African Fusion November 2017

NOVEMBER 2017

Journal of the Southern African Institute of Welding

AFRICAN

www.esab.co.za

ESAB South Africa +27 (0) 11 240 4000 1A Booysens Road, Booysens, Gauteng salesjhb@esab.co.za

ESAB / www.esab.co.za

Contents

November 2017 FEATURES 4 Record numbers celebrate welding success SAIW held is 69 th Annual dinner and Awards on Friday October 20, 2017 at Emperors Palace inGauteng. With actor and presenter Jason Greer as Master of Ceremonies and the Supreme 3 – Tebogo Louw, Danny K and Loyiso Bala – singing Mowtown era classics, record numbers of welding industry stakeholders turned up to celebrate the industry’s success. 7 Afrox presents Harvey Shacklock Gold Medal On 20 October at Emperor’s Palace in Johannesburg, in celebration of 90 years in the gases and welding industry and in honour of its founding CEO, Afrox presented the prestigious Harvey Shacklock GoldMedal Award at the 69 th SAIW Annual dinner. 8 Visual Testing: the first line of defence SAIW’s NDT Training Manager Mark Digby talks to African Fusion about the increasingly important role of Visual Testing (VT) and its place as an NDT method in own right. 10 The MegChem way: long-term support: well beyond project scope African Fusion visits MegChem/SecMet in Centurion, Pretoria and talks to Andrew Seebregts, the company’s principal welding engineer, and Ronald Koenis, business unit manager for metallurgical engineering. 14 Modified GTAW orbital tube-to-tubesheet welding technique and the effect of a copper weld retainer during welding of alloy 825 This paper won the SAIW Harvey Shacklock Award in 2017 for its principal author Angel Krustef. 18 The influence of helium content in shielding gas on metal melting characteristics for narrow gap GMA welding Presented in Shanghai at the IIW 2017 International Conference in June this year, this work details research done at the Harbin Institute of Technology in China. 23 Afrox unveils welding school at LIV Village The LIV Welding Academy is a custom container welding school that was developed by Afrox in partnership with LIV and the Southern African Institute of Welding (SAIW). 24 Stainless welding consumables with low Cr VI emissions Oerlikon has developed a new range of stick electrodes and flux-cored wires for Grades 308L, 309L and 316L stainless steel that significantly reduce fume and Cr VI emissions. 28 Renttech outlines renewed focus under Bidvest Renttech SA’s DuncanWhitehead is striving for ‘business as usual’, but at higher than ever levels of service, product and technical excellence. 30 Seamless SAW basic-cored wire improves productivity In a step to further improve submerged arc welding productivity, voestalpine Böhler Welding has introduced SUBARC T55 HP, a seamless cored wire for submerged arc welding applications. REGULARS 3 Sean’s comment 12 Front cover story: ESAB South Africa refocuses for growth 28 Welding and cutting 32 Today’s technology: Thermal spray coatings and solid particle erosion

Published four times a year and mailed out together with MechChem Africa by: Crown Publications cc Crown House Cnr Theunis and Sovereign Streets Bedford Gardens 2007 PO Box 140

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Bedfordview 2008 Tel: (011) 622 4770 Fax: (011) 615 6108

Editor: Peter Middleton E-mail: peterm@crown.co.za Advertising: Helen Couvaras E-mail: helencou@crown.co.za Publisher: Karen Grant Deputy publisher: Wilhelm du Plessis Cover design: Afrox Production & layout: Darryl James Circulation: Karen Smith Printed by: Tandym Print, Cape

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African Fusion talks to Chris Eibl, who has returned to formally re-establish ESAB South Africa as the premier supplier of the world leading ESAB brand in Southern Africa, about the entity’s expanding facilities at How- den Africa and his vision for better servicing the welding industry.

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www.africanfusionmagazine.co.za

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November 2017

AFRICAN FUSION

SAIW: Sean's comment

SAIW and SAIW Certification

SAIW Governing Board President: Morris Maroga – Eskom S Blake – SAIW L Breckenridge – CEA G Joubert – SAISI A Koursaris – Metforensics DJ Olivier – Olivier Survey Group A Paterson – University of the Witwatersrand T Rice – Personal member J Tarboton – SASSDA JR Williamson – Wilconsult J Zinyana – New Age Welding Solutions SAIW Certification Governing Board Chairperson: G Joubert – ArcelorMittal B Beetge – Sentinel Inspection Services P Bruwer – Sasol Synfuels F Buys – TUV S Blake – SAIW G Buitenbos – Steinmüller G Joubert – SAISI A Koursaris – Metforensics D Olivier – Olivier Survey Group H Potgieter – SAIW Certification P Pistorius – University of Pretoria R Williamson – Wilconsult J Zinyana – New Age Welding Solutions M Maroga – Eskom S Moodley – SAPREF

I am thrilled to report that, despite a very difficult year for the welding industry and the economy in general, nearly 400 people attended our 69 th An- nual Dinner in October, a record number

and the biggest event we have ever held. Thank you all. And congratu- lations to all our winners, you represent the excellence that we are striving for at SAIW. I amparticularly pleased to have recognizedWillie Rankin this year with the Institute’s Gold medal. Willie, I believe, was instrumental in setting SAIW on the path to excellence. He steered the organisation in the direction of sound business practices – and we have now become financially self-sustaining – and he supported Jim Guild throughout the transformation of SAIW into the highly respected, IIW-accredited and internationally recognised body it is today. Congratulations also to Afrox on its 90 th anniversary and many thanks, not only for the sponsorship of this year’s dinner, but also for the initiative, 69 years of work, involvement and support that Afrox has provided since SAIW’s inception. And next year SAIWcelebrates its 70 th Anniversary, which we intend to do in similar style. As I reported at the Annual Dinner, our ISO3834 Company Certifica- tion is attracting significant numbers of fabricators. We now have 154 Certified companies on the scheme, and most of these have adopted Part 2 Certification, the highest level of weld quality. This reflects the increasing value companies are placing on weld quality and SAIW’s role as the custodian of quality and standards in welding. Philippus Terblanche, our young welding champion, has now re- turned from World Skills Abu Dhabi, unfortunately without a medal. We do not think his result in the competition reflects his true skills level, however, and we thank him for his dedication to the task, all of the time spent away from home and the training effort he put in. Thanks also to those who went the extra mile to prepare Philippus for the competition: Lincoln Electric for the use of the facilities and for the training in the USA; ArcelorMittal for the support during his apprenticeship and training; Chieta for their invaluable support and generous sponsorship; as well as Etienne Nell and Eduan Terblanche, who were directly involved in the skills training. We remain committed to the SAIW Welding Challenge and to partnering with the DHET and WorldSkillsSA for the welding skill. We still feel SAIW is best equipped to provide effective training at the high levels required for success. On the welding skills development front, we are pleased with the progress being made to establish new QCTO-based training programmes at TVET colleges. With the DHET, two pilot delivery programmes are being prepared at Boland TVET College in Worcester and the Eastern CapeMidlands TVET College inUitenhage. SAIW is cur- rently passing on training expertise as well as advice on the welding curriculum, equipment and resources required. Our latest piece of exciting news is that, in January 2018, SAIW is acquiring the assets of the NDT Academy of South Africa (NASA) Cape Town. This will enable us to deliver our internationally recognised ISO9712NDT training courses inCape Town, as a complementary offer- ing to theWelding Inspection andWelding Technology courses already on offer through the Cape Town Branch. To cater for an expected qua- drupling of training activity, the SAIW branch will be expanding at the Milpark Centre onKoeberg Roadwhere our branch is currently located. We hope you all have a safe and relaxing Christmas break and that 2018 brings certainty and stability to the economy and steady growth to our welding industry. Sean Blake

SAIW Foundation Board Chairperson: M Maroga - Eskom S Blake - SAIW P Pistorius - University of Pretoria P Venter – ArcelorMittal J Pieterse- Afrox

SAIW and SAIW Certification representatives

Executive director Sean Blake Tel: (011) 298 2101 sean.blake@saiw.co.za

Training services manager Shelton Zichawo Tel: (011) 298 2148 shelton.zichawo@saiw.co.za

SAIW Certification manager Herman Potgieter Tel: (011) 298 2149 herman.potgieter@saiw.co.za

NDT training manager Mark Digby Tel: (011) 298 2169 mark.digby@saiw.co.za

Executive secretary Dimitra Kreouzi

Technical services manager Riaan Loots Tel: (011) 298 2144 riaan.loots@saiw.co.za

Tel: (011) 298 2102 Fax: (011) 836 6014 dimitra.kreouzi@saiw.co.za Finance and administration manager Michelle Warmback Tel: (011) 298 2125 michelle.warmbank@saiw.co.za Cape Town branch manager Liz Berry Tel: (021) 555 2535 liz.berry@saiw.co.za SAIW regional representatives

KZN branch manager George Walker Tel: (087) 351 6568 george.walker@saiw.co.za

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SAIW: Annual dinner 2017

Record numbers celebrate welding success

SAIWheld its 69 th Annual dinner andAwardsonFriday October 20, 2017at EmperorsPalace inGauteng.With actor Jason Greer as Master of Ceremonies and the Supreme 3 – Tebogo Louw, Danny K and Loyiso Bala – singing Mowtown era classics, record numbers of welding industry stakeholders turnedup tocelebrate the industry’s success.

“ T his occasion offers a won- derful opportunity to get together with colleagues and friends and to acknowledge and reward thosewho havemade significant contri- butions to the Institute and the welding fraternity at large over the past year,” says SAIW President Morris Maroga in his welcome address. “Great achievement is usually born of great sacrifice and is never the result of selfishness,” he continues, quot- ing American author Napoleon Hill. “Through these awards, the Institute strives towardsworld-classperformance and to build a high achieving South African nation,” he says, beforewelcom- ing past SAIW presidents, Willie Rankin, Andy Koursaris and Robin Williamson; previous SAIW executive director, Jim Guild; award winners; and guests. He also congratulated Afrox on its 90 th Anniversary this year. “We acknowl- edge this commendable achievement and we are extremely grateful that you have chosen to celebrate your anniver- sary with us tonight,” Maroga says. Executive director Sean Blake fol- lows Maroga onto the podium: “Despite the difficult economic position that in- dustry finds itself in now, it is extremely encouraging to see the tremendous support that industry has provided to SAIW. Once again we have had an ex- cellent response to our annual dinner, selling all of the available tables for this venue,” says Blake. “I am also most grateful at the con- tributions we have received from our eight event sponsors tonight. Without your support this event would not have been possible,” he adds before also con- gratulating Afrox on its 90 th Anniversary. Turning attention to SAIW’s achieve-

ments in the past year, Blake reports that the SAIW Welding Inspector

The SAIW Presidents’ Award For NDT winner, Learn Mogane, flanked by SAIW President Morris Maroga and Sean Blake, SAIW executive director.

ister, “a tremendous achievement” that “would not have been possible without the support of our industry partners”. SAIW is continuing to expand and next year “we will be offering NDT courses from our branch in Cape Town, which is currently being expanded to accommodate this additional activity. We are also expanding our ISO 9712 SAQCCNDT scheme based on our ICNDT accreditation,” he says. “I would like to pay a special tribute to Jim Guild who completed his term as IAB Chairman and member of the IIW board at the Shanghai Annual As- sembly. Jim’s work and achievements in IIW have done both SAIW and South Africa proud. We would like to extend our sincere gratitude and thanks for his contribution,” Blake adds. “I look forward to reporting further positive SAIW and industry develop- ments at future annual dinners, but for now, please enjoy this evening with us,” he concludes. The SAIW Awards Following dinner and entertainment from Supreme 3, Jason Greer invites Sean Blake and Morris Maroga back onto the stage for the presentation of the SAIW Awards for 2017. Starting with the training awards, Greer announces that The Institute in- volves industry representatives in every aspect of the development of a course – the syllabus, the trainingmaterial and the examinations. “It does this to ensure that its training programmes and the qualifications that are issued are well suited to industry requirements. Using

programme was fully converted across to the IIW International Welding Inspec- tor (IWI) programme during 2017. From the beginning of this year we started of- fering the IWI Basic programme in place of the SAIW Inspector Level 1 course. “Skills development is a key area to ensure the success of the South African economy,” he continues. “In order to address the skills shortage problem, SAIWhas entered intoa long-termagree- ment with the Department of Higher Education and Training to assist in the pilot implementation of the new QCTO Welder programme in twoTVETcolleges, before extending the programme to all other applicable colleges,” Blake says, adding that SAIW believes that this will result in an effective welding artisan training programme for industry. “We have also made strides with the SAIW Welding Challenge. Late last year we ran this competition with both a senior and junior category, where the junior category winner fed into the WorldSkills programme. Two South Afri- can representatives competed in the Arc Cup in China and, I am very pleased to report, Samuekelo Mbambani won first prize in the Student Project category. “SAIW, along with Lincoln Electric, also invested extensively in the prepa- ration of Philippus Terblanche for the WorldSkills competition in Abu Dhabi,” he continues, adding that the results of WorldSkills show that there is still much work to be done in terms of welder skills in South Africa. SAIW’s ISO 3834 Manufacturer Cer- tification Scheme, Blake reports, now has 154 certified companies on the reg-

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SAIW: World Skills Welding

Aglika and Angel Krustef celebrate at the SAIW Annual Dinner 2017. Angel Krustev won the Harvey Shacklock Gold Medal Award.

Above: Manare Kola, who achieved a distinction in the Welding Inspectors Level 2 training course, receives her Phil Santilhano Memorial Award from Maroga and Blake. Right: Willie Rankin won the Institute’s Gold Medal award in recognition of his dedicated service to the Institute as the Institute’s President from 1998 to 2002.

T h e awa r d i s made in the name of Phil Santilhano who was one of South Af- rica’s leading weld- ing technologists, best remembered for the work he did on submerged-arc and

this approach helps ensure that gradu- ates from Institute courses have good prospects of employment and of meet- ing employer expectations,” he says. To be successful really takes special effort and SAIW aims to recognise the very best of its students through these training awards. The SAIW Presidents’ Award For NDT The SAIW Presidents’ award goes to the best NDT student. SAIW has been training NDT personnel for more than 30 years – the same period of time in which SAIWhas offered training inweld- ing. NDT is a very important part of the Institute’s programmes and SAIWwants to encourage more young people to enter this field, which offers good career opportunities. The Presidents’ award is made in the name of the past Presidents of SAIWwho have helped guide the Insti- tute to become a prominent part of the local welding industry and to be South Africa’s reference point for high quality training in welding and NDT training. The SAIW Certification Board gives this award to Learn Mogane for achiev- ing distinctions in SAIW’s Ultrasonic Testing Wall Thickness Level 1 and Level 2; Radiographic Testing Level 2; Magnetic Particle Testing Level 1 and Level 2; and Liquid Penetrant Testing Level 1 and Level 2 courses. Phil Santilhano Memorial Award The second training award of the eve- ning is the Phil Santilhano Award, which is presented to the best student on the Institute’s courses in Welding Supervi- sion and Inspection.

electro-slag welding of heavy wall pres- sure vessels. He became the Institute’s first full time employee when he was appointed Technical Director in 1977. “Our winner tonight is Manare Kola, who achieved a distinction in the Weld- ing Inspectors Level 2 training course,” announces Greer. The Harvey Shacklock Gold Medal is awarded to the author of the best technical paper presented at an Insti- tute event. Harvey Shacklock was the managing director of BOC, now Afrox. He was instrumental in founding the South African Institute of Welding and was the President when it was founded on 1 st March 1948. This awardwas named inmemory of his contribution to the welding industry and it was first presented in 1949. Afrox, part of the worldwide Linde group, generously donates a gold medal for the award. After showing Afrox’s 90-year cel- ebration video, Schalk Venter, the 11 th Afrox MD was called onto the stage to announce the recipient of the Harvey Shacklock Gold Medal for Afrox’s auspi- cious year. “This year we are very pleased to Harvey Shacklock Gold Medal Award

be recognising Angel Krustev for his presentation ‘ModifiedGTAWorbital tube to tubesheet welding technique and the effect of a copper weld retainer during welding of alloy 825’ . The paper was presented at a SAIW Technical evening meeting in Johannesburg on the 6 th of September 2017,” Venter reveals. “The final award for the evening is the Institute’s GoldMedal Award. The award was introduced in 1966. It is the Insti- tute’s highest award and can be made to a company or an individual in recog- nition of outstanding contributions to welding technology or to the Institute,” Greer says. “For 2017, the award is being made to Willie Rankin. The award citation reads: ‘In recognition of Willie Rankin’s dedicated service to the Institute and exceptional leadership contribution through a period of difficult and chal- lenging circumstances in the years 1998 to 2002 when he served as the Institute’s President.’ A tribute video for Willie Rankin by former SAIW chief executive Jim Guild followed, before Jason Greer an- nounced the conclusion of the evening’s formalities. Institute Gold Medal Award For 2017

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SAIW: Afrox’s 90 year celebration

Afrox presents Harvey Shacklock Gold Medal

T he Afrox-sponsored Gold Medal Award is significant as itwas intro- duced in 1949 in memory of Har- vey Shacklock, the first CEOof Afrox, who was alsoa foundingmember of theSAIW. The 2017 awardwas presentedby Afrox’s 11 th MD, Schalk Venter, to Angel Krustev for his presentation entitled ‘Modified GTAW orbital tube to tubesheet welding technique and the effect of a copper weld retainer during welding of alloy 825’ . The accolade is bestowed in ac- knowledgement of exceptional con- tribution to the industry in terms of research and innovation, and is granted to recipientswhohavepresented techni- cal papers of a very high standard, either on a local or international level. Shacklock established the Southern African Institute of Welding (SAIW) in 1948 as a non-profit, technical organisa- tion dedicated to furthering standards in welding-fabrication and related technologies. SAIW is also a founder member of the International Institute of Welding (IIW). Johann Pieterse, Business Manager for Manufacturing Industries at Afrox, says that the SAIW Annual dinner is the biggest annual event on the southern African welding calendar and that the Harvey Shacklock Gold Medal Award is still highly significant to Afrox as it embodies its ongoing commitment to promoting welding in the industry. This award is oneofmany accolades, training programmes, welding schools and skills development programmes that Afrox sponsors and actively sup- ports each year in order to promote the growth and expansion of welding skills and employment opportunities in southern Africa. On20October at Emperor’s Palace in Johannesburg, in celebration of 90 years in the gases and welding industry and in honour of its founding CEO, Afrox presented the prestigious Harvey Shacklock Gold Medal Award at the 69 th SAIW Annual dinner.

At the SAIW Annual Dinner, Afrox MD, Schalk Venter, presents the 2017 Harvey Shacklock Award to Angel Krustev, together with SAIW president, Morris Maroga.

“Afrox also sponsored the Stainless Steel Awards Student Category to en- courage South Africa’s youth to consider welding as a profession in a time of high unemployment,” says Pieterse, adding that Afrox stands firm in their belief that skills development is key to growing the country’s economy. “Afrox also offers bursaries for learn- erships and apprenticeships, and part- ners with training bodies to develop individuals into qualified artisans,” continues Pieterse. In addition, the gases and welding company actively participates in the advancement of new training facilities and has played a key role in establishing welding training centres in Gauteng, the Eastern Cape and Western Cape. Most recently, the LIV Welding Academy, a custom container welding school that was developed by Afrox in partnership with LIV and the SAIW, was unveiled at the LIV Village in KwaZulu-Natal. Pieterse says that Afrox has also partnered with the Department of Edu- cation, supporting its Technical School Recap programme in a drive to re-estab- lish welding facilities at schools, kitting them out with advanced technology equipment and up-skilling educators to facilitate training. Since its humble beginnings as the Allen-Liversidge Industrial Gases Com- pany, first opened by Shacklock on 1 April 1927, African Oxygen Limited has prospered by constantly meeting the needs of its customers and developing solutions that add value to industry.

Annual dinner and awards sponsors, 2017 The SAIW thanks and recognises the contributions made by its sponsors, who have enabled the resounding success of the 2017 Annual Dinner and Awards. Gold Sponsor:

Afrox, a leading provider of industrial gas and welding, cutting and gas products and services to the SouthAfrican, SouthernAfrican andAfrican markets. Wits University School of Chemical and Metallur- gical Engineering has run post-graduate welding coursesforthepasttwentyyearsandtheIIWWeld- ing Engineer course for some ten years.

Silver sponsors:

Lincoln Electric is a global manufacturer of weld- ing products, arc-welding equipment, welding consumables, plasma and oxy-fuel cutting equipment and robotic welding systems. ESAB, locally represented by ESAB South Africa, is a leader in the production of welding and cutting equipment and consumables. TÜV SÜD services cover inspection, consulting, test- ing, certification and training in order to increase safety and add economic value for the customers. Welding Alloys South Africa (WASA) is a producer of flux-cored arc welding (FCAW) wires in Africa and a go-to provider of welding consumables, automated equipment for wear protection. Techtra specialises in the sales and service of NDT Testing equipment: ultrasonic, phased array, eddy current and array eddy current, magnetic particle testing, dye penetrant, visual and remote visual inspection equipment and radiographic inspection systems. Bronze sponsors:

GIANNA Welding Solutions is a business growth, optimisation and efficiency com- pany focused on offering balanced services

to welding-related projects and businesses.

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SAIW: Visual testing

Visual Testing: the first line

SAIW’s NDT Training Manager Mark Digby talks to African Fusion about the increasingly important role of Visual Testing (VT) and its place as an NDT method in own right.

“ V isual Testing is now being taken on as the ideal start- ing point for NDT inspection programmes. In the past, many profes- sionals did not formally recognise VT as an inspectionmethodat all, arguing that a visual check shouldalways be followed by Penetrant (PT) or Magnetic (MT) Test- ing methods,” says Digby. “There are formal VT qualifications and these are accepted and referenced by ISO 9712: Non-destructive testing – Qualification and certification of NDT personnel,” he continues, adding that SAIW now offers VT qualifications at Level 1, Level 2 and Level 3. “VT is the first line of defence for any non-destructive inspection testing pro- gramme. Generally speaking, if aweld is regular, the right size and clean, and the welder has obviously taken care to avoid or remove any slag or spatter, there is a much better chance that the weld qual- ity will be acceptable,” Digby notes Since 85% of all weld flaws can be visually detected on the surface, Digby says that considerable amounts of NDT testing requirements are surface-based. “Any good NDT testing programme should startwith surface techniques and VT is oneof the easiest of these toaccess, since it requires relatively simple tools such asmagnifying glasses, torches and lights, reflectors and, most critically, an inspectors eyes that are tuned to detect all types of surface flaws,” he says. “Surface breaking flaws are much more dangerous than embedded flaws,” Digby explains. “If you look at the frac- turemechanics calculations of a surface breaking flaw, they always pose a bigger risk because of the higher stresses at the surface of the material, which become concentrated at the tips of a surface breaking crack or flaw. “Flaws in the body of a material are usually exposed to less stress and crack propagation is likely to be slower. But it is important to separate embed- ded flaws into volumetric flaws such as slag inclusions and porosity, which may be less dangerous, and planar

flaws – cracks, lack of fusion or lack of penetration – which are very danger- ous,” he warns. “So when doing NDT, we never simply conduct surface or volumetric testing, we conduct both. Starting with the surface inspection and then, once that is cleared, we look for volumetric/embedded flaws using a method such as ultrasonics or he notes adding, “but the most dangerous of all welding flaws are planar de- fects that break the surface, and the presence of these can almost always be detected using one of the surface techniques, VT, PT or MT.” SAIW’s VT training courses deal with the method on an equal footing to any other NDT qualification on offer. “We train candidates how to conduct VT thoroughly and systematically: using the appropriate tools; drawing sketches and/or taking photographs using high resolutions cameras, video cameras or borescopes; and keeping accurate records. These days the resolution of cameras is excellent and very short fo- cal distances are possible. Borescopes can be used to look inside tubes and these can be manipulated to enable the penetration seam of a weld to be thoroughly examined, for example,” Digby notes. “Equipment originally developed for the medical industry has been used for years to look into turbines to check blades and even for retrieval inspection, to make sure no spanners or welding helmets or welding rods have been left inside the internal structures of boilers or turbines,” he adds. Describing ongoing NDT training being conducted for Transnet Engineer- ing’s Durban-based manufacturing radiographic test- ing (UT or RT),”

Above: VT used for plant

inspection and maintenance involves using human senses such as vision and hearing mostly with non-specialised inspection equipment.

VT is one of the easiest of these to access, since it requires relatively simple tools such as magnifying glasses, torches and lights, reflectors and, most critically, the trained eyes of a good inspector.

facility, Digby says that Transnet has embarked on a

large local manufacturing programme to build locomotives for South Africa’s freight rail services: 1 064 new electric and diesel locomotives have been ordered and all but 70 are going to be assembled by Transnet Engineering’s facilities in Pretoria and Durban. When preparing for fabrication, Transnet discovered that it was short of trained NDT personnel, particu- larly those meeting the requirements of ISO 9712. All the locomotives being built have to conform to ISO 15085 re- quirements for the fabricationof railway vehicles and components. Transnet did have some NDT people that were qualified according to the ASNT NDT scheme, but following the SAIW-organised ISO 15085 audit by representatives of GSI-SLV inGermany, it became apparent that ISO 9712 qualifi- cationswere required inorder to comply with ISO 15085. “This led to Transnet Engineering approaching SAIW to develop a full ISO 9712 training course to upskill its personnel. FromOctober 2015 andas re- cently as June 2017, we have conducted

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SAIW Member profile: Efficient Engineering

of defence

Borescopes can be used to look inside tubes and these can be manipulated to enable the penetration seam of a weld to be thoroughly examined.

method,” Digby tells African Fusion . In addition to the inclusion of Visual Testing in Transnet Engineering’s NDT personnel development programme, VT 1 has been introduced into the Sasol- sponsored programme since 2016. “This programme for young people was started in 2007 with Group A and we are now training Group G. Many of the past people SAIWhas trained are now estab- lished inspectors or AIAs working on plants all over the country,” Digby says. “By investing in training for local people, the teams on the ground are strengthened for the long term thus avoiding bringing in inspectors in from overseas. And like all of SAIW courses now, the NDT courses we offer, including the new VT course, are internationally accredited, either through the IIW or, in the case of NDT, through ISO9712, which means that certificatedpersonnel trained in South Africa can get jobs anywhere in the world.” he concludes.

tion and support as possible by Keeping It Simple, Super NDT Colleague – KISS,” he says. By following the ‘KISS’ approach, SAINT is encouraging application- based presentations, practical dem- onstrations and hands-on technical experiments to take centre stage at this unique event. “There will also be something special for the DYI gurus. We are aiming to engage school learners, NDT technicians at all levels and all round curious individuals to sit through 30 minute sessions without having to count the number of ceiling panels or trying to balance their heads while this has enabled the facility to bring its NDT work back in-house,” he says. Describing howNDT training, quali- fications and certification works, Digby says that candidates need to do training courses for everymethod at every level. “Following each course, candidates write an exam and those that pass are awarded a qualification in that method and level. This enables them to get jobs in industryworkingwithin amentorship programme. After gaining the experi- ence required by the ISO 9712, the can- didate can then apply for certification from an accredited body, such as SAIW Certification. “After completing Visual and Pen- etrant testing at Level 1, for example, only one month practical experience is required, but this varies depending on the complexity of the method. For UT 1, for example, nine months expe- rience is required before a qualified NDT Inspector can be certified in the

VT, PT, MT and UT courses at Level 1 as well as VT and MT Level 2 training at our Durban-based branch – and addi- tional PT Level 2 and UT Level 2 training courses are still to be delivered in the New Year,” says Digby. He adds that both NDT inspectors andweldingoperators arebeing trained, “the idea being that while welders can’t officially test their own welds, if quali- fied in a NDT method such as VT, they can test the welds of their colleagues. VT training also helps welders to assess the finishedquality of their ownwelding, so that any obvious issues can picked up immediately before official ND testing begins,” he suggests. According to Digby, the results have been good. “Transnet’s Durban fabrica- tion facility is now in a position to for- mally apply for ISO 9712 certifications for all of its NDT-trained personnel and

SAINT’s Golden NDT Conference SAINT, the South African Institute of Non- Destructive testing, is celebrating its 50 th anniversary next year. “To commemorate this auspicious occasion, we are hosting a very different kind of NDT Conference,” says Harold Jansen, the NDT Insitute’s vice president. “What do I mean by very different?

their eyes glaze,” Jansen adds.

SAINT also believes that keeping it formal can be interesting and fun. “World renowned plenary speakers such as the chairman of ICNDT SK Babu and the ASNT Africa Chair will give us insight into the global NDT industry, which will be followed by an exciting technical pro- gramme topped off with a celebrity filled Gala event. ‘What celebrities’ youmight ask, well, we are talking about the most important individuals within NDT today, namely you!” Jansen concludes. The SAINT Conference will be held on February 7 and 8, 2018 at the Accolades Conference Centre in Midrand, Johan- nesburg. www.ndtgoldconference.co.za

Well, how often have you sat in a techni- cal presentation and wondered what the presenter is talking about? He lost you at the first mention of ‘magnetic dipole’ and turned your attention to playing ceiling Tetris. “During SAINT’s Golden Conference, we are aiming to attract as much atten-

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SAIW Member profile: MegChem/SecMet

The MegChem way: long-term support well beyond project scope

African Fusion visits MegChem/SecMet in Centurion, Pretoria and talks to Andrew Seebregts, the company’s principal welding engineer, and Ronald Koenis, business unit manager for metallurgical engineering.

ployees on board, of whom 80 are qualified engineerswithmore than 1100 man-years of engineering experience between them,” he notes. Due to its roots, MegChem’s Process Engineering and Design services for the petrochemical and chemical industries is particularly strong. “As well as front- end process design and integration across engineering disci- plines, we can offer problem identifica-

dent company. This gives us the distinct advantage of being able to focus more widely on metallurgical quality and fo- rensic work, withMegChem focusing on themechanical and project engineering side of the business,” he informs African Fusion . MegChem’s offering and successes MegChem’s primary expertise is me- chanical, process engineering and project management. “Our in-house mechanical and piping drafting of- fices can produce detailed fab- rication drawings, isometric drawings and process flow sheets for both refurbishment and new-build projects,” says Seebregts. “MegChemhas the ability to execute EPC and EPCm projects, from a brief provided by our clients and all the way up to commissioning: conceptual engineering, feasibility stud- ies, basic engineering, detail engineer- ing, specifications andprocurement and construction. – “ “We have approximately 300 em-

M egChem and SecMet have been supporting clients in various business environments ranging from petrochemical, Oil & Gas, Energy to mining, processing and other heavy industries. “In the mid 90s, Sasol initiated a management buy-out process which resulted in the start up of MegChem and SecMet as independent service providers to the petrochemical indus- try,” Seebregts says. Then, in 1997, MegChembought SecMet and, although the SecMet name was retained for trad- ing purposes, it was run as a division of MegChem. “Until July 2016 when we ap- proached MegChem management to reintroduce SecMet as an independently run entity,” continues Koenis. “Now, although we are still fully owned by MegChem Holdings, we have been op- erational since July 2017 as an indepen-

tion and resolu- tion by apply- ing advanced

MegChem’s Process Engineering can offer problem identification and resolution by

applying advanced techniques such as 3D CAD, finite element analysis (FEA) and fatigue analysis. techniques – finite element analysis (FEA); fatigue analysis andmuchmore.” Seebregts continues. “We have significant experience in process plant and equipment design andweoffer one-stop, phased-approach project execution, which includes com- missioning assistance,” he adds. Facilities for developing and draughting engineering flow sheets and process diagrams – process flow (PFDs), mechanical flow (MFDs) or piping and instrumentation (P&IDs) diagrams – are all available and, with respect tobusiness support, MegChem’s process teams can assist clients through conceptual process engineering studies to the development of new processes and products or the upgrading and op-

At the Chevron refinery in the Western Cape, MegChem was the engineering contractor for four major upgrades at the refinery: the fluid catalytic cracking unit (FCCU), replacing the Texas tower and the crude column, and for a fast track project to implement the required plant changes in order to produce 50 ppm diesel.

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SAIW Member profile: MegChem/SecMet

Stress corrosion cracking (SCC).

Wire analysis.

A cleavage failure.

timisation of existing plant with respect to efficiency and throughput. “Our plant support activities include rendering process engineering services to themechanical engineering, mainte- nance and production functions within a company and generating ideas and defining requests,” he says. A few of many notable projects include Reactor replacements, column renewals, storage facilities, gas clean- up facilities and other plant improve- ments that added value to our clients’ business. “We have also completed a highly successful turnaroundat theChevron re- finery in the Western Cape, in which we managed the complete scope of work for the projects at the refinery for and on behalf of our clients. Chevroncontracted MegChem to take full responsibility for the projects on an EPCm basis,” says Seebregts. MegChem was the engineering contractor for four

A state of the art scanning electron microscope (SEM) enables accurate identification of failure mechanisms, metallographic structures, and corrosion products.

FFS, RLA and forensic services Describing SecMet’s role within the MegChem Group, Koenis says that pro- cess plants and equipment are increas- ingly being used for extended periods, oftenwell past their original design lives. “There is, therefore, a growing need to monitor and confirm continued fitness for service and remaining life of critical equipment. SecMet is very well placed to fulfil this need, based on globally ac- cepted practices,” he says. “Our strongmetallurgical andmate- rials engineeringbackground, combined with state-of-the-art structural model- ling and testing capabilities, enables us to offer world-class fitness-for-service (FFS) and remaining life assessment (RLA) services,” he tells African Fusion . Staring with theoretical and prac- tical knowledge of the degradation processes involved, combined with knowledge of materials and structural behaviour, SecMet is able to establish if continued plant operation is feasible and safe. Typical projects have focused on pressure vessels, tanks, rotating equip- ment and high–temperature applica- tions. “A recent success in the Middle East established that two large and ageing pentane tanks were fit for con- tinued service, provided that certain recommendations be followed,” he says, adding that “life extensions such as these can save operators enormous amounts of money”. SecMet’s Materials and Forensic Engineering Division also offers a com- prehensive metallurgical consulting service encompassing all aspects of physical metallurgy, materials engi- neering, welding and corrosion. “Our metallurgical experts are supportedby a well-equipped metallurgical laboratory and an ISO 9000 certified testing facility, which enables us to provide a one-stop metallurgical service to the petrochemi- cal, mining and manufacturing indus- tries. This includes advanced failure investigations and integrity studies and all the way down to basic material testing and certification,” Koenis says.

A state of the art scanning electron microscope (SEM) enables accurate identification of failure mechanisms, metallographic structures, and corro- sion products and, “due to our history and close co-operation with the petro- chemical industry, we can offer special- ist capabilities in the field of corrosion engineering, testing and monitoring, as well as plant integrity and risk-based assessment and inspections,” he adds. SecMet also offers forensic engi- neering investigations to establish the cause and sequence of events leading to accidents or failures. “This work is usedby the legal profession for both civil and criminal court proceedings,” Koenis notes, adding, “forensic engineering is also often used in investigations with a commercial or industrial focus, to attri- bute responsibility in event of a dispute, for example. “We combine specialist knowledge ofmaterials behaviour, stress, structural analysis and failure to determine the root cause of a failure. In so doing, we rely on state-of-the-art techniques and software, alongwith the extensive expe- rience of our people,” he notes. From a welding engineering per- spective, he adds that SecMet also offers a comprehensive range of quality and other services to fabricators and plant operators, including: developing weld- ing procedures specifications (WPSs) and welding procedure qualification records (PQR); coding and qualifying welders; developing heat treatment procedure; and investigatingandsolving welding related problems. “Through MegChem and SecMet, we strive to add value to our clients’ businesses by taking ownership of a job and applying innovation, creativity and sound engineering and business practices,” says Koenis. Seebregts concludes: “We strive for excellence in everything we do. We pride ourselves on providing long-term maintenance and support, well beyond installation and the implementation of our project scope and, often, even beyond the design life of a plant.”

major upgrades at the refinery: the fluid cata- lytic cracking unit (FCCU), replacing the Te xa s t owe r and the crude col- umn, and for a fast

track project to imple- ment the required plant changes in order to produce

50 ppm diesel.

“Byworkingaheadof the shut- down andusing technologies such as high-definition laser scanning tomodel the existing plant work areas, and then fabricating replacement components in advance to perfectly integrate during installation, the turnaround time on the entire upgrade was completed within the shutdown window,” he notes, add- ing that as well as the scheduled work, unexpected modifications were also accommodated within the required timeframe. The fabrication work for the Chev- ron upgrade was done at a number of fabricators, with the critical fabrication work performed by fabricators certi- fied to ISO 3834. “As per some client requirements across the petrochemi- cal industry, we tend to prefer using ISO 3834 certified welding fabricators. The quality of the welding on refineries and petrochemical plants is critical,” Seebregts adds.

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Cover story: ESAB South Africa

ESAB South Africa refocuses African Fusion talks to Chris Eibl, who has returned to formally re-establish ESAB South Africa as the premier supplier of the world leading ESAB brand in Southern Africa, about the entity’s expanding facilities at Howden Africa and his vision for better servicing thewelding industry.

F or the past two years, ESAB’s local activities have been man- aged from offices at Howden in Booysens with ESAB South Africa as a division of Howden Donkin. “ESAB is 100% committed to the Southern Afri- can market and by partnering with its sister company Howden, who is a top company in South Africa, bodes well for continued stability and support of the ESAB product and service offerings to its current and future customers. We are able to tailor our local offering to customer needs and opportunities and to return to growth,” says Eibl. “So ESAB is back with a view to becoming even stronger than we were under the ESAB Africa banner,” says the man who started ESAB Africa Welding & Cutting. “ESAB South Africa is busy re- sourcing so as to specifically service the welding needs of South and Southern Africa,” he adds. “We are restoring the competence we have had in the past in South Africa: by resourcing and appointing the right personnel; setting up a demonstra- tion area; beefing up the servicing and support of our machines and putting the structures in place for servicing clients and managing their needs,” Eibl continues, adding that ESAB is also launching new products, which are be- ing introduced into the local market in Quarter 1 of 2018: the Renegade range of portable MMA/SMAW and TIG/GTAW the Rebel MIG/GMAW range, along with the ESAB’s Edge gas cutting equipment, for example. “Through acquisitions, we also have some new brands available to us; Victor for gas and plasma cutting equipment; the Stoody range of hardfacing con- sumables; and, most recently, ESAB has acquired Sandvik Welding, which gives us access to the stainless steel and high- alloyed nickel-based wire consumables manufactured in Sweden,” he reveals. An early priority for Eibl is to re- establishing an ESAB demonstration centre as a showcase of the company’s welding capabilities. “We have missed having a facility for customers to visit.

to certificated high-quality ESAB consumables,” Eibl notes. “With the up skilling of our employees in the technical aspects of our welding offer- ing and beefing up our sales resourcesandcus-

tomer service advisors, we are

investing significant amounts of money and resources in the local entity. “We have now completed a com- prehensive re-evaluation of our product range and stocking levels with a view to better supporting our growth efforts and we believe we have an optimised range that will minimise delivery times for clients while keeping costs within a sustainable window,” he says. “ESAB is one of the few leading global companies that is able to provide a complete solution from the power source to the filler welding consum- ables, gas equipment and all associated accessories. Many of our competitors manufacture and supply only filler welding consumables or power sources and are therefore not positioned to of- fer complete solutions to customers. When things go wrong, each separate supplier of the power source and weld- ing filler consumable ends up blaming the other leaving the customer as the piggy-in-the-middle. With ESABproduct being used from the power source to the welding filler consumable, ESAB is able to optimise the arc and takes full responsibility for the performance of the ESAB solution,” he states. Results are already beginning to show, Eibl says, citing a recent multi- million rand success. “Gibela, the con-

ESAB’s modern submerged-arc welding solutions rely on its flagship Aristo 1000 AC/ DC welding power source. Our new facility here at Howden will showcase our latestmachines and tech- nologies so that customers can come in and try things out. We will also use it to develop and demonstrate specific welding applications and procedures for customers. “All of our modern arc welding processes will be available: our tandem welding and twin wire solutions using Aristo 1000 AC/DCs and A6 submerged arc tractors as one example, to enable customers to test our equipment and consumables and quickly find cost- effective whole welding solutions,” Eibl explains. In addition, ESAB’s in-housewelding facility for special consumable testing will be fully re-established. “We will be producing customer-specific and stan- dard tests certificates on every batch of premium consumables we import,” he tells African Fusion . “Many clients require client-specific conformance certificates for some of the consumables they use. We will however be testing all of our consumables, across the board, so that even clients who do not require certificates will have automatic access

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for growth

Renegade machines are “a step-change in terms of portability” and are suitable for anyone needing portability with high performance.

capable of switching between single- and three-phase supplies from 208 V to 480 V automatically, delivering preci- sionwelding current output of between 5.0 and 300 A. In addition, Renegade power sources can function off ESAB South Africa will focus on its premium consumable range, such as its ASC-coated Aristorod 12.50 copper-free wire for advanced MIG/MAG welding.

welding cables and work leads of over 100 m, with minimal power loss – and a remote amperage con- trol extends operator range by providing extreme accuracy

over these long distances.

At 15 kg and mea su r i ng 460 × 200 × 320 mm, this 300 A unit is the most compact and light- weight welder in its class. “Renegade redefines the onsite welding machine. It has three handles to make it easy to grab, pull, or push it and padded straps to allow it to be carried over a shoulder into hard-to-reach areas with limited access,” Eibl says. Notable features include: • Automatic voltage detection: There is noneed to rewire every time the machine is plugged in. • Excellent cellulosic performance (E6010 and E6011): The unit pro- vides higher arc voltage and longer arc length for a soft arc with impec- cable starts and stops. • High-speed machine-to-arc com- munication: Renegade reads thearc faster thanmostmachines, equating to better control, a more stable arc, and virtually no spatter. • Arc gouging: The machine can ac- commodate gouging rods of up to 6.0 mm. • Hot start: The unit automatically increases current output to avoid sticking. • Arc force: A feature that provides a softer, crisper arc. • Intuitive interface: The machine’s digital readout display, along with large buttons and controls, make

sortium currently manufacturing new locomotives for PRASA, has chosen the ESABOrigoMIG 4002 CW, completewith the advanced U82 Plus pendant control as its welding workhorse,” he reveals. “Thesemachines are fully digital, multi- process, multi-featured power sources and theywill be used to do stainless and mild steel welding on the new locos.” Renegade is ESAB’s new TIG and MMA inverter-based power package. This modern machine is suitable for appli- cations across the whole spectrum of industries. “Renegade machines are suitable for anyone needing portabilitywith high performance. These are a step-change in terms of portability. Previously, machines had to be down-spec’d and de-featured in order to achieve portabil- ity, but Renegade offers the very high levels of quality, consistency, reliability andwelding performance of a premium welding power source,” says Eibl. “ESAB’s Renegade package is ideal for anyone who needs to do high qual- ity work in the field without having to organise transport tomove equipment,” he informs African Fusion . Renegade runs stick, TIG and arc-air gouging and boasts the widest input power range on the market, making it Renegade: a step change in portability

Gibela has chosen the ESAB Origo MIG 4002 CW as its welding workhorse for the manufacture of the new locomotives.

it easy to set parameters and read them from a distance. • Cable management: An integrated latch systemhelps control cables so they can be secured to themachine, making it easy to pack up and go. While thewelding industry is depressed, Eibl remains cautiously optimistic. “Real progress is now taking place in the railway industry and if the renew- able energy agreements are signed by Eskom the wind tower business can be back on track. Oil and gas inWest Africa is starting to come back, too, which does impact on our business a little,” he notes. “We are fortunate in that our prod- uct range covers all industries, from power generation, shipbuilding and petrochemical plants to automotive and its supporting tiered manufactur- ing industries. We are able to switch our focus very quickly. “We are back,” concludes Eibl, “and more determined than ever to restore the ESAB brand in Southern Africa to its rightful place as one of the leading welding equipment and consumable OEMs in the region.”

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