawil, oil To register for the conference, visit www.
specialist at the International Finance Corporation fairconsultants.com. To register as a visitor
in Washington, is especially appropriate within to the exhibition, visit www.exhibitionsaf-
this context.” rica.com.
Working in conjunction with their respective South
African Business Chambers and Economic Counsellors
from the Department of Trade & Industry, organisers
have scheduled inbound buyer/delegate groups from Please make a point of visiting
the various African oil producing countries.
“SA Mechanical Engineer’s”
In addition, industry related associations and stand at
organizations are planning various complimentary
technical workshops, seminars and briefings to Oil & Gas Africa 2010.
supplement the main conference. The African Refin- We’d love to see you!
ers Association, for example, has scheduled their

OIL & GAS 2010
Fabrication in Saldanha
The port of Saldanha is best known for “SA Mechanical Engineer”
its iron export facilities, but over the past speaks to Steve Hrabar,
couple of years, long-term infrastructure immediate Past President
developments have progressed to include of SAIMechE and director
the establishment of a fabrication facility to of the South African Oil &
serve the oil and gas industry off the African Gas Alliance, who has for
west coast. This steel fabrication facility is many years been actively
built on the same site where the fabrication involved in promoting the
development of such a
and construction of the 14 500 tonne fixed-
facility at Saldanha. “Gri-
leg platform jacket for the Mossgas offshore
naker LTA has now been
platform took place in the 1980’s.
appointed as the operator Steve Hrabar
of this facility and they
hope to get the ball rolling with projects this year,”
he says. “The company is familiar with this type
of heavy fabrication work as they had a similar
yard in Nigeria.”
Offshore projects
The fabrication site is well equipped for the con-
struction of offshore oil and gas projects with the
first phase of the centre consisting of a fabrication
yard of 220 000 m2 that includes an open weld-
ing area, high bay fabrication workshops with 15
and 25 tonne capacity gantry cranes, a blasting
and priming workshop, a pipe spool fabrication
workshop and an electrical and instrumentation
workshop.
Other facilities include material warehouses, cus-

OIL & GAS 2010
toms control and a bonded warehouse, a 35 metre

load-out quay, high mast flood lighting as well as
medical and first aid facilities.
Serviced by a fleet of mobile cranes, fabrication ca-
pacity will focus on the fabrication and construction
of jackets, process topside modules, decks, booms,
bridges and sub-sea infrastructure.
More suitable for the manufacture of the

various components for offshore platforms
Background
“Originally, after the Mossgas project, it was hoped
that future offshore projects would be available in
South Africa and internationally, however this was
not possible and the site lay fallow until 2006,” ex-
plains Steve. “Due to the offshore activity on the West
Coast of Africa, the National Ports Authority formed
a committee to see what infrastructure changes they
would have to implement to support the oil and gas
activities on the West Coast.”
The committee was made up of representatives of
businesses in engineering and project management,
fabrication and construction, ship repair, upstream
development and logistics.
Base to operate from
Joining this committee was the Provincial Government
of the Western Cape, National Ports Authority, Industrial
Development Corporation, the Department of Trade
and Industry, South African Revenue Service, Chamber
of Commerce, Petroleum Agency of South Africa and
the West Coast Business Development Centre.
“An interim report was issued in August 2003 and a
final report in September 2004,” adds Steve. “The
report recommended that the Saldanha fabrication
facility be re-commissioned and a dry-dock be con-
structed to support the activities in Saldanha Bay. In
addition, a dedicated berth should be allocated for
repairs to rigs and oil and gas vessels in Cape Town
so that the ship repair industry would have a base
to operate from.
Offset
“MAN Ferrostaal, who supplied three submarines

OIL & GAS 2010
to the South African Navy, had

an offset obligation to the South
African Government and they
became interested in the recom-
mendations of the NPA report and
commissioned an Investment Op-
portunity Analysis in the Marine
Sector,” adds Steve.
“This analysis was examined by
MAN Ferrostaal who targeted two
opportunities on which a Due
Diligence was performed. Once
approval had been given by the dti,
to these opportunities, a business
plan was developed, including lo-
cal business to participate in the
venture. In 2006 new buildings
were erected and the fabrication
site was re-commissioned.”
When the NPA Oil & Gas Com-
mittee submitted their report,
the Provincial Government of the
Western Cape created a Section
21 Company called the South
African Oil & Gas Alliance, where
business and government mar-
keted the abilities of South African industry to the Arduous process that will take some time to resolve
offshore oil and gas market. “This company was
formed in 2004 with the strategy of creating the “There have been discussions whether to locate the
infrastructure so that businesses could cooperate offshore oil and gas business in Saldanha Bay or
and compete with other countries for the West keep certain activities in Cape Town,” says Steve
African market,” Steve elaborates. in conclusion. “Cape Town has an existing dry-dock
but is not suitable for semi-submersible rigs as
“The plan for the infrastructure was to have a fab- they are too wide to fit into the facility. There are
rication site in Saldanha Bay, a dedicated berth in ongoing talks between the Provincial Government
Cape Town harbour for repairs and maintenance of the Western Cape, Transnet National Ports Au-
to rigs, the building of a dry-dock and establishing thority and the Saldanha Municipality to plan the
an onshore base to support offshore activities,” he road ahead, but this has been an arduous process
adds. “Two of these plans have come to fruition that will take some time to resolve.”
with the dry-dock and the onshore base being fol-
lowed up as funds become available.” Steve Hrabar, Tel: 082 558 8656, Email: stefanzh@iafrica.
com
Components
Although Saldanha Bay is the
deepest and largest natural port
in Southern Africa, and has
the capacity to build complete
platforms, fabrication work for a
complete platform may very well,
like the Mossgas project, also be
distributed to other harbours such
as Cape Town and Durban.
“As they’re currently doing, Cape
Town harbour’s repair facility can
work on complete rigs and there-
fore we foresee that Saldanha will
initially be more suitable for the
manufacture of the various com-
ponents for offshore platforms,”
explains Steve. “These include
jackets, bridges, outriggers, decks
and modules.

OIL & GAS 2010
New Kid On The Block

in 1904 and the development of the world’s first
There’s a new player in the South African welding industry welding electrode, Esab has contributed to the welding
and all indications are that this firm is rapidly following market with a continual stream of innovations. This
in the footsteps of its mother company, a global leader in includes submerged arc welding in 1937, gravity
welding supplies and associated services. In light of a man- welding the year after, TIG-welding in 1944 and
ufacturing industry that can only grow, the South African then in 1947 MIG/MAG welding.”
industry has welcomed the influx of new technology which More milestones
this company is bringing to the table. Other technological milestones in the company’s
history are plasma cutting in 1955, cored wires in
1956, robot arc welding and narrow gap welding
S
A Mechanical Engineer” speaks to Chris Eibl, in the seventies, low moisture electrode coating,
the managing director of Esab Africa Welding bulk pack of wire and high speed cored wire in the
& Cutting, who elaborates on the company’s 80’s. In the nineties they brought out friction stir
history and the advantages of the product welding technology called SuperStir and in 2001
range offered to the local market. “Esab is a world introduced the first modular platform for welding
leader in advanced welding and cutting solutions equipment.
Most recently they came up with AristoRod, and
Seventy years of cutting experience and a constant keen advanced surface coating wire which was followed
ear for our customers’ needs by the Qset function in 2005. In 2008 Esab was
the recipient of the Frost & Sullivan Global Welding
with a product and geographical spread that is Consumables Customer Excellence Award.
unrivalled in the majority of the world’s markets,”
Services
he says. “Our global representation covers
The company’s services and product range is ex-
five continents and has 35 manufacturing
tensive, ranging from cutting systems, to welding
locations to serve customers throughout
equipment, accessories and consumables. “Seventy
the world.
“From the company’s
foundation in
Sweden

OIL & GAS 2010
years of cutting experience and a constant keen most products. “Our range includes covered elec-
ear for our customers’ needs have resulted in an trodes, cored wires, solid wires, TIG rods, strips
extensive range of products, from thermal cutting and fluxes, covering all customers’ needs for every
technologies such as plasma, oxy-fuel and laser type of welding,” says Chris. “The company has
cutting systems, to new waterjet cutting technolo- tailored its range of consumables to the requirements
gies,” says Chris. of the South African market with the introduction
“One of our specialities, welding automation, has of consumables that conform to ASME II, Part C
advantages such as high quality, capacity and SFA 5.01, Schedule H, I, J, K, Class S3, C3, C5
much better productivity. We develop and produce and T3.”
a wide range of mechanised and automated welding Replace the old technology of copper-coated wires
systems to meet any need, tailored specifically to within the next decade
each user’s special requirements and needs.”
As far as welding equipment is concerned, Esab’s The invention of advanced surface coating (ASC) on
systems are based on solid-state technology. “The MIG wires has proved to deliver significant savings
latest generation of welding equipment can be to welders across the globe. “This next generation
programmed with specific process preferences for of MIG wires will replace the old technology of
individual needs or for the actual welding processes,” copper-coated wires within the next decade,” Chris
explains Chris. “State-of-the-art plasma cutting predicts. “Already over 50% of Europe has moved
equipment is available in manual, mechanised away from old copper-coated wires.”
and precision mechanised formats. This range is Esab packaging solutions for consumables combine
rounded off with our highest quality welding PPE production efficiency with environmental responsi-
and accessories.” bility. The Marathon Pac wire delivery system can
offer truly non-stop production in robot applica-
Consumables
tions, meaning zero downtime for spool changes
Esab is one of the world’s leading manufacturers
and zero downtime for drum changes when using
of consumables with a vast array of approvals on
the endless wire set-up.

OIL & GAS 2010
premium alternative that is unrivalled in terms of

product quality and worldwide acceptance. Fabrica-
tors now have access to this leading global welding
and cutting brand.
“We’ve acquired the best people in the industry
both in terms of technical and business compe-
tence to the extent that our local personnel have
a combined experience in the welding market of
over 150 years,” he adds proudly.
Slick supply chain
For enhanced customer service, the entire supply
chain has been outsourced to specialists in this
field, namely Hellmann Worldwide Logistics, a
global company that has extensive coverage of
the southern African market. “Hellmann has ware-
houses in Johannesburg, Durban, Port Elizabeth,
East London, Cape Town and many other African
countries.
“This unique distribution network enables us to react
We’ve acquired the best people in the industry both in quickly to changing market demands and offers a
terms of technical and business competence seamless supply of products to the market. With our
Commitment business partners, often referred to as distributors,
“Esab has committed itself to the southern Afri- we have the geographical coverage and presence
can market with the establishment of Esab Africa to support all the needs of all southern African
Welding & Cutting,” says Chris. “For the first time fabricators,” says Chris in conclusion.
we’re now a part of the welding and cutting market Chris Eibl, Esab Africa Welding & Cutting, Tel: (011) 240-
in southern Africa, bringing customers a viable 4000, Email: chris.eibl@esab.co.za

COMPRESSORS AND VACUUM PUMPS
Filling the Vacuum

Although the How it works
The liquid ring principle used in a vacuum pump
operation of a vacuum pump
compresses gas by rotating a vaned impeller within
is straightforward, it’s easily installed
an eccentric space in a cylindrical casing. Liquid,
incorrectly and then even the slightest air leak usually water, is fed into the pump and, by centrifugal
in the feed system to the pump will cause it to run acceleration, forms a moving cylindrical ring against
inefficiently. For a closer look at vacuum pumps “SA the inside of the casing. This liquid ring creates a
Mechanical Engineer” speaks to André Vorster, director of series of seals in the space between the impeller
Horma Pumps in Edenvale. vanes to form compression chambers.
The eccentricity between the impeller’s axis of
rotation and the casing’s geometric axis results in
J
a cyclic variation of the volume enclosed by the
ust because the pump is turning does not
vanes and the ring, creating a vacuum at the inlet
mean it’s actually pumping effectively,”
port of the pump. Gas, often air, is drawn into the
he says. “The gap between the vanes and
pump via the inlet port and is trapped in the com-
the housing gets bigger over time due too
pression chambers formed by the impeller vanes
wear which reduces the pump’s performance
and the liquid ring. The reduction in volume caused
significantly.”
by the impeller rotation compresses the gas before
it goes to the discharge port at the other end of
the pump casing.
Doing it right
“Although the principle of a vacuum pump is simple,
many don’t fully understand its workings and they
just don’t get it right,” Ryan says. “Calls come in
regularly for us to help out in such instances. We go
to site, do a complete test of all the vacuum pump
systems and draw up a comprehensive report to
indicate the performance of each pump and whether
it needs to be serviced, repaired or replaced.”
Apart from repairs and service to all makes of
vacuum pumps, Horma Pumps also locally manu-
factures their own series used in the sugar, mining,
pulp and paper and petrochemical industries. “We
service the platinum mining industry extensively
and therefore Rustenburg is the one area where we
have appointed an agency,” adds Ryan. “The fact
that we manufacture locally allows a delivery time
for a new pump, built from scratch, of six weeks
as opposed to an import that usually takes around
three months to deliver.”
André Vorster, director of Horma Pumps (left) and sales manager, Ryan Testing
Baptista “We’ve also invested in an in-house test facility
in order to apply the necessary ISO certification
We apply a Monarch coating on all the wet-end standards as well as the different specifications
components to reduce wear that are required by each client,” says André. “Our
door is always open for customers to come in and
A simple vacuum test will immediately reveal this
witness the tests we do on their specific pumps.
or other faults such as an air leak in the system
This gives them the confidence that they’re getting
which forms part of the service that Horma Pumps
what they’re paying for,” he adds.
offers vacuum pump users. “We don’t charge to
test a vacuum pump system, provided the pump “In addition, we keep data packs for our regular
comes to us for repair,” says sales manager, Ryan customers containing site inspection reports,
Baptista. “Sometimes it’s not the pump itself, but specification and repair records,” says André.
rather a poor installation which causes the system “Through this we can see when a trend develops
to leak air.” and be prepared with the necessary stock when a

A complete vacuum pump, ready for delivery
pump has to be replaced instead of waiting for it parts, regular maintenance and supervision by a
to break down.” properly trained operator is crucial for a full pump
life. “The first thing that usually fails on a vacuum
Bearings and chemicals
pump is the bearing,” explains André. “The seal
Although vacuum pumps do not have many moving
starts leaking due to a lack of maintenance and

water gets to the bearing, contaminating it. It’s then

just a matter of time before it fails.
“To prevent this from happening, we’ve made improve-
ments in our design to reduce the risk of neglected
maintenance. The bearing cover is machined and
fitted with extra high quality seals to make sure no
water gets to the bearing.”
A unique feature of the Horma Pump series is a
special coating that can be applied to the inside the
pump housing to reduce chemical wear. “In chemical
processing, the acids eat away at the pump hous-
ing very quickly. As a counter measure, we apply
a Monarch coating on all the wet-end components
to reduce wear,” says Ryan. “We have instances
where a pump used to last six months in a chemical
application, but since we’ve coated it, it lasts over
two years.”
Since fitting these, we’ve had no failures

due to overloading of the system
A vacuum pump for refurbishment
Overloading
Another unique feature found only on Horma pumps
is a vacuum relief valve. “Through plant design, or
ignorance, operators often feed too much water into
the system which creates a very high vacuum that
either breaks the shaft or the second stage impeller,”
explains André. “We’ve come up with a vacuum relief
valve that will open in such a case to suck more air
and not water, thereby preventing the shaft of the
pump from being overloaded. Since fitting these, we’ve
had no failures due to overloading of the system.
“Vacuum pumping is not a complex concept, but if
you don’t know enough about it, mistakes can cost
you a lot of money,” says André in a final comment.
“Make use of reputable companies that are certified
to provide you with the right equipment from the start
and then it’s simply a matter of proper maintenance
to get the optimum life out of your pump.”
Ryan Baptista, Horma Pumps, Tel: (011) 452-4300, Email:
sales@horma.co.za

What’s in a
As much as everyone wants a premium
brand along with the technology, service and
longevity associated with it, not everyone
can afford it. However, if the premium brand
incorporates its technology and support into
Name?
lower end products, end-users can rest as-
sured they’re getting value for money.
T
his is what the company Multibrands is
all about. It offers a range of compressor
products that complement the high-end
range of compressors of its mother company,
Atlas Copco. “SA Mechanical Engineer” meets
with Chris Makume, manager of Multibrands in
South Africa, to talk about the Worthington and
Ceccato range of compressor products that are
now available on the local market.
Can’t afford all the bells and whistles of a premium

brand
Reaching the goal
“Recognising the market requirements, Atlas Copco
acquired Worthington Creyssensac and Ceccato,
both well respected international manufacturers
and suppliers of compressors and quality air prod- Chris Makume of Multibrands
ucts,” he explains. “In South Africa we established
Multibrands as an independent business unit to Ringing bells and whistles
market these products. The portfolio offers an extensive product range
including professional and industrial reciprocating
“The main objective
piston compressors, oil lubricated screw compres-
is to complement and
sors with fixed or variable speed technology, oil-free
enhance the well en-
units, compressor management systems, quality
trenched and highly
air products that include dryers and air receivers
recognisable premium
and spares. “In piston compressors the range, from
brand,” adds Chris.
both the Worthington and Ceccato brands, starts at
small units of 1.5kW and goes up to 11kW,” says
Chris. “The rotary screw compressors range from
11kW up to 160kW.”
To distinguish between the two, Chris explains that
Worthington compressors fit into the higher end of
the low-end market while the Ceccato range caters
for low-end users who are looking for machine reli-
ability but can’t afford all the bells and whistles of
a premium brand.
Serious support
“All the products feature low noise level technol-
ogy, reliability, energy efficiency and they’re easy to
install supported by service commitments from our
distributors across the country,” says Chris.
“We have established long-term business rela-
tionships with some of the reputable compressed
air companies in major provinces to market our
Multibrands products locally,” he elaborates.
“Maintenance and after sales service is sustained
at the Atlas Copco service levels that customers
have come to expect. Our distribution channels
enjoy 100% committed and dedicated product
A Worthington compressor

products before the acquisition, but have

since been improved by applying some
of the premium brand’s technology and
know-how to this range of air products.
Explains Chris, “Aspects like better en-
ergy efficiency and reliable availability,
for example, were incorporated in our
range of no-nonsense machines.
“Just because the Multibrands range is
aimed at the low-end market does not
mean the product is inferior in terms of
technology, it just means the end-user is
getting a machine with the basic essentials
of a reliable product,” adds Chris.
How it works
A typical Mutibrand customer is looking
for quality and reliability, while the Atlas
Copco customer looks for more, such as
LAN connectivity, remote monitoring and
control, etc.
Big brother is watching
Over five hundred Multibrands units have
marketing and after market support to ensure the already been sold through the fifteen distributors
necessary backup for customers.” currently in the local market. “This indicates that
we’re filling a niche requirement,” Chris states.
Top-of-the-range technology
“This business concept has also been implemented
Both Worthington and Ceccato were well-established
in other parts of the world, but the South African
setup, with Atlas Copco Compressor Technique
(South Africa) as the big brother, has proved to be
particularly successful.
Energy efficiency and reliable

availability in our range of no-nonsense
machines
“Even now, with the global financial crisis, there are

still lots of opportunities and we are confident that
Multibrands will continue to grow from strength to
strength in the South African market,” concludes
Chris. “We’re currently working on expanding the
local distribution network and intend to take the
concept up into Africa through suitable distributors
in the SADEC countries.”
Chris Makume, Multibrands, Tel: (011) 821-9141, Email:
chris.makume@ceccato.com

Nowhere to
Stick
T
Industrial sites like mining plants have sumps in here are clear pollution guidelines for deal-
the form of pits in the ground at the ing with effluent in industry, but complying
lowest points on the site. Wastewater and debris with these regulations can be hindered
is collected there so that it can controllably be by the unreliability of the types of pumps
pumped from these sumps to specific traditionally used in the industrial waste disposal
treatment areas like slimes dams or waste process. “SA Mechanical Engineer” speaks to Nico
disposal systems. This wastewater not only van Schalkwyk, general manager at Watson-Marlow
contains large abrasive objects, but also Bredel South Africa about this age-old problem.
chemicals, oil and other spills from all over the
site. This means there is an absolutely clear
path of flow with no valves, seals or
glands
Problems
“The sump provides an unglamorous yet essential
function in any industrial process or facility, because
the removal of wastewater and process liquids
maintains a clean and safe working environment
as well as allowing plants to comply with pollution
laws,” explains Nico.
“However, the capacity of industries to comply with
these regulations can be limited by the reliability
of their equipment. The sump pump that transfers
site effluent from the sump where it collects, to
the foul sewer where it is transported to a sewage
treatment works for decontamination, is notoriously
unreliable.
The lowest point
“Unfortunately, problems occur far too frequently
Nico van Schalkwyk of Watson-Marlow Bredel, South due to the challenging nature of the effluent as
Africa the sump is usually situated at the lowest point

PIPES, PUMPS & VALVES
of a process to allow waste to flow in freely and they are less than satisfactory for sump applications
therefore it is also the place where other items due to the challenging conditions.
will inevitably end their journey,” Nico adds. “The “In fact, they are particularly ill-suited to the task
liquid in the sump therefore often contains grit, oil, as the dust and grit causes wear in all three pump
rags and various items of debris. For many pump types, while debris can build up on the impeller
types, such abrasive effluent causes severe wear of the submersible and on the valves of the dia-
on the pump, while certain debris may block it phragm pump, obstructing the flow and causing
altogether and has the potential to cause the sump the pumps to block.”
to overflow.”
A solution
Has no difficulty handling thickened slurries up to An increasingly popular solution to the problem
concentrates of 80 percent solids is the peristaltic pump, due to its reliability and
capacity to cope with debris without blocking.
Equally vulnerable “Peristaltic technology is designed to handle dif-
Many site managers have overcome this issue by ficult applications where its non-contacting pump
installing secondary pumps that can take over op- mechanism wins over other pump types,” says
eration should the primary pump become disabled. Nico. “Where conventional pumps use valves to
The secondary pump can also run in unison during push liquid through them, peristaltic technology
peak times. However, as these pumps are usually employs pressing shoes to compress and release
of the same type, they are equally vulnerable to a hose. This means there is an absolutely clear
blocking and therefore can’t provide a long- term path of flow with no valves, seals or glands, and
solution to the issue. therefore nowhere for debris such as rags and
stones to get stuck.”
“The submersible is just one type of pump that can
be used for this application,” explains Nico. “Other Watson-Marlow Bredel SPX peristaltic hose pumps
types include diaphragm pumps and progressive are increasingly finding favour in demanding effluent
cavity pumps. These are often the first choice simply disposal applications. Unlike the submersible pump,
because operators know how to handle them, but the peristaltic self-primes and can be mounted at

Moving waste water with a peristaltic pump
ground level. This makes it much easier to access Extremely pleased

for maintenance as opposed to the submersible Maintenance is also as easy as replacing the hose
which has to be kept under the fluid level precisely which is the only part of the pump to get worn,
because it won’t self-prime. and it’s relatively cheap to replace too. Chemically
Portable resistant hoses can be changed quickly while the
“The SPX’s ability to achieve and maintain the pump itself is not affected by the substance, ensur-
specified flow rate is crucial to efficient flocculation. ing long-term reliability and endurance.
This and the fact that it has no difficulty handling
thickened slurries up to concentrates of 80 percent Maintenance is also as easy as replacing the hose
solids, makes it the ideal pump for these duties,”
Nico says emphatically. “Though not as cheap as “With sumps performing such an important func-
your everyday submersible, it does, at the end tion in any process, plants simply cannot afford for
of the day, provide a much more cost-effective them to fail,” concludes Nico. “So all our custom-
solution.” ers have been extremely pleased and relieved to
In addition, an occasional blockage caused by have finally found a reliable solution to their sump
a particularly large solid can usually be cleared problems.”
simply by reversing the pump. Flow can be re- Nico van Schalkwyk, Watson-Marlow Bredel South Africa,
directed easily by changing the rotation of the Tel: (011) 796-2960, Email: nico@wmbpumps.co.za
pressing shoes, and the sludge often found at the
bottom of a sump is no problem to pump straight
through. Above all, the peristaltic pump is easily
mounted on wheels, giving it the flexibility of just Log onto www.promech.co.za to
one portable pump system that can be used on all read back issues of “SA Mechanical Engineer”
the sumps on a site.

Long-awaited Development
C
ustomers in the fluid power and hydraulics
industry can soon expect a major upgrade
in the quality of hose assembly and hose
products. For several years, the industry has
been plagued with sub-standard materials
and inadequate knowledge of assembly and maintenance
techniques by poorly qualified staff.
Considering the negative consequences that affect numerous
applications in which hose and couplings are an integral formal guidelines. In future, all customers serviced by accred-
part, the council of the South African Fluid Power Associa- ited and certified SAFPA members will be assured of quality
tion (SAFPA) has resolved to remedy the situation by issuing components and assemblies that meet the standards set by
the SAFPA Hose Assembly Accreditation Scheme.
Approved products
The comprehensive guidelines
based on Standards set by the
British Fluid Power Association
cover a number of relevant issues
in hydraulic engineering, includ-
ing safety, especially relating to
compatibility of components used
in hydraulics systems. Specifica-
tions for assembly, testing and use
of recognised, approved products
will prevent the use of unmatched
hose and end couplings, the mixing
of inserts and ferrules from differ-
ent or unknown manufacturers,
and unbranded or reworked hose
end couplings – all potentially
dangerous.
Come on board
Further specifications relating to
health, training, quality control,
testing, storage, maintenance etc.
are contained in the guidelines and
are expected to streamline plant
operations and reduce excessive
downtime.
It is anticipated that the majority
of manufacturers and hydraulics
suppliers will come on board.
This scheme is a long-awaited
development and will bring South
Africa up to standard with global
operations.
Brian Rogers, SAFPA, Tel: (011) 888-
7163, Fax: 086-503-4524, Email:
ctr@safpa.org.za, Website: www.
safpa.org.za

Riding Out
the Storm
I
Equipment manufac- n addition to the recent major economic
turers really have a downturn, equipment manufacturer,
rough ride during a Weir Minerals Africa, had to cope with
recession. Raw materi- the long-term merger of CH Warman
als cost more, labour and Weir Envirotech to establish the
wants their usual company’s new identity while retaining
increases, utilities go customer confidence in their products.
up, customers want Also, the extensive product range result-
ing from the merger brought its own set
better prices because
of challenges. “SA Mechanical Engineer”
they’re struggling, yet
speaks to Rob Fawcett, operations director
manufacturers have to
of Weir Minerals Africa, about the chal- Rob Fawcett, operations director, Weir Minerals
remain competitive in lenges of the past 18 months. Africa
a market that gener-
ally has less money to Trends
spread around. “It’s been a very difficult time for us because “Although we’ve sold fewer pump units, the trend
we’re caught between our customers who is toward bigger ones and therefore we’ve made
need price relief and the market inflationary the necessary changes to extend our range of pump
pressures on our business,” he says. “We’ve had products to cater for this development. We have
to look very hard at our businesses and how we undertaken an unprecedented number of product
can assist customers by absorbing price increases. developments over the last 18 months which has
Looking ahead, there may be tougher challenges in required significant capital investment. We’ve also
terms of increased labour and utility costs. invested heavily in our manufacturing facilities to
“In spite of this we have not really experienced a ensure that the required efficiencies are achieved
downturn in business over the past year,” Rob adds. to remain competitive in a global market.
Issues
Although we’ve sold fewer pump units, the trend is
“Apart from extending certain equipment ranges and
toward bigger ones improving designs, we’ve also
looked at total cost of ownership
on some of the products out in
the field,” says Rob. “Customer
requirements are changing in
terms of labour becoming more
expensive and it being difficult to
secure skilled labour to operate
equipment. Therefore custom-
ers are expecting equipment to
last longer with fewer service
intervals.
Upgrades
“We’ve made a conscious deci-
sion to change the rubber com-
pound used in our products to
R55, a premium brand rubber
which dramatically increases
wear characteristics and avail-
ability in pumps and cyclones.
The R55 material is particularly
suitable for large particle erosive
View of new pump assembly facility with its in-line spray capability slurry applications such as mill

sues relating to the servicing of

a pump in terms of disposal of
the parts every time the pump is
serviced, are a lot more onerous
than they were five years ago,”
explains Rob. “So, the less the
pump has to be stripped for a
service, the less risk there is
for injury or disposing of parts
that may be hazardous to the
environment.
The company is focusing its
expertise on providing mill
circuit solutions with the sup-
ply of premium quality valves,
hydrocyclones and mill liners
Front view of Weir Minerals Africa’s Alrode manufacturing facility incorporating pump as- where applications typically
sembly, distribution and rubber manufacture involve heavy abrasive and/or
corrosive slurries that make
severe demands on the equip-
ment used.
Efficiency
“All this adds to operation costs
and we therefore addressed the
efficiencies of our products and
the processes within our two
manufacturing plants,” says
Rob. “Every product has a set
efficiency when it’s first installed,
but the question is, is this ef-
ficiency sustainable throughout
the life of the equipment? From
our side, new designs will ensure
that customers are optimising
efficiency over the lifespan of a
The new designated area for pulse line assembly of smaller units product.”
In general over the last 18
discharge applications,” adds Rob. “The compound months, the pump ranges available from Weir
and the manufacturing process are more expen- Minerals have been upgraded to the latest Weir
sive, but this cost was entirely absorbed by us. standards and technology. These have been ap-
This change alone has resulted in an approximate plied to achieve extended life and performance.
twenty percent improvement in wear performance “The pump might run a little better in terms of
of the pump unit.” throughput, but improvements will be noticeable
in terms of power consumption and extended wear
Whole new range of mill pumps with options of unlined performance.”
metal or a rubber lined unit New
Already on offer is Weir’s new SLR pump, a rub-
“Upgrade kits have been developed to increase the ber-lined, medium-to-light duty pump that has a
performance of our older tried-and-tested pump number of significant benefits. Rob elaborates, “It
technology. Improvements have been made to the is equipped with a double adjustment system that
impeller design and the sealing arrangements. allows for the pump to be adjusted while running,
The improved dry gland expeller sealing system reduced time to overhaul, and requiring a minimum
can be fitted during a single maintenance service number of replacement parts. “The design optimises
or fitted as components wear and require replace- the critical balance between wear performance and
ment. “For a heavy duty environment, there is a pump performance efficiency. These improvements
whole new range of mill pumps with options of all contribute to end-user assurance that they’ve
unlined metal or a rubber lined unit,” adds Rob. got the best possible option in terms of total cost
“These will be produced locally and released to of ownership.”
the market soon.”
Rob Fawcett, Weir Minerals Africa, Tel: (011) 617-0809,
“In addition, health, safety and environmental is- Email: r.fawcett@weirminerals.com

NUCLEAR INSTITUTE (SA BRANCH)
Without the Hot Air

By now, hopefully, everyone has heard of David MacKay’s least a thousand years. The question mark over clean
marvellously informative and readable book ‘Sustainable en- coal stems from the fact that even if sequestration
ergy – without the hot air’. It should be required reading for works, coal will not last that long.
everyone with an interest in energy. David J C Mackay is a Breeder technology
professor in the Department of Physics at Cambridge and, as The reservation concerning nuclear is that to be
of November 2009, Chief Scientific Advisor to the UK Ministry sustainable we must use breeder technology. He
of Energy and Climate Change. The 350-page book is a free declares himself insufficiently qualified to comment
download - except that it’s full of coloured diagrams and cost on the safety of breeder reactor systems. Nuclear
me R295 to have printed. Prof Mackay is clearly trying hard industry, please note the concern, it’s widespread.
to get his message across. There are presentations of vari- Finally, even with all sources tapped, Britain will
ous lengths available, presumably on video, and there is a ten not be able to find enough truly renewable energy.
page abstract on the web. He therefore envisages solar energy imported from
the Sahara, referencing the recently announced
H
German-led Desertec scheme.
e addresses the question of how the
UK is to support itself energy-wise with He comes up with five alternative plans for provid-
minimal recourse to fossil fuels. He says ing the 1,1 million GWh per year needed. That’s
he’s not necessarily pro-nuclear but he about four times the current South African usage.
is vigorously pro arithmetic. The various plans cater respectively for those who
don’t like the idea of importing energy, for those who
He’s not necessarily pro-nuclear but he is vigorously pro object to renewables sources cluttering the English
arithmetic countryside, for those who don’t like nuclear, for
those who don’t want either nuclear or coal, and
The book is full of revealing back-of-
for those who just want cheap energy.
envelope calculations. Did you know,
for example, that the ‘embedded’ ‘Rough costs’
energy of an average motor car is Nuclear looms largest in the last of these provid-
around 76 000 kWh, perhaps 14 ing over 60% of electricity generation. Finally, for
kWh for every day that you own a brief discussion of ‘rough costs’, he produces a
it? Goods imported into Britain median Plan M and an astonishing diagram show-
have an energy content of around ing how much of the British Isles would have to be
48 kWh per day for every man, given over to biomass and other energy generation
woman and child – plus 12 kWh activities to meet it.
for transportation into the UK. Plan M foresees respectively 23 and 29GW of
The three main primary energy on- and off-shore wind backed up by 30GW of
gobblers in Britain are indeed pumped storage. We also have 48GW of photovol-
transportation and space heating taic panels, 40GW of imported solar energy and
John Walmsley (both estimated at 40 kWh/d per 45GW of nuclear.
person) and electricity generation
Move the debate forward
(18 kWh/d per person). The author begins by
The numbers he uses for nuclear capex translate to
insisting that energy consumption must be cut,
about $2300 per kW installed which, after recent
transportation being a prime target. He calculates
escalation, is probably too low by a factor of two.
that with widespread electrification, principally the
That said, his capex estimate per unit delivered for
use of battery-power, the transportation energy bill
wind power (including pumped-storage back-up as
could be halved.
per Plan M) is 2,7 times greater than nuclear, im-
Heat pumps ported solar is six times more expensive and PV 25
Space heating energy use could be reduced by 25% times. The small contribution of clean coal in Plan
by better insulation and, particularly, by replacing M comes in at 1,4 times the estimated nuclear cost
conventional heaters with heat pumps. He is much – but subsequent fuel costs would militate heavily
more interested at this stage of the book in techni- against using coal, clean or otherwise.
cal feasibility than in cost implications. This is an entirely inadequate account of a mar-
He then sets out to discover where the required vellously informative effort to move the debate
energy is to come from - concentrating on UK re- forward. The hope must be that someone will have
newables, “clean” coal (perhaps), nuclear (perhaps) the energy to produce something similar for this
and on solar energy from the Sahara. He defines a country – and quickly.
sustainable energy source as one that will last at John Walmsley

INCOSE
What is a
Configuration Item?
A configuration item is defined as a deliverable item in terms of a development or a manufacturing contract.
There are additional criteria for designating an item as a configuration item. To continue with the previous ex-
ample: the customer has contracted a prime contractor to develop and construct a Spacecraft, and the Space-
craft is the configuration item in terms of that contract. One of the lower-assemblies is a Battery that is to be
reused in another spacecraft. That means that the customer, who has contracted to receive the Spacecraft,
needs to keep specification control over the Battery. The Battery is thus designated as a configuration item
even though it is not a deliverable. Similarly, items that have been standardised, or that need to be operation-
ally reprogrammed, or that are likely to be changed after initial deployment, should also become configuration
items.
I
s the concept of a configura- ration item is a contractor, since
tion item still valid once the • different items from a single contractor potentially
item is in operation? During form a single configuration item, and
the operations and support
phase, a configuration item • items from different contractors are by defini-
is determined by the selected tion different configuration items.
level of management. It is that A configuration item should be designable and
level where the user organises, producible by one contractor, and should be test-
assigns responsibility for and able as an entity — not as part of its next-higher
controls maintenance, supply, assembly.
procurement and modification
The selection of configuration items is a crucial
activities.
trade-off decision. Dividing a complex item into
Any item needing maintenance, separate configuration items to create more vis-
or that has been designated for ibility and easier control is self defeating. It results
separate procurement, is by in more management effort, more paperwork and
Ad Sparrius definition a configuration item. more coordination problems. It is similar to break-
Note that this is the same concept ing down a large contract into a few smaller ones.
as used during development and production, but Neither size nor visibility is a valid criterion for
the nature of the contract is of course completely selecting a configuration item. In general, fewer
different. configuration items are better.
Configuration items are the basic building blocks for The limit of resolution
configuration management A configuration item is not the level where configu-
ration management starts, neither is it the level
During development and production, all deliverable where it stops. Configuration management occurs
items contractually referred to are configuration throughout the product breakdown structure right
items. During operations and support, an end item down to the lowest level. But at the configuration
and all its subassemblies right down to items of item level the customer transfers configuration
supply (those items that populate the supply sys- management implementation responsibility to the
tem), are configuration items. Management occurs contractor. The customer controls lower-level items
at the level of items of supply, but it would not be indirectly, since their specifications are derived
possible to contract development and production from the configuration item’s specification, and
for those items of supply since they will only be configuration management responsibility is recur-
identified late in development. sively enforced by contract.
Computer software, since it controls functionality, Configuration items are the basic building blocks
is almost always designated a configuration item. for configuration management. A configuration item
Operational software should always be designated may be viewed as “the limit of resolution” since
as a configuration item but separate from support it is the lowest level of assembly that is visible to
software. the customer.
Fewer is better Ad Sparrius, 082-574-0266, Email: ad_sparr@iafrica.
The essential starting point for selecting a configu- com

MATERIAL SELECTION
Catching
Not all that glitters is gold. For centuries chrome plating
has given vehicles that extra bit of sparkle. Bumpers, door
handles, side mirrors, trimmings, rims and exhaust tail pipes
are the parts that are usually chromed on standard cars while
hobbyists go a bit further to chrome tappet covers, gear le-
vers, oil caps and engine nuts and bolts.
the Eye
We found a DIY kit to give your Hummer a chrome-
look for just over R10 000. Another option is to
polish the raw aluminium panels on your Audi TT
until it has the shine of a chrome finish and then
lacquer it to protect it from the elements.
The real thing
To do the real thing by chrome plating all the panels
on a car is by far the most expensive and tedious of
all. To find out whether it’s possible and how you’d
go about it, we speak to Laurence Segal director
of Edison Electroplating in Johannesburg. “It can
be done, but it will cost an arm and leg,” he says.
“If you can get the car in its raw metal state all
the better because then you forego the huge task
of stripping off the paint first, then smoothing the
metal surfaces of the various metals on the car to
a highly polished state before chrome plating.
“You’d need special tanks and anodes to accom-
modate the size of body panels over and above the
Mario Beltrame (left) and Laurence Segal of Edison Electroplating fact that the different metals making up a car have
to go through different processes for chrome plating,”
O
adds Mario Beltrame, the automotive specialist at
f course, there are always the extrem- Edison. “In electroplating, the preparation of the
ists. “SA Mechanical Engineer” found surface is crucial as even the slightest scratch can-
a Bugatti, a Lamborghini, Mercedes not be filled with electroplating, it’s just too thin.
and BMW’s on the internet that have So all surfaces would have to be polished to a very
been chrome plated completely, from the grille right smooth finish before you even start plating.”
through to the tailpipe including all the body panels.
The all-chrome 2009 Bugatti Veyron is the only Polishing
one in the world, but no word on how much it cost The process consists of first plating the polished
for the whole chrome treatment,
considering the car itself costs
about twenty million rand.
Turn your weather-beaten faded old jalopy

into a chrome lustre
How to do it
There are several ways of chrome
plating a whole car. By far the
easiest and cheapest is to take
a series of digital photographs of
your car from various spectacular
angles and then, using Photoshop,
turn your weather-beaten faded
old jalopy into a chrome lustre
that will dazzle all your friends
on Facebook. Another way is
to paint the car with a special
chrome-finish paint. Is this BMW real chrome or just painted?

MATERIAL SELECTION
A chromed Lexus
Even something for the ladies which they would not chrome plating onto the layer of nickel. “Considering
elaborate on that you’re doing an expensive sports car the final
surface of the raw metal with a layer of copper about finish can’t have any flaws, so all the layers, one at
as thick as a human hair, then it’s polished before a time, have to be well-polished.This would take a
it’s covered with a layer of nickel plating. In turn lot of time and very special care, but for the right
this layer is polished to a fine finish before finally money, I’d do it,” says gung-ho Laurence.

MATERIAL SELECTION
The polishing process consists of a

series of buffing wheels, coarse first
and then progressing on to finer and
finer buffing wheels. “The trick is to
remove small nicks and scratches on
the surface of the metal to be plated
as you go along as the quality of the
final finish depends on the previous
plating layers which are so thin that
they follow the contour of the surface
and won’t fill even very fine scratches
or indents in the surface”.
Plating
The actual plating isn’t long, however.
The base coat of copper acts as a
primer for the nickel metal to follow
and fills any minor imperfections in
the part. Generally, depending on the
size of the part, it will remain in the
copper tank anywhere from 20 to 45
minutes. Next is the nickel tank. This
is the beginning of a bright, quality
chrome job. Depending on the size
and shape of the part, a stay of around 30 min- people don’t mind the expense, they simply want to
utes in the nickel tank results in about a 1/1000 preserve the item,” says Laurence in conclusion.
to 1/2000 of an inch thick coating. Then finally Laurence Segal, Edison Electroplating, Tel: (011) 607-2011,
it goes to the chrome tank where it takes under a Email: laurencesegal@edisonsa.co.za
minute for a layer of chrome to deposit.
We’re just not prepared to take the risk

of guaranteeing such a weld
Laurence and Mario have electroplated plated

many weird things in their time, even something
for the ladies which they would not elaborate on.
But baby booties, cowboy hats, running shoes
and cutlery, apart from car and motorbike parts,
are by far the most popular items. “Silver plating,
brass, copper and chrome can all be done on non-
metallic objects,” says Laurence. “In fact, we’ve
just done the nickel plating on the headlamps of a
vintage Rolls Royce according to the original Rolls
specifications.”
Preserving the item
“Then, the owner of a Lear jet comes to us the
other day to have all the fittings and ashtrays in
his jet gold plated,” adds Mario. “The only thing
we’ve stopped doing is to chrome mags rims for
cars as there is a risk involved. Chrome is a slug-
gish compound and to get it into all the gaps of a
deep rim requires the rim to be cut in half and then
re-welded after the plating. We’re just not prepared
to take the risk of guaranteeing such a weld.”
People often confuse brass and gold plating or silver
and chrome plating as the difference in appearance
when these surfaces are polished is subtle, but the
experts at Edison will guide you in the right direc-
tion. “Gold and silver costs more because it is the
real thing, but when it comes to heirlooms most

Unmanned Flying Machines
S
outh Africa’s biggest supplier of Unmanned extensive. The availability of capable and affordable South
Aerial Vehicles (UAVs) systems, Denel (the African UAVs of various sizes will trigger the enhancement of
other being ATE) is respected for developing not only national security, but crime fighting, disaster man-
and producing some of the most rugged and agement, election monitoring and search and rescue. UAVs
reliable tactical UAV surveillance systems even provide benefits to the agricultural, mining, health and
in the world. While the US and Israel dominate the global environmental sectors.
market, there is scope for South Africa to use local skills Within the next five years UAVs will be used by a diversity of
to create market-leading UAVs to developing nations - a industries from policing poachers on coastlines, carrying test
market estimated at R2bn per annum. The South African specimens from remote clinics to laboratories for analysis, to
UAV industry aims to capture in excess of 20% of this end keeping an eye on livestock on farms, and will prove to be a
of the market at an estimated value of R400m a year. lucrative parallel market for international UAV players.
The global increase in operational use of UAVs is a direct South Africa has an enviable edge in comparison with the
result of lessons learnt by allied forces in Iraq and Afghanistan. many international (including European) countries intending
The surveillance benefits in the defence world of being able to enter the booming world-wide UAV market which is at-
to survey borders and enter war zones without a pilot are tracting an estimated R50 billion a year.
UAVs are not generally allowed to access civilian airspace
because current regulations were originally drafted for manned
flight. This is changing, with regulatory bodies across the globe,
including SA’s Civil Aviation Authority driving the process of
drafting internationally compliant, UAV friendly regulations.
International competition is fierce to master what is termed
‘sense and avoid’ technology aimed at enhancing the safe
use of UAVs in controlled airspace. Once this capability has
been perfected, the opportunities will lead to an explosion
in UAV demand.
Denel Dynamics, Shantall Tshoshane, Tel: (012) 671-1555, Email:
market@deneldynamics.co.za, www.deneldynamics.co.za
SKUA, High-speed Target Drone

Market Forum
Stopping blockages mid-market ERP and business software specialist 4most, to
The new generation Flygt F pump has been engineered to supply, install and commission a SAP Business One solution.
put an end to costly clogging problems in wastewater trans- A core requirement was greater control, tracking and infor-
port applications, and the use of this innovative pump will mation sharing for repair job costing and invoicing and for
eliminate unnecessary stoppages. the large and complex inventory, says Hydra-Quip managing
director, Bradley Flynn.
The pump is equipped with The new generation Flygt F
an impeller that rotates pump has been engineered “We needed safeguards. We hold 8 000 different
inside a cutting plate to put an end to costly line item part numbers and each has variations
giving it a heavy duty clogging problems so the total inventory amounts to about 40
chopping capability. 000 spares and components. Tracking and
This means that traceability of pumps, hoses, seals, metal
as fibrous waste pipes, clamps and other fittings were a
and debris pass critical requirement for us.”
through the im- Bradley adds that the SAP Business One
peller it is effort- system has been live for almost a year
lessly chopped and fully available since switch-on.
into small and “Initially it can be a little intimidating
easy-to-pump to new users and as laypeople we are
pieces. probably using only 20% of the system
The pump de- capability. That will increase as time
sign has under- goes on but in the meantime our audi-
gone extensive tor is getting the right information first
testing in the field, time, every time.”
and data shows What Flynn likes about the SAP system
considerably fewer is that there are a lot of features that safe-
running problems as guard the business. “Debits and credits are
well as lower energy totally accurate, debtors are properly managed
consumption. Both of these and creditors are easier to deal with. It works for us
translate into significant cost the way we want it to.”
saving on wastewater transport pump
Another bonus for Hydra-Quip is the fact that Rapid Trade,
installations.
an on-line marketing and sales tool that helps customers
An inspection chamber, between the seal unit and bearings, find the products they need and order them while they’re
increases operational reliability and allows for rapid spot on-line, easily integrates with SAP.
checks and easy maintenance. Should a seal leakage occur,
Colleen Bellas, 4MOST, Tel: (011) 234-3000, Email: colleen@logic-
a built-in sensor provides an early warning reducing the risk
group.co.za, Website: www.4most.co.za
of expensive repair work.
A patented impeller fastener facilitates faster removal, trim-
ming and mounting of the impeller, while the Flygt Plug-in™
seal unit ensures a perfect fit and simpler, quicker replace-
ment. This design also protects the seal surfaces during
disassembly and mounting.
The smoother, rounder design of the exterior casing keeps the
pump cleaner which is an important factor when servicing.
Catering to Rustenburg
Hydro-pyrometallurgical and mineral processing engineer-
Fewer external screws allow easy disassembly and reassembly
ing and project management company, K’Enyuka’s, recently
translating into greater productivity and less downtime.
opened a branch in Rustenburg.
Lanelle Wheeler, Itt Water & Wastewater, Tel: (011) 966-9300, Web-
site: www.flygt.co.za
“In spite of the branch opening just prior to the current re-
cession when many companies were tightening their belts,
K’Enyuka considers the branch to be an investment in the
future sustainability of its clients,” K’Enyuka business de-
velopment manager, Trevor Anderson, says.
“We recognised that in order to fully support our clients
on the western limb of the Bushveld Complex, we needed
Safeguarding the business to pay more than lip service and hence the opening of the
Hydraulic and pneumatic systems and equipment specialist branch and the subsequent addition of further staff mem-
Hydra-Quip has discovered the power of ERP accounting bers,” Trevor adds.
and financial software to take business control, traceability, “We have had many enquiries in the past three months, and
accuracy, transparency and stability to new levels. we optimistically believe that clients are reviewing old feasi-
The headquarters of Hydra-Quip in Pretoria West contracted bility studies or are considering new projects,” he adds.

Market Forum
In 1893, industrial expansion led to the
construction of one of the earliest but
most innovative river crossing systems
in the world: the Bizkaia suspension
bridge.
The bridge is constructed from riveted
steel girders. A bogey runs under the
span of the bridge and carries a gondola
suspended on 18 steel cables, which
transports pedestrians and vehicles
from one side of the river to the other.
The empty weight of the gondola is 20
tons.
To maintain its remarkable reliability, the
bridge is now driven by twelve Bonfiglioli
F302 UH40 24.4 P112 H3 gearboxes
powered by 2.2 kW, 3,000 rpm electric
motors with encoder control. Rated torque
is 176 Nm and the duty cycle is 1.9.
The gear motors are controlled by closed
loop vectorial frequency converters.
The main challenges of the application
The K’Enyuka Rustenburg branch are continuous operation all year around,
massive inertia (varying from 20 to 50
The company’s expertise covers project and construction tons), and an aggressive marine environment. Another strict
management in two areas: EPCM (engineering, procurement, requirement is the need to ensure excellent passenger comfort
construction, management) and LSTK (lump sum turnkey). in addition to total reliability.
“K’Enyuka can provide feasibility studies and reviews with Bonfiglioli parallel shaft helical F series gearboxes were
respect to conceptual studies; pre-feasibility, feasibility and selected as the most suitable product for the application
bankable feasibility and third party reviews,” Trevor says. because of their low noise operation and reduced angular
Project support in the form of document control, estimating, play (which translates into greater comfort) in suspended
procurement, cost control and planning take the hassle factor installations.
out of the project equation for clients. Their use also ensures that the installation is unaffected by
“We have decided to investigate platinum projects in other radial loading generated by alignment errors between the
areas, specifically on the eastern
limb and we will look at opening an
office in Steelpoort to support this
decision,” Trevor concludes.
Mike Symonds, K’enyuka, Tel: (011)
498-6000, Fax: (011) 498-6060, Web-
site: www.kenyuka.com
World’s oldest transporter

bridge
Portugalete is a small town of
some 50,000 inhabitants, not
far from Bilbao, in the Basque
region of Spain. The town was
founded in 1322 on the estuary
of the river Nerviòn.

Market Forum
bogey frame and its wheels. A high duty fac-
tor was calculated to suit input power and the
installation position was chosen to ensure that
all gearbox components run in a permanent
oil-bath. This helps ensure the operational
reliability that the application demands.
To ensure that the drive system is adequately
protected against the salt air, the gearboxes
are fitted with Viton seals and are externally
finished in a 200 μm thick coating of RAL9010
white epoxy paint.
Bonfiglioli Power Transmission Pty Ltd, Tel: (011)
608-2030, Fax: (011) 608-2631, Email: bonfigsales@
bonfiglioli.co.za, Website: www.bonfiglioli.co.za
To exacting standards
The latest in round separation design from
Sweco, available from Chamdor-based Lockers
Engineers, is the new generation MX Separator. Currently
available in 76-, 101-, 122- and 152-inch diameters, the The unit separates solids from liquids or segregates dry
separator is designed to increase safety, provide stronger materials into various sizes. Particles as fine as 400 mesh
construction and allow for a more sanitary process. (37 microns) can be screened, with up to 4 screen decks

Market Forum
incorporated in one Sweco separator. No special flooring or “Pall Ultipleat SRT (Stress Resistant Technology) filters,
foundation is needed and less working floorspace is required. which offer improved contamination control and increased
The simple and efficient design requires less horsepower. Other protection of components like pumps and valves, are used
features include long screen life and ease of changing. in industries that include aluminium extrusion presses and
The Sweco Separator is a vibratory screening device that continuous casting processes,” says Alick Granger, general
vibrates about its centre of mass. Vibration is accomplished manager, BMG Filtration.. “Ultipleat SRT high performance
by eccentric weights on the upper and lower ends of the filters ensure improved fluid cleanliness, high flow capability
motion-generator shaft. Rotation of the top weight creates and enhanced equipment protection in arduous operating
vibration in the horizontal plane, which causes material to conditions.
move across the screen cloth to the periphery. The lower “Increased reliability of the hydraulic system and better
weight acts to tilt the machine, causing vibration in the contamination control means fewer pump failures. Machine
vertical and tangential planes. reliability is also improved and downtime is significantly
The angle of lead given the lower weight with relation to the reduced.”
upper weight provides variable control of the spiral screening Efficient filtration reduces the frequency of pump and valve
pattern. Speed and spiral pattern of material travel over the repairs in extrusion presses due to excessive contamination.
screen cloth can be set by the operator for maximum through- Ultipleat SRT filters improve fluid cleanliness, extend the
put and screening efficiency of any screenable product...wet life of pumps and valves and the overall performance of the
or dry...heavy or light...coarse or fine...hot or cold. extrusion press.
The totally enclosed weight guard on the MX prevents “reach In continuous casting processes where systems are affected
in” injuries, complying with European CE Standards. The by variable displacement pump failures, recurrent proportional
extremely rugged construction of this machine utilises conical valve blockage, as well as excessive fluid contamination levels,
construction rather than flat plates which creates a more rigid Ultipleat SRT filters are installed on the pressure line and on
geometric structure. Additionally, the open base construction off-line loop circuits. High performance filtration stabilises
allows for cleaning underneath the unit, therefore preventing the cleanliness level, reduces piston pump and valve failures
dirt and product build-up. and improves machine reliability.
Johan Breet, Lockers Engineers SA, Tel: (011) 769-1420, Fax: (011) Alick Granger, BMG Filtration, BMG, Tel: (011) 620-1760, Fax:
762-4719 086-670-3347, Email: alickg@bmgworld.net, Website: www.bmg-
world.net
High performance filters

BMG, exclusive distributors of Pall Corporation’s range of
industrial filtration and separation systems in Africa, sup- Mimicking a caterpillar
plies a new range of filters that plays a vital role in reduc- Vanguard recently completed a project involving the
ing piston pump and proportional valve failures in many transportation and rigging into position of a cold box and
applications. exchanger for use in a smelting plant in Tsumeb, Namibia.
The company collected the items from Walvis Bay harbour
and transported them to site.
A modular trailer configuration was used which was 40 metres
long and featured a custom-made lightweight deck. “While the
cold box was only 29 metres long and weighed approximately
50 tons, the added length on the trailer allowed us to cor-
rectly position it on the trailer in order to make manoeuvring
on site easier. We were also able to transport the cold box
on a continuous deck without the use of a turntable,” says
James Robinson, Project Engineer, Vanguard.
“The modularity and hydraulic suspension of the trailer
worked to our advantage once on site because there were a
number of obstacles to overcome.”
Vanguard had to work around machinery and foundations
6 x Pall Ultipleat SRT UH 319 series on the pressure line protect on site, especially narrow foundation bolts that could not
the continuous casting process be driven over.

Market Forum
recently-launched Sonata,
beating the mid-size sedan
competition to market with
this exciting new technol-
ogy. GDI application will
subsequently be expanded
across the gasoline engine
family and applied to other
Hyundai models.
One serious limitation of
conventional fuel injection
is that as engine revolutions
increase, the valve open-
ing and closing times get
progressively shorter, thus
reducing the time available
to inject fuel. GDI avoids
this problem altogether by
positioning the fuel injec-
tor in the most optimal
location, directly inside
the combustion chamber
to offer unparalleled preci-
sion. With this shorter and
more direct path, far greater
control is attained over the
The 29 metre long cold box was slowly and precisely lifted using strand jacks combustion process. A
high pressure fuel pump
“Our modular trailer is extremely versatile and we basically injects the fuel at pressures of up to 150 bar, in precise
mimicked a caterpillar in moving over the bolts. It was a amounts and intervals.
slow and precise undertaking in which we would use the The injection is split into two phases to achieve optimum
hydraulic suspension to lift one tyre at a time straddling the combustion. In the first phase, the pilot injection and igni-
bolt, moving over it and then lowering the axle, in effect tion trigger the piston’s downward power stroke. Then, in
climbing over the bolts,” says James.
The trailers were then accurately steered into position, beneath
gantry towers which Vanguard used in conjunction with its
strand jacks to lift the cold box, and turn it 90 degrees into
final position. “We transported and lifted the cold box first,
then brought our gantry towers forward and rigged the 17
metre long, 40 ton exchanger into position.”
Bryan Hodgkinson, Vanguard, Tel: (011) 616-1800, Fax: (011) 615-
1012
First gasoline direct injection engine

Hyundai Motor Company has unveiled the 2.4 Theta II GDI,
its first gasoline direct-injection engine.
GDI marries three seemingly incompatible goals: GDI low-
ers emissions while raising power output and improving
fuel economy. Prior to GDI, a gain in one area came at
the expense of the other two. With a compression ratio of
11.3:1, the 2.4 Theta II GDI delivers 201ps@6300rpm
and 25.5kg.m@4250rpm.
Developed with a budget of 170 billion won over a 46 month-
long research period, the new 2.4 Theta II GDI engine will
make its debut in the first half of 2010 starting with the Hyundai 2.4 litre Theta II GDI Engine

Market Forum
the main injection phase, during the piston’s descent, more This incinerator has been installed at Allerton Laboratories
fuel is injected and is ignited. This split-injection technique in conjunction with a top mounted chimney stack, with ac-
reduces loading on the catalytic converter and helps lower curate natural draught control. Access ladders have also been
emissions. This is particularly beneficial during cold starts attached to the system and will be used for future emission
when emissions are highest because the catalyst has not tests that will be conducted as required by DEAT.
reached its optimal operating temperature. Split-injection The Macroburn incinerator, with no moving or wearing parts,
enables the catalytic converter to reach the optimal operating has automatic control for combustion rates, temperature
temperature faster thus reducing emissions by 25 percent and air movement.
during cold starts.
Arnold Retief, Advanced Industrial Technology (Ai-Tec), Tel: (032)
Compared with a conventional engine of the same displace- 552-2658, Email: arnold@zsteam.co.za, Website: www.ai-tec.co.za
ment, GDI delivers 7 percent more torque at low revolutions
and 12 percent more torque at the high-end for better take-
off and overtaking performance. And perhaps best of all, a
vehicle equipped with a GDI engine will get about 10 percent
better mileage than a vehicle equipped with a conventional
multi-point fuel injected engine.
Jacques Geurtse, Hyundai, Tel: (011) 372-0800, Email: jacquesg@
hyundai.co.za, Website: www.hyundai.com Largest seawater desalination plant
VWS Envig has been awarded the contract to refurbish an
existing desalination reverse osmosis (RO) plant for the Albany
Coast Water Board (ACWB) at Bushmans River Mouth, next to
Kenton-on-Sea, 100 kilometres
east of Port Elizabeth.
Specially-designed incinerator Once the refurbishment is com-

Macrotec, Ai-Tec’s manufacturing facility, has recently completed, the ACWB desalination
pleted the fabrication and installation of a specially-designed plant will have a throughput
incinerator for Allerton Laboratories - KZN’s provincial diag- of 1800m3 per day, which is
nostic veterinary laboratory, based in Pietermaritzburg. the largest desalination plant
in South Africa.
“This Macroburn V330C incinerator, which was designed and
manufactured according to stringent EU emissions standards, The contract, awarded in Au-
as well as ISO 9002 specifications, also meets the required gust 2009, involves maintain-
Department of Environmental Affairs and Tourism (DEAT) ing a supply of potable water
specifications for the incineration of animal carcasses,” says while the existing plant is being
Arnold Retief, a director of the Ai-Tec Group. refurbished, the supply of a
new RO skid, as well as the
“This incinerator, which has an efficient emission control integration and optimisation VWS Envig Project Engineer
system that eliminates potential obnoxious emissions, is of existing plant equipment. Gareth Kearns
unique in this country because of its operating principle The project also includes the
which produces no smoke. implementation of energy saving devices
to improve efficiency and reduce opera-
tional costs, as well as the running and
maintenance of the plant for a year.
The project has been challenging as VWS
Envig’s design team needed to consider
means by which to implement modern
solutions and technologies into existing
plant infrastructure. Gareth Kearns,
Project Engineer, VWS Envig, explains,
“With a greenfield project it’s easy to
stipulate, design, and build facilities
which meet the exact requirements of the
equipment being installed. A brownfield
project on the other hand requires that
you adapt your equipment and installation
techniques to meet the requirements of
the existing infrastructure.
Gareth Kearns, VWS Envig, Tel: (021) 871-
1877, Fax: (021) 872-2664, Email: info.
vwsenvig@veoliawater.com
Macroburn incinerator Allerton Laboratories in use

Market Forum
Largest trommel
The largest self-driven trommel
ever built by Multotec has been
successfully commissioned at
the QMM’s Mandena Mine in
Madagascar where it is installed
in the mine’s heavy minerals
process plant.
Anthony Yell, product manager
screening at Multotec Manufac-
turing, says the trommel has the
same diameter as the one which
was manufactured for Hillendale
more than ten years ago, but it
is far longer. “This massive trom-
mel has a 3.5 metre diameter, is
15 metres in length and weighs
just under 50 t,” he says. The
Multotec self-driven trommel will
process 3200 tph of dry solids
or 5943 m3/h of heavy minerals
slurry. “This is almost double
that of the Hillendale trommel,”
Anthony says.
The Multotec trommel being loaded onto a truck at the harbour
Rutile and zircon will be the
primary minerals recovered by
this process plant, and Anthony says that one of the uses
of these is in the manufacture of paint.
Spaltoflex hand cast polyurethane panels, each 1086 mm
x 1000 mm, have been fitted to the trommel. These large
panels, with slotted apertures were selected as they provide
good life and are easier to replace during maintenance. The
trommel also has steel rubber-lined bolt-on scrolls to convey
the feed through the trommel in a uniform manner.
The trommel is equipped with a peripheral discharge ar-
rangement and is driven by a Hägglunds variable speed
drive system. “This hydraulic drive system facilitates vari-
able speed allowing optimisation of the screening process,”
Anthony concludes.
Multotec Group, Bernadette Wilson, Tel: (011) 923-6193, Email:
marketing@multotec.co.za, Website: www.multotec.com
Greater than its capital cost

The need for accurate compressed air flow monitoring has
never been greater as South African power costs are set to
escalate yet again! As a guide to the cost of compressed
air, a 185kW air compressor will consume more money in
electricity in the first year of operation than its capital cost!
The majority of energy management engineers agree that a
large percentage of cost savings for almost any company can
be found in the compressed air sector of any plant.

Market Forum
The DS 300 system of static or mobile compressed-
air monitoring provides plant engineers with all the
answers on the status of their compressed air system.
It provides accurate data on flow, pressure, tempera-
ture, dew point amps drawn, pipeline velocity, and
most importantly air leak losses.
From this, the state of the plant is easily assessed and
corrective action to fix air leaks or install improved
control systems can be taken as necessary. Available
to purchase or to hire with the help of a technician,
the DS 300 range from Artic Driers International is
an excellent choice for any company looking for ac-
curate information. Artic is a distributor and service
agent for a broad range of compressed-air treatment
products.
Artic Driers International, Tel: (011) 425-3484, Fax: (011)
425-3462, Email: allen@articdriers.co.za, Website: www.
airinstruments.co.za
On the Move SEW Eurodrive has appointed a new young engi-

neer to their team. Gert van den Berg will assist
in developing business in the Northern Cape.
Dot Coetzee has been appointed as Account
Manager: Sasol New Business Development based
at Honeywell’s head office in Midrand.
Bosch Projects (Pty) Ltd, part of the B & A Group,
has made the following appointment announce-
ments: William Leshilo is non-executive director
of Bosch Projects, and Paul Hamilton is senior
business manager, Sugar.
Gert van den Berg Dot Coetzee William Leshilo Paul Hamilton
Subscription
Index to Advertisers
Please fax us if you wish to subscribe to “SA Mechanical En-
gineer” at R400,00 (incl postage and VAT) per year; R945,00 Artic Driers 37
per year for Africa/Overseas. We will post you an invoice on AST Inside Front Cover
receipt of your fax. Atlas Copco Outside Back Cover
Bonfiglioli Inside Back Cover
PROMECH PUBLISHING Fax No: (011) 781-1403
Ceccato 23
From:...................................................................................... CerAdvance 38
Chorus Call 45
(insert your name)
Donaldson Outside Front Cover
Title: ...................................................................................... ESAB 4
Engen 22
Company: .............................................................................. ILS 24
Address: ............................................................................... Messer 16
Multi Alloys 26
............................................................................................... Multotec 28
Oil & Gas Africa 2010 14
...................................................................Code: ..................
SAID 36
Telephone: ( ) .................................................................... Spirax Sarco 30
Tegnon 20
Fax: ( ) ................................................................................
Voith Turbo 41
Email:..................................................................................... Weir Minerals 10

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Power & Diversity - for every Application.
Atlas Copco is a leading manufacturer of fully comprehensive, technologically advanced air packages
as well as their own range of fully compatible filters and dryers. The right solution for every application.
Legendary customer care & after sales service. Full range of generators with super silent options also available.
•Compressors (oil-free & oil-injected) •Scroll •Portable Air Compressors •Dryers •Filters •After Coolers
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Atlas Copco - committed to sustainable productivity.
Atlas Copco South Africa (Pty) Ltd

P O Box 14110, Witfield 1467
Tel: (011) 821 9000, Fax: (011) 821 9106/7
E-Mail: air.compressors@za.atlascopco.com
www.atlascopco.com / www.atlascopco.co.za

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THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 

 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

State of the Nation

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 

Featured on the Cover Contents

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 

Chief Executive Officer: Vaughan Rimbault

 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

SAIMechE Saldanha Branch

Geoff Alder - Consultant, author, publisher and

Training Events Calendar - 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 

Skiing Without a Boat

 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

tum from the cable that’s running at

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 

Mines don’t make money when they

Weir Minerals Africa is committed to

10 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

Setting a superior standard for bulk filtration cleanliness

Driving down TCO

The Worldwide Fuel Charter requires an ISO 4406

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 11

Oil & Gas 2010

Great interest Confirmed speakers

12 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

the continent's growing importance as a new source

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 13

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 15

toms control and a bonded warehouse, a 35 metre

More suitable for the manufacture of the

16 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

to the South African Navy, had

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 17

New Kid On The Block

18 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 19

premium alternative that is unrivalled in terms of

20 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

Filling the Vacuum

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 21

A complete vacuum pump, ready for delivery

22 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

water gets to the bearing, contaminating it. It’s then

Since fitting these, we’ve had no failures

A vacuum pump for refurbishment

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 23

Can’t afford all the bells and whistles of a premium

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 25

products before the acquisition, but have

Energy efficiency and reliable

“Even now, with the global financial crisis, there are

26 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 27

28 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

Moving waste water with a peristaltic pump

ground level. This makes it much easier to access Extremely pleased

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 29

30 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 31

sues relating to the servicing of

32 THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

Without the Hot Air

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010 33

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010

THE SOUTH AFRICAN MECHANICAL ENGINEER VOL 60 February 2010