African Fusion November 2018

NOVEMBER 2018

Journal of the Southern African Institute of Welding

AFRICAN

Contents

November 2018 FEATURES 4 SAIW celebrates 70 th milestone The 70 th Annual Dinner of the SAIW was held at Emperors Place on Friday September 7 with two new awards introduced to reflect the rising importance of ISO 3834 certification. 10 Anderson Engineering: 60 years of engineering excellence African Fusion profiles Anderson Engineering, a specialist fabricator in stainless steel and the 2018 winner of the Sassda Stainless Steel award in the Agro-Processing, Food and Beverage Category. 12 eNtsa: Innovation through engineering African Fusion visits eNtsa, the internationally recognised research and innovation hub and engagement institute within Nelson Mandela University, and talks to its director, Danie Hattingh. 16 The feasibility of modified pulse arc deposition on thick section Q&T steel This IIW paper from the 2018 IIW Bali conference details a comparison betweenmodified pulse gasmetal arc welding (GMAW-P) and conventional shielded metal arc welding (SMAW) for welding thick-section quench and tempered steels. 24 Hardfacing cored wires for ultimate protection Jürgen Tuchtfeld of voestalpine Böhler Welding talks about UTP’s AF ROBOTIC seamless hardfacing wires. 26 Digital welding technology at affordable prices African Fusion talks to RenttechMD, DuncanWhitehead and national sales manager, Eduan Naude, about their new UNIarc range of welding equipment. 29 Thermal spray coatings protect ball valves The HVOF thermal spray process from Thermaspray is helping to extend the service lifecycle and enhance the performance of metal-seated ball valves. 30 Air Products opens state-of-the-art DA facility African Fusion attends the launch of Air Products’ new R90‑million Dissolved Acetylene plant inMidvaal and takes the tour with plant manager, Anton Grobbelaar. REGULARS 3 Sean’s comment 9 SAIW bulletin board 14 Front cover story: A 360° integrated TIG-welding solution for welding at heights 32 Welding and cutting forum 36 Today’s technology: Welder training on a whole new level

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

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Deputy publisher: Wilhelm du Plessis Production & layout: Darryl James Circulation: Brenda Grossmann Printed by: Tandym Print, Cape

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Afrox has developed a forward- looking gas delivery solution for TIG welders working at height on high-integrity pipework. African Fusion talks to the development team: Arnold Meyer, applications development manager; Roberto D i on i s i o , R&D mana ge r f o r Hardgoods; and Johann Pieterse, businessmanager formanufacturing industries.

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www.africanfusionmagazine.co.za

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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

O n reflecting on recent events, I think it appropriate to first pay tribute toPhilip Doubell, who died just over a year ago. Philip was this year’s recipient of our Gold Medal Award, in recognition of his dedication as a welding engineer.

On October 25, in association with Nelson Mandela University, we hosted the Philip Doubell Memorial Lecture at the Eskom Academy of Learning in Midrand. It was presented by Neil James, who was Philip’s friend and colleague and, with Philip and Danie Hattingh of eNtsa, an integral part of the development team for WeldCore®. According toNeil James,WeldCorewas a step change in the industry for creep monitoring of high-pressure, high-temperature equipment. What Philip, Danie and the eNtsa team came up with was a system to bore out a core shape from the wall of a pressure pipe, cut off the core for creep sampling and then to immediately weld up the hole using Hydro Pillar Processing. WeldCore has saved Eskom millions of rands, because accurate creepmonitoring enables the life of power plants tobe safely extended. And today, because of Philip’s vision, eNtsa and Eskomareworld lead- ers in the development and use of this unique technology, which is now ASME approved and deployable. As Neil James said, the leap of faith between industry and academic research & development is often huge in this country, but Philip was a visionary who loved locally innovated solutions. WeldCore is exactly that; aworld-leading technique developed right here via a partnership between industry and eNtsa, a university-based R&D group. A dedicated contributor to the welding industry who made many valuable technical contributions and provided inspiration and men- torship to many of his colleagues, Philip Doubell was a truly worthy winner of our SAIW Gold Medal. Also at this year’s annual dinner, we introduced two new awards: the Best IIW ISO 3834 Manufacturing Certification Company award, and the Best Responsible Welding Coordinator Award. The number of nominees for these awards speaks volumes about the progress SAIW and the South African welding industry have made with regard to implementing ISO 3834 and raising our weld quality standards. We have made significant strides in increasing the numbers of manufacturing companies certified to ISO3834 and there are nowover 160 companies onour approved list. Thenumbers of qualified IIWWeld- ing Coordinators, IIWWelding Engineers and IIW Inspection Personnel is another pleasing and significant indicator of our industry’s progress towards achieving international quality and qualification levels. Looking forward, I ampleasedwith the progress beingmade in our Future Welder Training Centre. We recently took delivery of a weld- ing robot donated to us by Yaskawa Southern Africa, which adds to the Lincoln Electric REALWELD and ClassMate Robotic welder trainer systems and two Soldamatic augmented-reality welding simulators. We will be using this centre to fast-track initial welder training and to enable us to add robotic welding courses to SAIW’s training offering. In early January 2019, we are hosting the SAIW Youth Challenge 2018/2019 here in Johannesburg. So anyone who knows of a promis- ing young welding talent, please encourage them to enter. There is a prize of R15 000 cash available to the winner. We see this competition as very important for promotingwelding as a challenging and reward- ing career. PhilipDoubell’s life teaches us that passion for welding and a vision for local innovation leads to success. We look forward to more of our young welding professionals following in his footsteps. 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: 70 th Annual Dinner

SAIW celebrates 70 th milestone

The 70 th Annual Dinner of the SAIW was held at Emper- ors Place on Friday September 7. Two new awards were introduced to reflect the rising importance of ISO 3834 certification in theSouthAfrican fabrication industry; and one of the welding industry’s finest sons, Philip Doubell, wasposthumously recognisedwithSAIW’shighest award, the SAIW Gold Medal. African Fusion reports.

kind assistance of Merseta. In addition, Yaskawa has agreed to donate an Indus- trial welding robot to SAIW make real welding possible as well. On the training front, the IIW Inter- national Welding Inspector programme will be offered at all three levels in 2019. Approximately 125 students fromHydra- Arc/Jomele completed this course last year with 40 currently in progress. “We have also recently completed training Sasol Group G on a full suite of SAIW courses and we look forward to doing Group H next year. And on the IIWWeld- ing Co-Ordination training programme, we qualified 117 personnel last year. which represents a 39% increase over 2017. “Our ISO 3834 Certification scheme continues to go from strength to strength and we currently have 168 companies listed on the register. We have also completed the ISO 17021 ac- creditation fromSANAS to reaffirmSAIW conformity as anauthorisedcertification body and we expect SANAS to issue our 17021 certificate shortly,” Blake told his dinner guests. The 70 th SAIW Awards The Institute involves industry repre- sentatives in every aspect of its training

“Last year the SAIW Foundation trained a group of six students on the International Welder programme in partnership with the ArcelorMittal Sci- ence Centre in Sebokeng. The group achieved excellent results and showed exceptional talent,” he said, adding: “For the next SAIW Foundation project we plan to train 15 students on a QCTO Artisan Welder Apprenticeship pro- gramme in partnership with ArcelorMit- tal once again. This project is aligned to the Centres of Specialisation project on which we are working with the Depart- ment of Higher Education and Training in order to equip the TVET training col- leges with the necessary skills to train artisan welders.” Other successes Blake cited include: the development of the SAIW Future Welder Training Centre, which will use augmented reality welder training systems such as Lincoln Electric’s Real- Weld and the Soldamatic Augmented RealityWelding Simulator. “Thismethod of practical welder training has the po- tential to revolutionise the way welding is taught and it ismy hope that the SAIW can show the way in Africa,” said Blake. SAIW will also be introducing Robotic Welding courses and have purchased a Robot Welding Training unit with the

“ I am astounded at the response to our 70 th Annual Dinner, given the economicbackdrop inour country at the moment. Tonight we have man- aged to fill 42 tables and 10 company’s have sponsored the function, which certainly allowed us to ensure that this evening is amemorable one,” said SAIW executive director, Sean Blake. Celebrating SAIW’s achievements over the past year, he started with the teamof five SAIWwelders sponsored by the MerSeta, who participated with 36 countries in the third Arc Cup in China and finished the competition in the bronze category. “Of the group, three were females, and only seven women were competing in the entire competi- tion,” Blake revealed, before thanking Ester van der Linde and Raymond Patel fromMerseta, formaking their participa- tion possible. SAIW executive director, Sean Blake, celebrates the Institute’s 2018 successes at the 70 th annual dinner and awards.

Left and centre: The two 2018 winners of Presidents’ Award for NDT, Bronwyn Nadene Geel (left) and Collen Morithinyana Tseke (centre) , with SAIW president, Morris Maroga. Right: Winner of the Phil Santilhano Memorial award, Chane Marais, for being the best student of the year on the SAIW Welding Inspectors Level 2 programme.

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SAIW: 70 th Annual Dinner

programmes and qualifications to en- sure that these remain directly relevant to industry requirements. This approach ensures that Institute graduates have good prospects of employment and meet employer expectations. “Anyone attending Institute courses will testify that they are very demanding. A lot of information has to be absorbed in a short amount of time. To be successful really takes special effort and we aim to recognise the very best of our students throughour trainingawards,” saidBlake. SAIWPresidents’ Award for NDT: The SAIW Presidents’ Award recognises the top NDT students on Institute courses and is made in the name of the past Presidents of SAIW who have helped guide the Institute to become South Africa’s reference point for high quality training in welding and NDT training. This year, the SAIW Certification Governing Board chose two recipients. The first winner is Bronwyn Nadene Geel, who achieved distinctions in Magnetic Testing Levels 1 and 2; Pen- etrant Testing Levels 1 and 2; Visual Testing Level 1; Ultrasonic Wall thick- ness Testing, Ultrasonic Testing Level 1 and Radiographic Interpreters Level 2. During the initial examination for Ultra- sonic Level 1, Bronwyn Geel achieved an average of 88% and in Radiographic Interpreters, which is SAIW’s most dif- ficult method to pass, she achieved an overall average of 91%during the initial examination. The second Presidents’ Award win- ner is Collen Morithinyana Tseke, for achieving distinctions in Magnetic Test- ing Levels 1 and 2; Penetrant Testing Levels 1 and 2; Visual Testing Level 1; UltrasonicWall thickness Testing, Ultra- sonic Testing Level 1 and Radiographic Interpreters Level 2. Morithinyana achieved an average of 92% during the initial Ultrasonic Level 1 examination and in the Radiographic Interpreters ini- tial examination, he achieved an overall average of 82%. The Phil Santilhano Memorial Award: SAIW’s second training award is made in the name of Phil Santilhano who was one of South Africa’s leading welding technologists. The award is presented to the best student on the Institute’s courses in Welding Supervi- sion and Inspection. The 2018winner? ChaneMarais, who achieved the highest mark of the year for the SAIW Welding Inspectors Level 2 programme.

Kristian Kruger (centre) won the Harvey Shacklock Gold Medal Award for his presentation ‘Cold repair of Inconel 625 clad layer on medium carbon high strength steel‘. The paper was co-authored by Frederic Laurent of 3C Metal and Pieter Pistorius (left) from the University of Pretoria.

From Kelvion Thermal Solutions, winner of the Best IIW ISO 3834 Manufacturing Certification Company, are, from left: Pieter Herbst, Angel Krustev, SAIW President Morris Maroga and Alex Dreyer.

Harvey Shacklock Gold Medal Award: Harvey Shacklock was the managing director of BOC, now known as Afrox, and he was SAIW’s founding President on 1 st March 1948, over 70 years ago. The Harvey Shacklock Gold Medal is awarded to the author of the best technical paper presented at an Institute or IIW event. This SAIW recognised Kristian Kru- ger for his presentation ‘Cold repair of Inconel 625 clad layer on medium carbon high strength steel‘. The paper was co-authored by Frederic Laurent of 3C Metal and Pieter Pistorius from the University of Pretoria andwas presented at the IIWAnnual Assembly andWelding Conference in Bali, Indonesia in 2018. Best IIW ISO 3834 Manufacturing

Certification Company: Being intro- duced for the first time this year, this award recognises a company that has excelled in the ISO 3834 Certification Manufacturing scheme and imple- mented an exemplary welding process control system. The nominees for this award are: • Actom John Thompson , a lead- ing designer and manufacturer of industrial boilers and associated plant with a name synonymous with well-engineered boilers. • Aveng Grinaker-LTA Mechanical and Electrical , a market leader in providing fabrication, construction andmaintenance services for process plants. • Gascon , a manufacturer of pressure

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SAIW: 70 th Annual Dinner

electrodes and detailed analyses of all weld repairs by both welders and welding supervisors –which resulted in the weld repair rate for the Matla Power Station shutdown work to decrease from7.2%to 2.5% last year. In the last general outage of Unit 1 at the power station, 10 000 butt welds were completed with a variety of materials with old to new connec- tions and a weld repair rate of 1.7% was achieved for all welds done in the boiler. A phenomenal achievement. • PhilipDoubell , adedicatedcontribu- tor to thewelding industrywhomade many valuable technical contribu- tions and provided inspiration and mentorship to many who crossed his path. A key focus of Philip’s work at Eskomwas life extension of plants with varying welding technologies andhe achievednotable successes at Koeberg Nuclear Power Station and Hendrina Power Station. He worked closely with Prof Danie Hattingh and was a co-inventor of the WeldCore® technology. To a large degree it was his inspiration and dedication that ensured the success of the project, particularly the industrial applica- tion and commercialisation of the WeldCore technology. Philip Doubell is cited as publishing 22 research papers on ResearchGate having co- authored many papers with leading international academics as well as

vessels for thepetro-chemical, power generation andoffshore industries as well as storage vessels for the trans- port industry. • Hi-Tech Pressure Engineering , which designs and manufactures code compliant pressure equipment and related plant for customers in a wide range of industries. • Kelvion Thermal Solutions Ser- vices , a specialist in themanufacture of heat exchangers, pressure vessels and process equipment. • Vessel Fabrication , which special- ises in the manufacture of pressure vessels, storage vessels, and shell and tube heat exchangers. The 2018 winner? Kelvion Thermal Solutions. Best Responsible Welding Co- ordinator Award: This award is also being introduced for the first time this year. The award is made in recognition of an exceptional welding co-ordinator for the IIW Manufacturing Scheme for the implementationandmaintenanceof sound welding processes and diligently managing weld quality. The nominees are: • Lorien Chettiar , quality and respon- sible welding co-ordinator at Aveng Grinaker LTA. • Angel Krustev , manager for weld- ing and quality assurance at Kelvion Thermal Solutions. • Eric Lemmer , quality manager at Manlimeli Projects and Fabrication. • Ravika Ramnath , QC and welding co-ordinator at SHM Engineering. • Jacques Venter , quality manager and welding engineer at GRW Engi- neering. • Tiaan Vosloo , divisional welding engineer and responsiblewelding co- ordinator at Actom, John Thompson. The award for Best ResponsibleWelding Coordinator for 2018 was presented to Lorien Chettiar of Aveng Grinaker LTA. The Institute Gold Medal Award, 2018: The final and most prestigious award for the evening is the Institute’s Gold Medal Award, made to a company or individual in recognition of outstand- ing contributions towelding technology or to the SAIW. There were two nominations for the 2018 Gold Medal: • Babcock Matla: a company that explored multiple innovations – strategic pre-heat methods, the switch from traditional 2% thoriated tungsten to 2% ceriated tungsten

Morris Maroga presents the award for Best Responsible Welding Coordinator for 2018 to Lorien Chettiar of Aveng Grinaker LTA. industry stalwarts. He was awarded the Harvey Shacklock Gold Medal award in 2006 for his paper titled ‘Weld refurbishment of heavy walled components, hydro-penstock repair’ . He was also part of the first group to be awarded the International Weld- ing Engineer qualification. For 2018, the SAIW Gold medal award is posthumously being made to Philip Doubell: ‘In recognition of his dedication as a Welding Engineer who inspired and developed welding technologies, which made significant contributions to the industry at large’ . The worthiest of winners.

The SAIW Gold medal award was posthumously being made to Philip Doubell: ‘In recognition of his dedication as a Welding Engineer who inspired and developed welding technologies, which made significant contributions to the industry at large’. His wife Grietjie Doubell, accompanied by their daughter and son received the award on Philip’s behalf.

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SAIW bulletin board

Yaskawa future welding robot handed over to SAIW

O n November 20, 2018, Yaskawa Southern Africa officially handed over a Yaskawa Robot Welder to sup- port SAIW’s vision for modernising welder training. Complete with an SKS welding power source, the robot now installed in SAIW’s Technology Centre is ideal for developing people with ro- botic skills who are needed by the likes of the automotive industry for setting up, programming and operating weld- ing robots on production lines. The new robot forms part of the SAIW Future Welder Training Centre with its focus on using modern technology to develop new-generationwelders for the modern workplace. “The Yaskawa robot welder is a fully functional robot cell, so we have installed it in our Technology Centre,” says SAIW training manager, Shelton Zichawo. “As well as being used for student demonstrations and training, it will also enable us to do welding trials and procedure development for fabrica- tors seeking to adopt more productive modern methods,” he adds. From a training perspective, using the Yaskawa robot is at the end-point of the new International Welder Train- ing Course that the SAIW is currently developing. The first of these courses will be presented in March 2019 by the W hile SAIWhas long offered courses leading to Competent Person certification for in-service inspection of steamgenerators and pressure vessels; and Inspector of Pressure Equipment (IPE) certification for new vessel con- structions and repairs, an additional need has now been identified for the certification of Pipeline Inspectors. The South African Pressure Equip- ment Regulations (PER) requires that in- stalled, in-service and new pipelines be assessed in accordance with SANS 347: Categorization and conformity assess-

Institute’s virtual and robotic welder trainer, Lourens Hand, who will be supported by the manager of practical welding, Willie Williams. “This is a brand new course that we are piloting based on the IIW’s Interna- tional Diploma in Robotic Welding – basic (IRW-B). Ultimately, we hope that, like most other SAIW courses, the SAIW IRB-basic course will also have full IIW accreditation,” notes Zichawo. The course will give robot welders the necessary theoretical knowledge on welding technology and equip him or her with the skills tomanage all aspects of a roboticwelding operation, including design of the welding task, program- ming the robot, safety and troubleshoot- ing of the welding operation. The course gives candidate anunder- standing of: terminology used for robot welding; the different levels of automa- tion, mechanisation and robotics for welding; the quality assurance, quality control and inspection applied in robot welding; productivity and economics of welding; NDT of roboticwelds; technical drawings, welding symbols and their interpretation and application; and much more. On the practical side, welders and robot operators will be exposed to programming a robot welder, online

The Institute’s virtual and robotic welder trainer, Lourens Hand, and SAIW’s manager of practical welding, Willie Williams, show off the Institute’s Yaskawa robot welder. and offline, and how to make these programs efficient. The use of seam tracking systems and sensors is also introduced and the practical module, which is where the Yaskawa robot comes in, teaches the welding opera- tor about how to implement welding procedures and to do qualification tests as required by ISO 14732. “While we are targeting the auto- motive industry and trailer, tank and other large volume manufactures of welded components, quality and com- petitiveness are becoming increasingly important and both small and large fab- ricators can benefit by adopting robot solutions,” says Zichawo. shelton.zichawo@saiw.co.za theoretical course, followed by an examination. The candidate is then re- quired to gain experience as a Pipeline Inspector for two years before applying for certification. laetitia.dormehl@saiw.co.za

New PER/SANS 347 Piping Inspectors course ment criteria for all pressure equipment. SAIW’s new Piping Inspectors course is based on these certification require- ments and consists of a one-week

SAIW Youth Welding Challenge 2018/2019 T he Southern African Institute of Weld- ing [SAIW), in conjunction with its members, partners and sponsors, is proud to announce that entries are open for the 2018/19 SAIW Youth Welding Challenge. The competition, which will be held from 14 to 18 January 2019, seeks to identify awelder, below the age of 22 years as at 31 December 2019, who is the most proficient in South Africa in welding three material categories: carbon steel, stainless steel and aluminium; using four welding processes: SMAW, GTAW, GMAWand FCAW. The overall winner of the competition will receive a R15 000 cash prize and there are further cash prizes for the overall

runner-upaswell as for thewinners of each metal category. Young welders from learning institu- tions and the workplace are invited to enter the competition. Entries must be accompanied by a short CV detailing the entrant’s current skill’s level and abilities. The competition will be held at the SAIWHeadOffice in Johannesburg and the SAIWwill take responsibility for each com- petitor’s transport and accommodation. For those wishing to become SAlW’s welding champion, visit www.saiw.co.za/ saiw-youth-welding-challengetodownload the entry form. Or contact Samuel Mnguni. samuel.mnguni@saiw.co.za

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SAIW: Member profile

Anderson Engineering: 60 years of engineering excellence

African Fusion profiles Anderson Engineering, a specialist fabricator in stainless steel processing equipment for the food and beverage industry that, on Thursday October 25 2018, won the Sassda Stainless Steel award in the Agro-Processing, Food&Beverage Category for its ACE mixing system.

E ric Anderson, who saw an oppor- tunity to manufacture stainless processing equipment for the dairy industry, founded Anderson Engi- neering in 1958. As the dairy industry evolved, so did Anderson Engineering. “Initially we repaired the milk churns that were collected every day on flat bed trucks from the farms and taken to the dairies. However, as time progressed a better systemwas required and Anderson was the first company in KwaZulu-Natal to build the refrigeratedmilk-cooling tanks that were installed on farms,” says Hen- nie de Jager, the company’s current MD. “We alsomanufactured the insulated milk collection tankers, whichwent from farm to farm on a frequent basis. As a result, the cold chainwas improved and with it, the quality of the milk,” he adds. Anderson Engineering was also the first company in South Africa to fab-

ricate chassisless milk tankers. “The benefit of having no chassis on the long-haul tankers was the saving in weight, which then allowed for a greater payload of milk,” De Jager informs African Fusion . The company currently still services the dairy and broader food and bever- age markets, but has also branched out into the manufacture of equipment for chemical, cosmetic and pharmaceuti- cal manufacturers. “Our expertise and experience spans a great breadth of equipment and solutions, from small standard installations to large complex customised solutions. Our business’s expert design and engineering capabili- ties have enabled us to deliver some of the most innovative manufacturing solutions to South Africa’s industries,” says de Jager. Anderson Engineering also works in many countries across South Africa’s

Anderson Engineering uses experienced and coded welders with production being done under the strict guidelines of its accredited ISO 3834 weld quality system. borders. “As well as in South Africa, we have completed projects in Nigeria, Ethiopia, Congo, Southern Sudan, Ke- nya, Mozambique, Zimbabwe, Mauritius, and Cameroon. In fact, on October 4 th , we received the prestigious 2018 KZN Exporter of the Year Award in the small business category, whichwas presented by the Durban Chamber of Commerce and Industry (DCCI),” he reveals. Anderson Engineering is a project- based company with production and turnover being largely dependent on successfully securing purchase orders for turnkey projects. “In this sense we have grown the business to include a level of flexibility that balances and offsets resource availability against demand. We are continually developing customers and looking for opportunities in new markets,” De Jager tells African Fusion . Current offering and capability Currently employing 58 people, the rangeof equipmentmanufactured in the company’s Pietermaritzburg premises is exceptionally broad. “Our key expertise is the ability to fabricate customised stainless steel processing equipment of the highest precision andquality. We are the ‘go-to’ business for highly complex projects and excel at turnkey design and build projects. “We have also developed a number of highly innovative mixing solutions, such as the AndersonContramix and the Anderson Magnetic Mixer. In addition,

On Thursday October 25 2018, Anderson Engineering won the Sassda Stainless Steel award in the Agro-Processing, Food & Beverage Category for its Combo Emulsi Mixer (ACE) mixing system. Inset: Ingredients are introduced directly into a low-pressure pre-mix dispersion chamber, which draws and then propels the various ingredients directly into the high shear region of the mixer.

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SAIW: Member profile

ago the value is of investing in our own in-house personnel,” De Jager notes. “Our facility has two overhead cranes with a capacity of 3.0 and 5.0 t, re- spectively. We have all the necessary metalworking equipment: press brakes for bending; straighteners, cutters, lathes, and more. This enables us to do most of our engineering and fabrication work in-house andwe have been able to overcome skill shortages by investing and training young talent and our loyal employees,” he adds The materials we use consist mostly of the stainless steel grades: 304L, 316L, LDX 2101, SAF 2205; alongwithmild and structural steel for support structures. “We use gas tungsten arc welding (GTAW) extensively, along with shielded metal arc (SMAW) andwe operate a fleet of 3-phase 380 V welding machines for both GTAW and SMAW processes – and we prefer using the Miller and Matweld high frequency inverter-based ma- chines,” he tells African Fusion . Anderson Engineering uses experi- enced and coded welders with produc- tion being done under the strict guide- lines of its accredited ISO 3834 weld quality system. “We have alsoappointed a responsible welding co-ordinator in accordance with the requirements of ISO 3834 to ensure compliance with the ever-changing codes and regulations and todrive continuous improvement of our welding procedures and end quality standards. “All projects are managed in accor- dance with strict quality management plans and in this regard, we are also ISO 9001:2015 accredited,” he adds. “I believe ISO3834, since its introduc- tion into South Africa about 10 years ago, has improved standards within our company. As well as guaranteeing compliance to all statutory and regula- tory requirements, the fact that ISO3834 is an international standard makes us competitive, not only on a national level but also on the international stage. The food and beverage, pharmaceu- tical chemical and personal care indus- tries we serve insist on extremely high weld finish and weld quality standards and our ability to demonstrate compli- ance to the ISO 3834 standard for fusion welding gives our customers the peace of mind they require,” De Jager says. Other notable successes Earlier in October 2018, Anderson Engi- neering alsowon the 2018 KZN Exporter

we have just launched a new mixing solution known as the Anderson Combo Emulsi Mixer (ACEMixer),” De Jager says. The Sassda awardwinning Anderson Combo Emulsi Mixer (ACE Mixer) was specificallydeveloped for thehomogeni- sation of products with poor miscibility suchasmayonnaise, creams, sauces and ointments; or those with high viscosity. The ACE Mixer has a three-stage multi-chamber modular hygienic de- sign. At the heart of this innovative solution is a rotor/stator combination that generates high shear and creates a stable homogenous product. Ingre- dients are introduced directly into a low-pressure pre-mix dispersion cham- ber, which draws and then propels the various ingredients directly into the high shear region of the mixer. The product is discharged through a recirculation pipeline back to the processing vessel by means of an im- peller. “The ACE Mixer combines years of experience in emulsification, effec- tive technology and innovation to de- velop amachine capable of quick batch times for high-quality emulsions,” says De Jager. Being specialists in stainless steel, Anderson Engineering has become very experienced in hygiene engineering. “True to our roots in the dairy industry, we specialise in servicingmanufacturers requiring extremely stringent standards of hygiene, such as those in the pharma- ceutical industry and many processed food producers,” he continues. From a welded fabrication perspec- tive, what sets Anderson Engineering apart from other processing equip- ment manufacturers is its ability to offer complete turnkey solutions. “Our involvement with these projects starts from conceptualisation and finishes with training and handover of the commissioned plant. We do this from a depth of knowledge and experience accumulated over the last 60 years. This puts us in the perfect position to offer unique ‘hygiene-engineered’ solutions to our customers,” he says. Anderson Engineering’s current team consists of qualified engineers, draught- sman and technicians, with years of practical experience. Workshop person- nel are responsible for the fabrication of the equipment and consist of ma- chinists, boilermakers, coded welders, fitters and grinders. “We are committed to increasing our skills base by develop- ing young talent and realised some time

Anderson Engineering has become very experienced in hygiene engineering, which requires exceptionally smooth surfaces so that clean-in-place solutions can be effectively applied. of the Year Award in the small business category. In 2016, the companywon two Sassda Awards for Product Innovation: for the Anderson Contramix and the Anderson Magnetic Mixer. “Our greatest success, however, is being appointed and completing highly complex and large scale projects such as, to name a few, the recently com- pleted NBI fractionation project in KZN, theSorbitol storageupgrade for Unilever inNigeria, a 500 ℓ Contra-mix System for Amka Products, and an Arachis Oil Bulk Storage System for Aspen Pharmacare in East London,” De Jager says. As a company, expertise in hygiene engineering and highly specialised cus- tomised turnkey solutions remain key. This enables the company to differenti- ate and specialise in the competitive market place. “Our core values are respect, flex- ibility, a positive attitude, honesty and commitment. More than ever, in this our 60 th year, we celebrate these values, together with our legacy of many ac- complishments. “With the momentum this gives us, we look toward to an ever brighter fu- ture. Although 60 years old, the face of our company is very young with a core group of talented young professionals and a focus on training and nurturing young people who show promise. “We at Anderson Engineering believe that this, together with our flexible and adaptable culture, makes us ready for the opportunities ahead and, as always, we remain committed to outstanding client service and design excellence,” De Jager concludes.

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WeldCore innnovation from eNtsa

eNtsa: Innovation through engineering

African Fusion visits eNtsa, an internationally recognised research and innovation hub and engagement institute within Nelson Mandela University, and talks to its director, Danie Hattingh, about the global success of its WeldCore® materials testing technology, its world-class high-temperature small punch creep testing facility, and the unit’s extended role in developing local business and technical competence.

N elsonMandelaUniversity’seNtsa, a registered Engagement Insti- tutewithin theuniversity, started operations as the Automotive Compo- nents Technology Station (ACTS) in May 2002atthethenPortElizabethTechnikon, which was merged into Nelson Mandela University (then NMMU) in January of 2005. The name ‘eNtsa’, derived from the word, ’eNtsha’meaningnewinoneof the local isiXhosaAfrican languages native to the Eastern Cape, was adopted in 2011 withaviewtostrengtheningtheindustrial focus of its work and commercialising patented technologies. The current director, Professor Danie Hattingh, was one of the group’s original

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The Weldcore® process involves two stages. Sample retrieval: a cored hole is cut (1); the core is extracted (2); the hole is tapered (3). Hole repair: a consumable taper is inserted and the consumable is rotated to form a plug weld (4).

a steam line for materials evaluation without compromising the integrity of the piping. A representative cylindrical metal- lurgical core sample is removed from the pipe wall while leaving a blind-hole, with the inner wall intact. The hole is then repaired using Tapered Friction Hydro Pillar Processing (TFHPP), a purpose-developed solid-state friction welding technique. Both the sample cutting and the TFHPP repair equipment are mounted onto the same machining frame – developed by Hattingh’s team in conjunction with Philip Doubell – en- abling sampling and repair to proceed as sequential processes. “Initially the process was applied outside of the existing welding codes but since achieving incorporation of the repair procedure into ASME IX (2015), the application numbers increased drastically to about 35 sampling tests per a year. “The total investment in the devel- opment phase of WeldCore was R32- million with the main support coming from Eskom and the TIA. The initial research in solid state welding at the Nelson Mandela University started in 2000 and can be seen as the knowledge foundation on which the WeldCore technology was built. Our involvement with the process and the first prototype application dating back to as far as 2006 gives us high levels of confidence in the process,” Hattingh tells African Fusion .

foundingmembers. Anactive consultant who continually develops networking links with industry, Hattingh employed twoMasters students during those early years. In the mid 2000s, Hattingh and his team were involved with research and development work in aid of high value large-scale engineering projects, most notably with Eskom to develop alter- native materials’ sampling and weld repair techniques for its ageing steam boiler fleet. From the Eskom side, this work was pioneered by the late Philip Doubell, Eskom’s Chief Welding Engi- neer, whowith the eNtsa teamwonmul- tiple awards for the work in developing techniques for determining the fitness- for-purpose and safe extended life for operating power plant components. At the heart of this development was the nowpatentedWeldCore® sample ex- traction and repair technique, whichhas now been widely adopted by Sasol and Eskom in South Africa as well as interna- tional plant operators for assessing the condition of turbine and thick-walled steam piping subject to high pressures and temperatures. Describing the technique, Hattingh says that WeldCore® is a novel sample and repair technique that involves in- situmaterial sampling, of high-pressure steam lines, for example, followed by an immediate hydro pillar weld repair to replace the extracted core. This allows a sample to be quickly extracted from

The Weldcore® sample cutting and TFHPP weld repair equipment was developed by Hattingh’s team in conjunction with Philip Doubell.

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Following sample extractionof cores, typically 8.0mm in diameter and 15mm long, thematerial conditionof thepiping in use is comprehensively characterised at eNtsa via a series of tests. “Most im- portantly, we need to establish the ex- tent of the accumulated creep damage and the remaining creep life,” notes Hat- tingh. The core sample is, therefore, first subjected to X-ray Tomography, which reveals aligned void-like defects based on the materials density variations. “The sample is then cut into several thin discs, which we then use for small punch testing for yield and tensile strengths; micro-Vickers hardness; and for wet chemical analysis. As a further extension of eNtsa’s WeldCore® value chain, the unit has es- tablished world-class expertise in small punch creep testing using 8.0 mm discs cut from WeldCore samples. “We have an onsite facility with 11 small punch creep testing systems, which we use for on-going and scheduled testing fromall over the world,” says Hattingh. Testing procedures and data evalua- tion are continuously being developing and a standardisation process is being undertaken in collaboration with inter- national leaders in this field. “We are determined to ensure that our knowl- edge and service is at the forefront of development. Small punch creep test- ing is gaining increasing and on-going acceptance by the petrochemical and power generation industries, where high temperature component condition monitoring is becoming increasingly critical to reduce risks, ensure safety and maximise economical plant opera- tion,” he says. As an extension of its WeldCore tech- nology and in support of small punch creep testing, eNtsa has also developed a surface sample extractionmachine for EDM (electro discharge machine) boat samples. Designed to collect a smaller sample from steam pipe for small punch creep and other testing, boat sampling also enables microstructural, chemical and mechanical properties to be established that enable accurate predictions of the remaining life of plant tobe establishedandplant performance to be evaluated – all without jeopardis- ing the structural integrity of operating components. “The prime focus of eNtsa is to stay at the forefront of technology innovation. We aim to be the preferred strategic partner for technology innovation and

eNtsa’s has established an onsite creep testing facility that has 11 small punch creep testing systems that are used for on-going and scheduled testing from all over the world.

• Supplier development initiative through the TIA fundedTechnology Station Programme: eNtsa assists over 120 SMEs/entrepreneurs per year, as well as many of the major automotive OEMS and Tier 1 compo- nent suppliers in the local manufac- turing industry. “We complete over 400 industry projects per year in sup- port of the local economy, providing much needed engineering skills and capabilities at all levels of the supply chain in South Africa,” Hattingh adds. • The new eNtsa Training academy: In keeping with its support for in- novation in industry, eNtsa has established a training academy that draws on its specialists and academ- ics todeliver focusedand customised training on specific technologies of immediate local interest. • SANAS accredited national bat- tery and materials testing facility: This unit also runs a laboratory that can offer materials and battery test- ing, a most comprehensive range of battery performance, materials and mechanical testing services as well as environmental testing, such as salt spray tests and weathering simulations. “We have established ourselves as a strategic partner to industry and have successfully delivered multi-million rand projects and innovative engineer- ing solutions. We believe in ‘innovation through engineering’ and, by constantly striving towards teamwork, integrity, in- novation and excellence, we hope to be contributing towards creating a better world,” Hattingh concludes.

commercialisation to the benefit of South African industry,” Hattingh as- sures. As a vehicle for the commercialisa- tion of WeldCore, EDM Boat Sampling and related technologies for the power generation and petro-chemical indus- try, a spin-off service company called Mantacor has been established at Nelson Mandela University. “Manta- cor’s primary objective is to assist the power generation and petrochemical industries to determine and manage the safe operating life of critical plant components,” he adds. Other notable eNtsa programmes of research, development and industrial support include: • The eNtsa Composite Innovation Centre (CIC), which uses finite ele- ment analysis (FEA) for the develop- ment of lightweight wing structures for light aircraft; buildsmoulds for the manufacture of wind turbine blades using a large format 3D printer; ex- plores the viability of composites in the automotive sector – by building a pre-preg carbon fibre spare wheel, for example; and performs reverse engineering using sophisticated equipment for shape profiling, super- structure design and for determining possible failure modes. • The uYilo e-mobility Programme, a national TIA fundedmulti-stakehold- er collaborative programme focused on electro mobility technology and research. uYilo offers the support funding, engineering services and coordination required to grow the electric vehicle sector.

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Cover story: Afrox South Africa

A 360° integrated TIG-welding for welding at heights

Specialist gas and welding market leader, Afrox, has developeda forward-looking gas delivery solution for TIG welders working at heights on high-integrity pipework. African Fusion talks to the development team: Arnold Meyer, applications development manager; Roberto Dionisio, R&D manager for Hardgoods; and Johann Pieterse, businessmanager formanufacturing industries.

the next step is to create an effective solution that will result in increased productivity, lower production cost and improved quality – and this all hinges on maintaining a safe working environ- ment,” he continues. Working at heights is one such cus- tomer challenge, as contractors are facedwithmultiple safety risks and chal- lenges. Particularly when welding, not only does the welder have to deal with having to produce the highest integrity welds while tethered to a safety harness hundreds of metres in the air, he or she is also required to bring up welding equipment and cylinders of shielding gas before the work can begin. In order to soften the difficulties encountered, Afrox has used its 360° solutions’ ethos to develop a reliable and convenient solution for the delivery of argon shielding gas to TIG welders working at height, coupledwith a range of portable high-end welding machines that make quality welds easier to achieve. At the starting point of this solution is Afrox’s patent-pending multi-user pressure panel (MUPP), an innova- tive design that removes the need for shielding gas cylinders tobe lift- ed to thewelding level. “TheMUPP enables separate argon torches to be supplied tomultiple TIGwelders working on the plant’s piping. And the panel is not a manifold. Through this pressurised user panel, eachwelder draws a constant pressure and flow, regardless of how many welders are working,” explains Johan Pieterse. “This completely eliminates the need to transport and lift bulky, heavy cylin- ders and cylinder packs onto elevated platforms, which results in amuch safer working environment with improved

The Afrox development team for its 360° integrated TIG-welding solution for welding at heights, from left: Roberto Dionisio, R&D manager for Hardgoods; Arnold Meyer, welding engineer and applications development manager; and Johann Pieterse, business manager for the manufacturing industries.

T he Afrox, 360° Integrated Cus- tomer Application Solutions programme, is an internally de- veloped approach to doing business. “It always starts with a complex customer challenge followedby apartnershipwith the customer to develop a joint solu- tion,” says Johann Pieterse, business manager for manufacturing industries. “Oncewe have a goodunderstanding of the challenges our customers face,

The new Miller TIGRunner Maxstar 280 DX is a 24 kg portable unit that is ideal for connecting to an MUPP for TIG welding at height.

quality and productivity and reduced operational costs.” he adds. Describing how the system works, Arnold (Arri) Meyer says that the MUPP is connected to a gas supply on the ground via a stainless steel braided hose. “The MUPP is connected to a bulk gas supply at ground level, which can be a manifolded cylinder pack (MCP), which, for argon, consists of a pack of 15 200 bar cylinders; a portable cryogenic container on a skid (PCC); or a perma- nently installed cryogenic bulk supply, depending on thewelding requirements and the construction duration,” Meyer tells African Fusion . From the ground supply, the gas is regulated down to a pressure of 10 bar and fed through a reinforced braided stainless steel hose to the MUPP at the welding level. The lower pressure and flow rate into the MUPP means that the pressure losses are relatively low – less than 0.5%– so the MUPP is at nearly the same pressure.

At the heart of Afrox’s 360° integrated TIG-welding solution for welding at heights is new multi-user pressure panel (MUPP), which enables up to eight TIG welders to work independently without the need for gas cylinders at the welding level.

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