MechChem Africa April 2018

Mech Chem APRIL 2018 AFRICA

This month: CCD thickeners: a retrofit opportunity

Engineered hydraulic solutions meet SA’s needs

RhoVol: real-time sample density measurement

Creo 5.0: Build better products faster

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Power transmission, bearings, bushes and seals 8 Better service support from engine OEM Following a Cummins Media Breakfast last month, MechChem Africa speaks to Orlando Ferrão, the recently appointed general manager for Cummins South Africa (CSA), about his service vision for the Cummins range. 11 Brushless drive solution to cut materials handling costs 12 Now anyone can monitor machine health 13 Geared motor drives for strict hygiene Hydraulic and pneumatic systems 14 Engineered hydraulic solutions meet SA’s needs MechTech Africa visits the Wadeville premises of Axiom Hydraulics and talks to Eugene Tondolo about how the company’s

P U B L I C A T I O N S CR O WN

Published monthly by Crown Publications cc Cnr Theunis and Sovereign Streets Bedford Gardens 2007 PO Box 140, Bedfordview, 2008 Tel: +27 11 622 4770 e-mail: mechchemafrica@crown.co.za www.mechchemafricamagazine.co.za Editors: Peter Middleton e-mail: peterm@crown.co.za Glynnis Koch e-mail: glynnisk@crown.co.za Advertising: Brenda Karathanasis e-mail: brendak@crown.co.za Design: Darryl James Publisher: Karen Grant Deputy publisher: Wilhelm du Plessis Circulation: Karen Smith The views expressed in this journal are not necessarily those of the publisher or the editors. P U B L I C A T I O N S CR O WN P U B L I C A T I O N S CR O WN 2015/02/10 01:17:09PM

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exclusive brands are custom engineered for the hydraulic systems that drive South African industry. 17 Compact, lightweight and mobile – the efficiency trio of Utility compressors

18 Cylinder downtime lowered with extended range 19 Innovative vacuum portfolio at ANUGA FoodTec Computer-aided engineering 20 Creo 5.0: Build better products faster

MechChem Africa talks to productONE principal applications engineer and subject matter expert, Thulani Mazibuko, and the company’s MD, Charles Anderson, about the new capability and direction of Creo Parametric 5.0, which was released on March 19, 2018. 22 The development of the SRK Generation 8 SUV Automation, process control and instrumentation 24 KISS Next’s onshore gas volume measurement Following the commissioning and construction of the KISS mobile measurement station for Shell’s reservoirs on the coast of Holland, the station’s successor, KISS Next, enabled by the SICK FLOWSIC600 ultrasonic gas flow meter, is adding new features for stable gas volume measurement. 27 Explosion-proof absolute encoder fits anywhere 28 Better results for mine water treatment Minerals processing, metallurgy and materials 30 CCD thickeners: a retrofit opportunity MechChem Africa talks to Terence Osborn, commercial manager of minerals in sub-Saharan Africa, and Roy Hazell, the region’s head of sales, about FLSmidth counter-current decantation (CCD) thickeners, the P-Duc feedwell innovation and the use of LDX stainless steel for highly acidic applications. 32 Debtech’s RhoVol: real-time sample density measurement

34 Modular solutions for small chlorine plants 35 SRT sugar silo commissioned in Thailand 36 Partnerships key as SA tackles Gamsberg project Innovative engineering 42 Eaton inaugurates Wadeville microgrid

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Global power management company, Eaton, recently inaugurated a new microgrid at its Wadeville site in Gauteng, South Africa, which includes the first deployment in Africa of Eaton’s energy storage system, xStorage. Glynnis Koch reports. Regulars 2 Comment: The revised IRP: towards a better life for all. 4 On the cover: Advantages of VEGA’s 80 GHz through-air radar level measurement VEGAPuls radar sensors are not only a trusted means of pinpointing level control; they are now accurate, reliable and less burdensome than ever. 6 SAIChE News: Gauteng Members’ EWB-SA evening 38 Product and industry news 44 Back page: New hydrogen filling stations for FCVs

Cover story: VEGA Controls SA Contact: Chantal Groom +27 11 795 3249 chantal.groom@vega.com www.vega.com

April 2018 • MechChem Africa ¦ 1

Peter Middleton Jobs, the revised IRP and a better life for all A nother curve ball has been thrown at the drive towards a less carbon intensive future in South Africa. Superficially associ- ated with the signing of 27 Round 4 and 4.5

the CSIR’s Jarrad Wright, Tobias Bischof-Niemz, Joanne Calitz, Crescent Mushwana, Robbie van Heerden and Mamahloko Senatla have produced a document entitled Formal comments on the Integrated Resource Plan (IRP) Update Assumptions, Base Case and Observations 2016 . They determined that solar PV, wind and flexible power generators such as gas, CSP, hydro and biogas are now the cheapest new-buildmix. In addition, they found no technical limitation to solar PV and wind penetration until 2050, and that a ‘greater than 70% renewable energy share by 2050 is cost optimal’. South Africa, according to these CSIR profes- sionals, ‘has the unique opportunity to decarbonise its electricity sector without pain’, and ‘clean and cheap are no longer trade-offs’. They found their least cost scenario was also the one that would emit the least CO 2 , consume the least water and create the most jobs in the electricity sector; this compared to both the Draft IRP 2016 Base Case and the Carbon Budget scenario. In numbers, the IRP 2016 Base Case would be R70-billion/yearmore costly, emit twice asmuchCO 2 , consume two and a half timesmorewater and provide 10% fewer jobs by 2050. And compared to the IRP2016CarbonBudget sce- nario, their least cost scenario – 49%wind, 21% solar, 11% coal, 10%gas with the balancemade up of hydro, peaking plants and biomass/biogas – is R60‑billion/ year less costly, emits 15% less CO 2 , consumes 20% less water and, by 2050, would result in 20% more jobs in the sector. In addition, this 70% renewable scenario is adapt- able, resilient to input assumption changes and more robustagainstunforeseenchangesindemandandcost. Beyond the inescapable fact that specific workers will have to seek newopportunities every time an old, inefficient, unsafe and polluting power station is shut down, replacing these units with renewables will not reduce the number of overall job opportunities. In addition, jobs in the cleaner new era are likely to be safer, more rewarding, more secure and better paid. Renewable plants are also more distributed, spreading access to energy sector employment away fromthe coal-rich areas ofMpumalanga and Limpopo, for example. Froma policy point of viewand for the future of the younger generation, we need to put aside our immedi- ate vested interests and take the tough decisions that will eventually deliver the ‘better life for all’. q

renewable-energy projects – delayed for over two yearswhile Eskomand our former leadership champi- oned nuclear energy and squabbled about the cost of renewables –Eskomannounced the decommissioning of five of its power stations: Kriel, Komati, Hendrina, Camden and Grootvlei. This led to outrage by directly affectedEskomworkers and contractors anddemands from COSATU and NUMSA to immediately suspend the renewable IPP programme. As a result, a newperceptionhas nowbeen created that the shift to renewable energy will result in huge job losses. The 27 suspended contracts were finally signed on April 4. Minister of Energy, Jeff Radebe, said at the signing that these “long-awaited agreements will bringmuchneededpolicyand regulatory certaintyand maintain South Africa’s position as an energy invest- ment destination of choice. This initiative will enable R56-billion of new investment in the economy over the next two to three years, which will immediately contribute to growth in the economy supporting the already positive achievement of 3.1% GDP growth in quarter four.” Addressing the jobs issue, he went on to say: “This programme, as well as the proposed future initiatives, will have a significant contribution on job creation across the energy value chain, including the re-estab- lishment of industrial development and support for the technical training of young people to be absorbed in the labour market.” Chris Haw, chairman of SOLA Future Energy cal- culates that these energy projects will create 61 000 jobs and says that: “Small IPP projects have huge potential to encourage economic growth. They have a sharp focus on B-BBEE, local procurement and local operation, which means that the economic spinoffs for local economies will be more pronounced per megawatt procured.” Also imminent is the ‘high-priority’ release of the revised Integrated Resource Plan (IRP) – the replace- ment of IRP 2010 and the originator of the infamous 9.6 GW nuclear procurement number. The revised version, according to DoE director-general Thabane Zulu, will further entrench policy certainty and end the era of stop-start policy implementation. In response to the 2016 draft of the revised IRP,

MechChem Africa is endorsed by:

2 ¦ MechChem Africa • April 2018

Radar is one of the most common level measurement technologies in the instrumentation market.Whether measuring liquids or solids, from chemical plants to wastewater facilities and for ready-mix cement manufacturers, radar provides accurate, reliable level measurement without the need for ongoing maintenance and frequent recalibration. Radar sensors are not only a trusted means of pinpointing level control; they are easy to use as well. Advantages of VEGA’s 80 GHz Accurate, reliable and less burdensome than ever

W hen the process automation community discusses radar for level measurement, the conversation veers in one of two directions: through-air radar and guided wave radar (GWR.) This article explains how through-air radar operates and it’s advan- tagesandlimitationsinindustrialapplications. How through-air radar works Radio microwaves are transmitted by the antenna systemof the sensor to themeasured product, reflected by the product surface, and received again by the antenna system. Themicrowaves travel through the air, hence the label, through-air radar. The time of flight from emission to reception of the signals is precisely proportional to the distance to the

product surface: The longer the time of flight, the greater the distance. This distance is in- versely proportional to the level in the tank. The greater the distance, the lower the level. Many parameters determine the strength of the signal returned to a radar sensor. An agitated, turbulent surface will affect the reflected signal strength, and distance to the product surfacewill, too. Evennormal process conditions such as build-up on the antenna system may influence a return signal. Signal strength also depends partially on chemical composition, as not every product reflects microwaves equally. Conductive products reflect almost all microwave energy and non-conductive products reflect only a portion of the energy. Non-conductive products with low dielectric

constant, oil for instance, produce weaker signals than those with high dielectric con- stant, such as water. The range of signals a radar sensor can detect is called its dynamic range. Sensors with large dynamic range are sensitive enough to register weak signals as well as strong ones. Radar sensitivity varies from manufacturer to manufacturer and they even differ from sensor to sensor in a manufacturer’s instrument line. The focus of the microwave beam de- pends on a radar transmitter’s antenna sizeand its transmission frequency. The smaller the antenna, the wider — and less focused — the beam. The larger the antenna, the more focused the beam. That’s why the development of liquid level sensors operating at a transmission frequency of 80 GHz was such enormous news in the process automa- tion industry. At VEGA, we have seen the practical benefits of our 80 GHz level sensors, the VEGAPULS 64 and VEGAPULS 69, in over 70 000 installations worldwide, every year. In containers and silos with many internal installations, enhanced focusinghelps reduce the influence of noise created by microwave energy reflecting back to the antenna from something other than the product surface. Noise is commonplace in vessels with agita- tors, baffles, or heating coils, and the walls of the vessel itself sometimes create it. Noise is a problem because it distorts level measure- ment, but it can be overcome. The most obvious advantage to using a through-air radar sensor is that it is a non- contact level measurement that requires less maintenance due to a lack moving parts and a lack of contact with corrosive product. Users also do not have to worry about the level sensor being damaged or blocked by adhesive solids. Through-air radar sensors are unaffected byfluctuatingproductpropertiesorbychang- Radar level measurement with 80 GHz Advantages of through-air radar sensors

The same directional performance and measurement certainty available from guided wave radar (GWR, left) is now available in a non-contact, 80 GHz through-air radar devices such as VEGAPULS 69 (right).

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⎪ Cover story ⎪

through-air radar

causemicrowaves can be absorbed right into the foam. Another limitation is that, in order to use radar for level sensing, a user must

have a connection at the top of the tank. The connection can be small, but it has to be present. Through-

air radar is a great fit for the vast majority of applications, even ones with foam, but not all of them. Users would be wise to discuss the specifics of their level application with their instrument providers before choosing a technology.

Conclusion The r e ha s neve r been a better time than right now to use

The VEGAPULS 64 is ideal for continuous

through-air radar for level measurement. The instruments are more focused than ever be- fore, making them a reliable option in vessels withobstructions or applications that require isolation valves. VEGA and other instrumentation manu- facturers are pairing this hyper-focus with incredible sensitivity and intelligent software so users can measure non-conductive prod- ucts and suppress noise from false signals. High transmission frequency sensors have made antenna sizes smaller than ever, so retrofitting and mounting are less costly and less burdensome than ever before.

level measurement in small tanks where the small process fittings offer special advantages. Excellent signal

VEGAPULS 69 works with very highly focused

focusing enables its use in vessels with internal components such as stirrers and heating spirals. ing process conditions such as temperature, pressure, or intense dust generation because theyuse radiowaves tomake ameasurement. Fewprocess variables candisturb theflight of a radio wave, making through-air radar sen- sors a reliable option for level measurement. Another benefit of using a through-air radar sensor is that initial set-up and adjust- ment can be done while the vessel is in use. Installing a level device without stopping the process saves time and avoids the costs of a shutdown. Radar level transmitters are used for non- contact level measurement of liquids and bulk solids, even under high pressure and at extreme temperatures. They can be used in simple as well as aggressive liquids and are suitable for applications with stringent hygiene requirements. Radar level sensors measure light as well as heavy bulk solids with absolute reliability, even in the presence of dust and noise, without being affected by build-up or condensation. Limitations Through-air radar has tremendous capa- bilities and offers many benefits to users. However, through-air radar is not a level measurement panacea; it’s not right for use with every product. In applications with rampant, heavy foam, radar is sometimes not the right solution be- Common applications for through-air radar

80 GHz microwaves, not sound waves, to provide a very small beam angle (3.5°), along with optimised sensor performance for solids handling. Anyuserswhohave shiedaway fromradar in thepast should rethink their position, while users relying on older radar sensor should consider an upgrade. The new instruments are now very good. q

After reports of success on valves in the field, VEGA tested the VEGAPULS 64 in its Learning Centre Lab and saw impressive results. The tests revealed that level measurement through a valve is easy with 80 GHz devices and impossible with GWR.

April 2018 • MechChem Africa ¦ 5

Report on Gauteng Members’ group EWB-SA evening

D avidMing, director of EWB-SA, startedoff the eveningheld atWorleyParsons,MelroseArch,byexplainingtomembers exactly what EWB-SA is and what it aims to address in South African society. Ming told the attendees that the EWB-SA group aims to facilitate the transfer of engineering skill sets and convert this into far-reaching benefitsforlocalcommunitiesusingaproject-basedapproachtoimple- ment, install and educate those areas in need of these critical skills. Hundreds of projects have been started around the country, each with their own set of unique challenges to understand and solve. The groupstartedin2008attheUniversityofCapeTownandtherearenow nine student chapters,mainlybasedat universities and technikons, and a member base of over 1 500, established in the space of eight years. While getting projects off the ground and running, a key focus of the group is the educational value and the approach to unlocking this. Human-centred design and rapid prototyping are commonly used methods for unlocking potential of members and their teams in order to achieve project objectives at a fast pace. EWB-SA studentmembers get exposure to valuable projectmanagement sessions by being a part of the group, which equips themwith the tools to get ahead. EWB-SA allows its members the chance to go back into their communities and use their knowledge to help build up and educate thosewhomay be involvedwith or affected by the projects. While the emphasis is on building infrastructure in their communities, another valuable output from these projects is the research papers written on the outcomes. As an engineering professional currentlyworking in industry, away of contributing to EWB-SA is by joining the technical advisory board at your local university chapter. Ming said that, living aswe do in the city for themost part, we often focus only on urban problems, tending to forget about the challenges that face a largemajority of our population. “Having an understanding of the complexities involved with the everyday lives of South Africans To kick off the year’s proceedings, the Gauteng members’ group opened on a high note by showcasing the exciting organisation, Engineers Without Borders SA (EWB-SA), and giving members a chance to find out more it.

David Ming, director of EWB-SA, addresses the gathering of some of the Gauteng members’ group.

Baraka Sempuga sheds light on some of EWB-SA’s projects.

and the nature thereof are at the very heart of getting ahead of these projects,” he noted. One of the projects completed by EWB-SA’s university chapter EWB-NMMU, along with Alliance Française de Port Elizabeth Werk, included the Green Day Care Centre in the Joe Slovo Township on the outskirts of Port Elizabeth, South Africa, which was featured in ‘ArchDaily’ (www.archdaily.com /775901/social-development- project-indalo-plus-collectif-saga) for its innovative approach to using green materials (such as used bottles) for building blocks. BarakaCelestin Sempugawent intomore detail by talking through the Green Day Care Centre project in more detail and shedding some light on the various other projects being done by EWB-Unisa. Some of the key projects include bio-digesters, which supply energy to supplement and/or supply power to homes. Additionally, a partnership with a local community who could sell/buy the products made, undertook soap-making, incorporating extraction techniques

The EWB team.

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⎪ SAIChE IChemE news ⎪

on essential oils used for their aromas. While biogas is not new technology, there are always challenges to overcome, the most important being overcoming social percep- tions related to the use of manure or sewage for an everyday activity such as powering the home and other household-related activities. “We heard the story of Joseph who in- stalled bio-digesters on his farm, and these have been running for three or four years. He uses the energy derived from the digesters to cook, heat up water and watch television. He is also able to use the manure on his farm, since processing of the manure helps break down and release nutrients into the soils, which is more beneficial than using fresh manure,” said Sempuga. With an emphasis on conversion and gas projects there has been a strong representa- tion of chemical engineers on these projects, however, there aremany other opportunities available for all other engineering disciplines to get more involved, noted Dr Sempuga. How can you help? If you are a professional engineer, you can contribute on a technical level by joining one of the technical advisory boards in Gauteng, the Western Cape, or KZN. Members can also help by volunteering their time on an or- ganisational level by helping to run EWB-SA.

The Green wall of the Day Care Centre in the Joe Slovo Township on the outskirts of Port Elizabeth, South Africa. With, on average, the same budget as an RDP house the centre was built with mostly recycled materials, which were free or of low cost, and using efficient building techniques. Photo ©Joubert Loots.

Johannesburg. As there was not, David Ming and Michelle Low founded a chapter. With the help of Lara dos Santos, they gave presentations to the various engineering schools within the engineering faculty and in that same year, implemented their first project in Vredefort. In 2011, EWB-Wits was recognised as a registered society on theWitwatersrand Campus. Early in 2012 Wiebke Toussaint met with Ming and Low to talk about forming EWB-SA. It was in this year that EWB-SA had their first annual leadership summit for the two existing student chapters, which brought about important governance ideas thatwouldproveessential for thegrowthof EWB-SA’s future. Since then, EWB-SA has been hosting the annual leadership sum- mit for the committees of each university chapter to equip them for the subsequent year and to build community spirit. Manypeoplehavecontributedtobuilding EWB-SAanditschapters,generouslydonat- ing time, ideas, effort and energy. Judging from the consistent effort, scaling impact andendlessenthusiasmoftheEWB-SAcom- munity, the organisation will make a lasting impressiononSouthAfricancommunities,as well as the country’s engineering sector. q The organisation is always looking for people to help with social media, administration and training programmes such as theHCDcourse and project management. Assistance is also needed for hosting events. If you are a university student, the easiest way to get involved is by contacting one of the university chapters closest to you or by contacting EWB-SA directly. Companies interested in working with EWB SA or discussing how best to work together can contact the CEO, Jason Huang, at jason.huang@ewbsa.org and copy in

info@ewbsa.org. EWB SA is constantly look- ing to expand its presence and it’s not always about money. www.ewbsa.org

SAIChE IChemE

SAIChE Board members: President: C Sheridan Imm. Past President D van Vuuren Honorary Treasurer L van Dyk + Vice President: Honorary Secretary: EMObwaka Vice President: D Lokhat Council member: JJ Scholtz Council member: AB Hlatshwayo Council member: K Harding Council Member: M Low Council member: BK Ferreira Council Member: HMazema Council Member: MChetty Council Member: A de Bondt Council Member: MMabaso Council Member NN Coni Member (co-opted): MD Heydenrych Chair Gauteng: C Sandrock Chair KZN: D Lokhat Chair Western Cape: HMazema Contact details SAIChE PO Box 2125, North Riding, 2162 South Africa

EWB: a movement in the making In 2008, Denis Wong and Brennan Hodkinson conceptualised the first official EWB chapter in South Africa. However the two-year journey, from 2008 to 2010, from conception to establishment, was not an easy one. It involved careful planning, regular meetings with university officials and frequent visitswith potential sponsors. Wong and Hodkinson were aided in their endeavours by an enthusiastic UCT engi- neering professor, Duncan Fraser.

The initial intention was to set up a national chapter, such as the current EWB- SA, however, despite numerous efforts, this ambitionhad tobeput onhold for a timeand a more modest and reasonable beginning was settled for. Hence the EWB movement in South Africa began as a student chapter. Wong and Hodkinson began to gather the support of a small group of students within the university’s engineering faculty as they focusedon launchingEWB-UCTas auniver- sity society. So it came to be that, in 2010, Wong and Hodkinson, officially founded EWB-UCT,whichwasheadedbyHodkinson. The second chapter was established in 2010attheUniversityoftheWitwatersrand, EWB-Wits.DavidMingcalledDuncanFraser to find out if there was a student chapter in

Tel: +27 11 704 5915 Fax: +27 86 672 9430 email: saiche@mweb.co.za saiche@icheme.org website: www.saiche.co.za

April 2018 • MechChem Africa ¦ 7

Better service support from engine OEM Following a Cummins Media Breakfast last month, MechChem Africa speaks to Orlando Ferrão, the recently appointed general manager for Cummins South Africa (CSA), about his service vision for the Cummins range.

“ C ummins’ vision is to deliver an excellent service experience to clients across all of our product ranges and service offerings,” begins Ferrão. “We have different entities within the company and across the continent but, likeour ’Power ofOne’ enginephilosophy, everypart of our company is designed towork together tosupplyproducts andservices from one platform. “If we talk about coolant, for example, we have a very good Fleetguard product manu- facturedusing organic acid technology (OAT), which ismanufacturedhere inSouthAfricaby Cummins Filtration. This is an excellent prod- uct specifically designed to extend the life of Cummins engines, most notably because it

protects the aluminiumalloyswe use tomake modern diesel engines,” he says. ES Compleat OAT Extended Life Anti­ freeze/Coolant provides protection against freezing, boil over, cavitation, liner pitting, erosion, corrosion, elastomer gasket degra- dation and scaling, and is described as the ‘Life-of-the-Engine’ organic additive. “Oneoftheminormaintenanceandservic- ing tasks is to drain the coolant. So to enable customers to take advantage of the long life of our coolant, we offer offline storage and filtration solutions so that drained coolant can be safely and economically reused,” he notes. “This is just one example of howwe are striving to make it easier for our distributed service networks to better support Cummins customers,” Ferrão says. Aswith the compositionof the oil analysis, the condition of the coolant can be analysed in order to reassure users that it is 100% safe to reuse and this service is also

beingmade available toCummins’ dealer and service network. Along with the coolant, Cummins’ dedi- catedMidrand plant manufactures a number of air filters for local use. “Fromthe lubricants, coolant filters, gaskets and other service components, we make up engine service kits for clients that each have a registered part number to make planned servicing easier and foolproof. By thinking ahead about the problems, service centres are likely to

The Cummins 90 kVA C90D5 open diesel generator for standby, prime or base load supply of electricity.

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⎪ Power transmission, bearings, bushes and seals ⎪

experience, we strive to offer a streamlined service to help our network look after Cummins products in the field,” he says. “We are one of only engine OEMs to have filtration development capabil- ity and, we believe, ours is superior to most because it is central to Cummins’ campaign to make engines last longer. The correct filtration, coolant, oil and fuel work together to better protect the engine so thatmaintenance intervals and engine life can be extended – with fuel efficiency being an essential feature. “Together with the extended design life of our engines, this approach makes the total costs of ownership forCummins engineusers very low,” Ferrãoassures. Going forward into 2018, he says that CSA is on a drive to ensure clients are better provided for. “We are tar- geting two key areas of improvement, service support and parts availability. “The starting point for improving service support levels is training. We are introducing various new training programmes to increase the number of people with the skills necessary to maintainour equipment. This includes recruiting and training internal service technicians as well as making training posi- tions available to our dealers, clients and end users. We see training as vital if we are to expand access to maintenance services for Cummins engines in the region,” he argues. From a parts availability perspective, Cummins has established a central distri- bution warehouse in Waterfall, Midrand, on the same site as the Filtration and OAT coolant plant. “We are now in the process of optimising the distribution of parts from the warehouse to our regional network, to give the fastest possible response times to minimise disruption to end users. “We are looking at betterways of support- ing branches and partners in each city, secur- ing contractswith logistic and freight services to quickly and seamlessly get products and spares to where they are needed,” he says. Talking of connectivity, Ferrão says that, Cummins is also looking to have a broader visibility of products being used in its equip- ment. “We are already able to advise clients when a service is due, but we want to able to alert themtopotential failure risks so thatwe can pre-empt them. “We are currently launchingnewfiltration systems with built-in sensors, for example, which will be connected to the vehicle’s lo- cal Can Bus. Condition information can be generated that will alert operators to any problems or imminent replacement needs. The cost of this technology is decreasing and, because the life of the components can be safely extended, service and ownership cost

Ideal for remote locations, the Cummins 22 kVA

C22D5 is available with an extended service change interval and a 20 months/4 000 hours warranty that includes unlimited hours within the first 12 months. reductions are making the business case for implementation easier.” Remote condition monitoring is an im- minent reality, Ferrão believes. “We are not exactly sure when this will be a mainstream technology, but we expect it to become part of our service provision within the next few years,” he says. Another CSA initiative currently being implemented is to create a light-duty dealer network for trucks, whichwill enable smaller dealers in the automotive sector to sell parts, offer routinemaintenance services and repair specific engines for local clients. “We have engines from 7 to 3 000 kW (10 to 4 000 Hp) and no dealer can comfortably support the whole range in every aspect. So, for the likes of truck OEMs that factory-fit our engines during assembly, we see a need for targeted support service outlets across the region. “There are also large numbers of older trucks that use our legacy ADT engines and, with Capex still being constrained, we see a role for light-duty dealers to provide better services for these engine users,” he says, adding: “We want to bring dealerships into a more affordable space where both dealers and their customers embrace us as the OEM

Now manufactured in South Africa, Fleetguard ES Compleat™ OAT (organic acid technology) is a life-of-the- engine ethylene glycol-based (EG) antifreeze/coolant. rather than going the pirate route.” Ferrão thinks

the economy is going though a difficult time: “But we are determined to find ways to add value to clients within these constraints. For this we will tailor the services to offer an en- gine or a back up power unit to best suit the clients needs. Thebig thing for us is our ability to integrate our products to align with the customers need. In spite of the wide product range and the number of sectors and regions inwhichweoperate, we strive to serve clients as an integratedCummins team, making sure we all focus on improving real levels of sup- port,” he says. “We are proudly obsessed with customer service. We really want to make a difference in the businesses of our clients and to make it as easy as possible for them to depend on Cummins’ support,” Ferrão concludes. q

April 2018 • MechChem Africa ¦ 9

⎪ Power transmission, bearings, bushes and seals ⎪

Brushless drive solution to cut materials handling costs Launched by SEW EURODRIVE in Germany in 2017, the ECDriveS ® (electronically commutated drive system) is a new brushless DC gearmotor, that is now being made available to all the company’s branches countrywide for customer demonstrations.

Norman Maleka.

T he latest trend inmaterials handling has seen sectors such as warehous- ing, packing and pick-and-place systems use cheaper components for light-load conveyor applications to re- duce total supply-chain costs. In response to this latest customer requirement, SEW- EURODRIVE South Africa has launched its new ECDriveS ®  24 V drive system. “The ECDriveS is a brushless DC gearmo- tor. It also stands for ‘easy drive’, a simple and cost-efficient drive solution for roller- conveyor applications,” SEW-EURODRIVE SouthAfrica national salesmanager, Norman Maleka, explains. The latest drive solution was launched in Germany in 2017 following an extensive research-and-development programme and customer consultation, and is now being introduced to the South Africanmarket. “We have commenced with training to ensure our staff are familiar with the new product and we are currently assembling six units to go to all of our branches countrywide for customer demonstrations,” Maleka says. A standout feature of the new drive sys- tem is that it is easily integrated into existing solutions, as it features both Ethernet and PROFINET communications for seamless interfacing. “The ease of integration is a major selling point for this product, as there is no need to change networks. Other ad- vantages are precise positioning, ramp-up and ramp-down, and the ability to vary the conveyor speed.” Sensor input and output is provided for easy monitoring, with an alarm triggered in the event of any problem. The drive system has an IP 54 protection rating, in addition to an IP 66 version for more demanding applications such as industrial and food-and- beverageapplications.Thetemperaturerange is -10 °C to 40 °C, while the roller speed is up to 5.0 m/s. Gearbox speeds range from 8.5 to 645 rpm for added flexibility. “This ‘easy drive’ is easy to work with, set up, install, and maintain. This means it is particularly suited to African operating conditions, where on-site technical skills are often limited,” Maleka says. Set-up is either by dual in-line package (DIP) switches, or the drive system can be programmed using SEW-EURODRIVE proprietary software.

ECDriveS ® is a highly compact solution for smaller conveyor applications with roller sizes ranging from 300 mm to 1 200 mm.

Despite the simplicity of the drive system, it even boasts a built-in encoder for precise positioning. “The encoder allows for accurate positioning of items whenever the conveyor is stopped, which is of particular benefit for sorting applications.” While SEW-EURODRIVEhas awide range of products, particularly gearmotors, the prevailing trend in materials handling is for smaller, quick-to-assemble, easy-to-handle and cost-effective solutions. “If a customer only needs to move empty cardboard boxes orcontainers,forexample,ahigh-endgearbox is not cost-effective, in addition to the space constraints in terms of installation and com- missioning,”Malekapointsout. Thesecustom- ers typically have lowpower requirements of only30Wto40W, whichmeans that a1.5kW motor and gearbox is not an ideal solution. ECDriveS is a highly compact solution, with roller size ranging from300 to1200mm, meaning it is especially tailored for smaller conveyor applications. “These are used mainly in pack houses in co-operative agri- cultural applications, where the bulk of the items are packed manually and then placed on a conveyor to be loaded onto a truck. No parameterisation is required, which means complex elements such as PLCs are unneces- sary. It is truly a ‘plug-and-play’ system that saves customers time and money.” The launch of ECDriveS will position SEW-EURODRIVE as a preferred solutions provider. “We have tended to focus on larger

applications. However, the introduction of ECDriveS means we can now compete effec- tively, especially against inferior-quality and cheaper imports,” Maleka notes. What gives SEW-EURODRIVE the leading edge in themarketplace is its service support. “We hold over R130-millionworth of stock at any given time to ensurewe can provide com- prehensive solutions to our customers. Our well-established footprint throughout Africa further extends our aftermarket capability.” ECDriveSwas launchedofficially at bauma CONEXPO Africa 2018. Many system inte- grators and end users were present. “Our strategy is not to limit ourselves to particular industries or products. We showcase our full range because we are involved everywhere. “Gearmotors have multiple applications, from construction equipment such as brick- and block-making machines to warehousing, logistics, and even hoisting.We could not just select a couple of products to focus on a few select market segments, but rather show- cased our total solutions approach.” Maleka says that the introduction of the high-volume ECDriveS is integral to SEW- EURODRIVE’s strategy of offering a total solution. “We strivecontinuously to introduce products that add toour overall portfolio, and which complement our existing range. “At the end of the day, we want to make our customers aware that we can offer them complete end-to-end solutions, and not just components,” he concludes. q

April 2018 • MechChem Africa ¦ 11

⎪ Power transmission, bearings, bushes and seals ⎪

Now anyone can monitor machine health

Simplified inspection, process and machine health data collection and analysis are now within everyone’s reach with SKF Enlight QuickCollect.

S KF has made it possible for anyone to monitor machine health without the need for extensive training or diagnostic expertise. Combining an easy-to-use sensor with mobile apps, us- ers can quickly and easily identify machine condition and share inspection, process and machine healthdata company-wide. Custom- ers can also tap directly into SKF’s remote diagnostic centres for expert analysis and advice. It’s easy to get started andwith entry- level setup costs, there’s no need tomake the case for capital expenditure. Handheld sensors and mobile apps make it easy to capture, share and store inspection, process and machine health data. In the past, collectingmachine andprocess data required expensiveequipment and reliedonhigh levels of in-house expertise to understand the data and diagnose machine problems effectively. SKF Enlight QuickCollect is designed to make it easy to collect and interpret this valu- ablemachine data, helping customers to opti- mise their rotating equipment performance. Simple and robust, the SKF QuickCollect handheld sensormonitors for awide range of issues relating to vibration and temperature. The sensor transmits datawirelessly toanapp on amobile device, providing instantmachine diagnostics and the ability to store and share data for further analysis. TheSKFQuickCollect appoffers entry lev-

el, on-the-spot analysis capability. Upgrading totheSKFDataCollectappprovidesextended diagnostic capabilities, customised forms for collecting all types of inspection and process data, aswell as the ability to connectwithSKF expert remote services. In addition, by con- necting directlywith SKF expertise, access to SKF’s industry-leading diagnostic personnel and resources can be obtained. Few organisations today possess a large body of in-house expertise on preventative maintenance, rotating equipment perfor- mance optimisation and root cause analysis. SKFEnlightQuickCollect can solve this prob- lem,providingbuilt-inexpertisethroughauto- mateddiagnostics.Andwhenusersneedmore advanced support, they can conveniently connect directly with SKF remote diagnostic services, giving themaccess toworld-leading machine and bearing performance analysts. SKF Enlight QuickCollect puts industry- leading expertise and benchmark data at the customers’ fingertips. Requiring limited training and no spe- cialist skills, SKF QuickCollect empowers the workforce to monitor plant machinery. Using the SKF QuickCollect Sensor and the SKF QuickCollect app, users can easily start checking the ‘on the spot’ condition of their rotating machinery. And upgrading to the SKFDataCollect app providesmore detailed, colour-coded machine condition feedback

When users need more

enhanced internal memory of the IMx-8 (4 GB as opposed to the 8 MB of previous models) enables stand-alone monitoring and logging of large amounts of data, which is particularly beneficial for remote ap- plications where routine site maintenance visits are infrequent. Moreover, following a critical event, data can be easily accessed for analysis. Freddy Hernandez, SKF product line manager, surveillance systems, comments: “Customer feedback confirms many ap- plications require less than the 16 chan- nels offered by our existing Multilog IMx solutions. The IMx-8 now offers a more compact, versatile means of monitoring rotating machinery and this cost-effective, reduced channel online system fills a large gap in the market, offering new features, functionality and flexibility not available anywhere else.” q based on ISO standards, guided measure- ment support, and the option to connect to SKF expert diagnostic support when needed. The SKF DataCollect app also provides customised forms to collect a wide range of useful data from around the customer’s facility. In addition to machine monitoring, operations staff can perform visual inspec- tions guided by instructions, and record information such as pressures, lows, lubrica- tion levels, etc. Instructions can be provided for operators to clean and inspect equipment, and to tell them when and how to seek help when needed. This kind of inspection data can be invalu- able to complement customers’ maintenance programmes, and can also be used to au- tomate support for activities such as plant safetyandEHSaudits,environmental/quality/ air leak inspections, equipment checks, and lubrication rounds. q advanced support, they can connect directly with SKF remote diagnostic services using SKF Enlight QuickCollect.

Affordable machine health monitoring with SKF Multilog IMx-8 The compact Multilog IMx-8 from SKF of- fers sophisticated yet highly cost-effective, fit-for-purpose condition monitoring for a multitude of industrial applications. for mechanical and fluid power train appli- cations while the combination of an ‘Event Capture’ featurewill appeal tomachine tool users who require a cost-effective crash- detection capability.

This latest 8-chan- nel unit forms part of SKF’s highly popu- lar IMx-16 and -32 channel machine health-monitoring platforms. Initially targeted

Taking up less cabinet space compared to the 16 and 32 channel variants, the com- pact DIN-rail mounting 8-channel IMx-8 is easily installed into instrument cabinet enclosures, often alongside existing instru- ments. Suitably housed, it also serves space- restricted applications such as small-size marine thruster pods or direct-drive wind turbines where instruments often need to be located as close as possible to the moni- tored machinery. Ethernet power and communications and the app-based configuration interface make installation of the IMx-8 extremely easy; most users can set up the systemwith little or no previous experience. The greatly

at the offshore wind and marine sectors, the versatile and easy-to-use IMx-8 brings affordablema- chinehealthmonitor- ing to a much wider industrial user base. The system is ideally suited

12 ¦ MechChem Africa • April 2018

Geared motor drives for strict hygiene Bearings International (BI) distributes the full range of Bauer geared motor drives to cater for the diverse hygiene requirements of the food and beverage industry. F romstandard cast-iron, epoxy coated surfaces to complete stainless-steel units, BauerGearMotor provides drive solu- tions for a range of application requirements. Its standard drives comprise Series BG helical-gear motors, Series BK helical bevel-gear motors, Series BS helical worm-gear motors, and the shaft-mounted Series BF gearmotors. In addition, CleanDrive™, AsepticDrive™, and AsepticDrive™ washdown duty drives, which all come with mounting solutions ideal for hygienic applications. In the hygiene-sensitive segments of the food and luxury foods industry, drive systems are usually located in the same area as open product flow, which means that very stringent criteria have to be adhered to. “Not only should the drive units be readily accessible and easy to clean, but they must also offer the best possible resistance to commonly-used cleaning products,” notes BI business unit head, Ross Trevelyan. Cleaning strategies incorporating the alternatinguseof acidic and alkaline productsmust also be taken into account. “Another problem that has to be contended with is the air turbulence generated by the drive and its associated air circulation,” Trevelyan points out. In addition, if the drive system is located above the product, it poses a risk of direct contamination of the entire product cycle. Proper hygiene is therefore critical, as bacterial growth on any surfaces must be avoided at all times. Bauer’s special geared motor design features fully smooth surfaces for efficient, comprehensive cleaning. All surfaces slope by at least 3.0° to prevent the formation of dirt deposits, as well as allowing cleaning products to run off. The outer surfaces of the drives are coated with a water-repelling paint, which results in even better hygiene properties than stainless steel, which is hydrophilic. In addition, all motors are designed to complywith the latest energy- efficiency rating. “With over 90 years’ experience in drive design, Bauer is a global leader in drive engineering for the food and beverage industry. Our distributorship of this leading brand is part of our strategy to offer best-in-class technology for diverse industries, backed up by our comprehensive aftermarket and technical support,” Trevelyan concludes. q

Bauer’s range of CleanDrive™, AsepticDrive™, and AsepticDrive™ washdown duty drives come with mounting solutions ideal for hygienic applications.

April 2018 • MechChem Africa ¦ 13

MechTech Africa visits the Wadeville premises of Axiom Hydraulics and talks to Eugene Tondolo about how the company’s exclusive brands are custom engineered for the hydraulic systems that drive South African industry. Engineered hydraulic solutions meet SA’s needs

S ince its inception in 1959, Axiom Hydraulics has been designing and installing hydraulic systems tailored to individual applications. “While we specialise in the design, supply, repair, reconditioning and servicing of a compre- hensive range of hydraulic components and equipment, we aremost proudof our custom- engineering capability,” Tondolo says. “On the service side, we have a large stockholding of the world’s leading hydraulic brands, which reduces leadanddelivery times for southern Africa’s fluid power industry. In addition, though, we have state-of-the-art production, design and testing capabilities at our 5500m 2 Wadeville facility, enabling us to deliver intelligent solutions toour customers,” he continues. Following the 2016 move to Wadeville, Axiom is now settled and embedded in its new home. “This is an excellent site and we now feels like we have always been part of the Wadeville community,” he says.

Taking MechChem on a tour of the facility, Tondolo starts at the dedicated warehouse, which is spacious and open with separate racking areas for each of the different brands in the stable. He points out the latest edition to Axiom’s collection, the Ausco brand of braking systems. “Ausco comes from the USA and the company is amarket lead- er in OEM brakes for off- highway vehicles. Its spring- applied multi-disc, hydraulic callipers and ball ramp brakes are widely used in South Africa, and a new design has been released for Land Cruiser braking systems cus- tomisedforuseunderground,”Tondolo tells MechChem Africa . He next points out the ASA range of forced draft coolers for hydraulic oil, a simple radiator-based system with a range of fan

A cornerstone of the Axiom Hydraulics range is the Black Bruin range of low-speed, high-torque hydraulic motors, which have been an exclusive and successful product for the company for many years. drive options: 12 and 24 Vdc; 230 Vac; and hydraulic motor options. “These coolers are available in cell-phone sized units for small pilot systems all the way up to very large industrial units with 7.5 kW fan motors,” he says,addingthat,likecarradiators,coolersare uncomplicated but essential and tend to be integrated intoAxiom’s custom-built systems. A cornerstone of the Axiom Hydraulics range, however, is the Black Bruin range of low-speed, high-torque hydraulic motors, which have been an exclusive and successful product for the company for many years. “We have recently had a lot of success with our Black Bruin motors on raise boring machines on an Anglo pilot project. These underground machines used our largest SD15 litre hydraulicmotor, which can deliver over 75000Nmof torque, todrill out the gold bearing reef between two parallel haulages, rather than having to drill and blast the rock face,” Tondolo explains. The mining industry is very excited by the possibilities of raise-boring technology, which significantly reduces the amount of waste

Axiom Hydraulics now has three state-of-the art HAAS VF3 CNC machines that manufacture manifold blocks, all day every day.

14 ¦ MechChem Africa • April 2018