African Fusion August 2015

SAIW Member profile: Hydra-Arc SAIW: Adopting wo ld-class fabrication

A Pemamek water wall panel being set up for fabrication at Steinmüller’s Pretoria West facility. Pema automatic welding systems were installed by several South Africa-based fabricators for producing membrane wall panels for the Medupi and Kusile boilers. (photographed in 2013).

The Kusile power station under construction during July 2015. The erection of Unit 1 (left) is nearing completion and local component and structural steel fabrication is now complete, leaving South African fabricators facing difficult times.

the country, because of the significantly better efficiency that new super-critical power stations produce,” argues Blake, “Emissions will also be improved be- cause much more effective emission control technologies can be installed,” he adds. “Our fabrication industry developed considerable amounts of experience through the Medupi and Kusile project work, so I am sure it will be able to build Coal 3 and Coal 4 power stations far more effectively now. All of the design changes and manufacturing challenges are resolved, so repeat projects would progress far faster and more cost ef- fectively than either Medupi or Kusile,” he predicts. “We know that the period between 2008 and 2014 was a very vibrant one for South Africa’s fabrication industry. The two power station projects, along with the World Cup stadium construc- tion projects, had an enormously posi- tive effect on the economy as a whole, shielding us from the worst effects of the global economic downturn,” Blake reminds African Fusion . “Projects such as these have a huge multiplying effect on downstream and upstream industries, creating jobs in mining and steel making; engineering, manufacturing, fabrication and con- struction; and all the way through to logistics, financing and management. Andwe are now in a better position than we were to localise the construction of additional coal-fired plants,” he says. Could a nuclear new-build pro-

safety critical welding applications,” Blake advises. In addition, he would like to see more welders trained in the use of modernwelding technologies. “Welders need to be trained to embrace technol- ogy andwelding automaton. Productiv- ity in South Africa is, unfortunately, rela- tively poor and advanced technologies can have a significantly positive impact on quality and productivity. In addition, the younger generation has grown up in this digital age, with smartphones, tablets and computers. The use of tech- nology is not new to them and it may, in fact, make welding a more attractive career choice,” he adds. Fabrication for a vibrant economy South Africa has a large workforce, which is necessary when implement- ing large projects such as Medupi and Kusile. For these two projects, however, most local fabricators have now deliv- ered on their allocated contract work and many are relatively idle right now. “This is having a serious impact on em- ployment and the entire steel industry is struggling at present,” notes Blake. “I am a firm believer that we should immediately invest in more coal-fired power capacity. The key reason is that many of our power plants are using old technology, which ismuch less efficient, and they are also nearing (or beyond) their end of life. Replacing these power plants with newer, more efficient coal technologies would be a positive step towards reducing the carbon footprint of

Blake’s vision is for the widespread adoption and rollout of the IIW International Welder programme to all welder training schools, following which, schools need to be accredited as Authorised Training Bodies (ATB’s) in the IIW scheme. gramme have the same affect? “Nuclear needs to be part of our future but we really need more time, training and up skilling before we attempt to build a nuclear power infrastructure for our- selves,” Blake responds. “In the short term, the only sensible nuclear plant procurement strategy is to appoint a foreign contractor to build own and op- erate. We will, almost certainly, have to import many of the skills and high-end components. Very little benefit in term of jobs and economic growth is likely to accrue to South Africa. Citing some positive developments for the local fabrication industry, Blake says that several rail projects are un- derway “progressing slower than the economy needs” but accelerating. “And the renewable generation projects are starting to have a positive impact. “South Africans have always been able to change adversity into opportu- nity. I am confident that, by adopting modern best-practices with respect to fabrication and welder training, we will pull though these difficult times and emerge as a top-tier fabrication destina- tion,” Blake concludes.

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August 2015

AFRICAN FUSION