Monthly Archives: May 2020

Client Focus

SPECIALISED DRY-TYPE TRANSFORMERS FOR SALDANHA PORT UPGRADE

Transnet’s upgrade of its port facility at Saldanha Bay will include dry-type transformers from specialist company Trafo Power Solutions.

The company is supplying specialised transformers for the Tippler 3 project at the iron ore load-out station. Factory-acceptance testing was completed in December 2019, according to Trafo Power Solutions managing director David Claassen. Delivery to site is scheduled for February 2020.

The construction of a third tippler at the Saldanha Bay port is to sustain iron ore export volumes of 60 million tons per year when the existing tipplers are refurbished in future. It will integrate with the rail system bringing ore via the 860 km line from mines in the Northern Cape. Key aspects of the new infrastructure comprise the 285 tonne tippler itself, a loading vault below ground and a conveyor tunnel. New buildings, service roads, bridges, railway lines, conveyors, lighting and bulk electrical supply infrastructure are also part of Transnet’s upgrade project.

Trafo Power Solutions’ contract was for the design, supply and commissioning of five dry-type transformers. There are two 1000 kVA units and a 3150 kVA unit, both stepping down from 11 kV to 400 V. The other two units are 3500 kVA and 4500 kVA capacity respectively, taking 11 kV to 3,3 kV.

To resist the corrosive sea air, all the transformer enclosures will be manufactured from 3CR12 grade of stainless steel. The enclosures are also to be IP33-rated to ensure a high level of ingress protection against moisture and dust.

“The enclosure design also incorporates cable boxes and Type C, totally enclosed plug-in bushings for the terminations,” he says. “This provides a boot covering which is touch-potential safe, and also provides for efficient plug-and-play installation.”

This is a significant improvement on the regular lug and bolt copper connection, which would just be shrouded by a heat-shrunk material. The special terminations also facilitate easier maintenance or removal.

“The units will provide the medium-voltage supply for the Tippler 3 project and its associated infrastructure, including equipment like conveyors,” he says. “All the transformers will be supplying non-linear load to a certain extent, so they have been designed with a K-factor of four.”

The K-factor is a measure of a transformer’s ability to withstand the heating effects of non-sinusoidal harmonic currents created by electronic equipment. The higher the K-factor, the greater the harmonic heating effects.

As dry-type transformers are cooled without the use of oil, these units will receive forced ventilation when a preset temperature is reached. This ventilation is provided from a row of fans which Trafo Power Solutions has designed to be bolted below the location of the transformers.

Designed locally by Trafo Power Solutions, these dry-type transformers are manufactured in Italy by strategic partners TMC Transformers, experts in cast resin transformer technology. All products are routinely factory-tested according to IEC standards, but type-testing and special testing can also be conducted.

“The standard applicable to dry-type power transformers is IEC 60076-11,” Claassen says. “TMC’s advanced laboratory facilities allow us to conduct the full range of tests in-house, in accordance with what these standards and whatever other requirements are designated by the customer.”

At Saldanha, Trafo Power Solutions is also responsible for building auxiliary protection and control panels, which it locates remotely from the transformers. These include temperature control sensors that communicate with the port’s broader control and monitoring network.

Client Focus

QUICK INSTALLATION BRINGS MINE UP TO SPEED WITH PDS REGS

Taking advantage of the mining industry slowdown over the Christmas period, Booyco Electronics equipped another South African platinum mine with its latest Level-9 Ready PDS system.

According to Pieter Wolfaardt, chief operating officer at Booyco Electronics, this rapid installation and commissioning was an important compliance step for the mine, and was achieved with minimal impact on its productivity.

“The industry is hard at work to meet Level 9 compliance by the end of 2020,” Wolfaardt says. “By working through the annual slowdown, we were able to avoid disrupting the production cycle while further enhancing the mine’s safety levels.”

Booyco Electronics has been a leader in developing and testing proximity detection systems that incorporate collision avoidance technology and comply with the required Level 9 standard. At this level, electronic systems are required to take mechanical control of trackless mining machinery (TMM) and automatically slow it down or bring these to a stop when detecting a dangerous and significant risk situation.

The recent contract involved equipping 35 underground vehicles with Booyco CXS PDS systems, the third and latest generation of Booyco Electronics’ offering. It included the fitment of 595 Exsence cap lamps, complete with intelligent buzzers and CXS tags, for pedestrians. Testing facilities for all equipment were also installed – in the form of test stations for lamps and vehicles – to ensure every item is fully functional before going underground.

“Great teamwork from our Rustenburg branch – led by our area manager Carel Snyman – in collaboration with the mine’s staff allowed us to respond immediately to the mine’s order and collectively complete the installation and commissioning in just 19 days,” Wolfaardt says.

Among the vehicles on which the Booyco CXS equipment was installed were load-haul-dumpers (LHDs), utility vehicles and personnel carriers, as well as a rock breaker, an ambulance and a road grader.

Wolfaardt highlights that training is a vital element in ensuring that PDS equipment is used effectively. Skilled training personnel from Booyco Electronics were able to train 50 TMM operators and 407 pedestrians before the mine resumed full operations in January 2020.

“Our local manufacturing capacity means that we can control and reduce lead times, giving customers unmatched availability,” he says. “Our quick delivery and installation times are matched by high levels of local support through our footprint of qualified technicians and offices throughout South Africa.”

The mine has also engaged Booyco Electronics through a service level agreement which will include regular preventive maintenance and condition auditing. The software in the equipment provided will also be updated whenever updates are developed, ensuring that safety performance remains at the leading edge of industry standards.

Client Focus

LEVEL 4 ALLOWS SOME CONSTRUCTION MATERIALS TO FLOW

As the gradual re-opening of the economy begins, the first steps in relaxing South Africa’s national coronavirus lockdown will allow critical supplies of cement and construction material to reach specified markets.

“With the lowering of the national coronavirus level to Alert Level 4, the new regulations permit AfriSam to resume some of its production and to supply certain customers,” Richard Tomes, sales and marketing executive at AfriSam, says. “The company will now be supplying aggregate, readymix and cement products to permitted Alert Level 4 customers.”

The changes were recently signed into law by Minister of Cooperative Governance and Traditional Affairs Dr Nkosazana Dlamini Zuma, in terms of provisions in the Disaster Management Act. Tomes highlights that, despite this relaxation in the regulations, there will still be stringent safety procedures in place to protect the health and wellbeing of employees, customers and other stakeholders.

“All visitors to our sites will be required to adhere to strict procedures – aligned to the current regulations – which remain in place,” he says. “These will apply to all permitted customers who will be collecting product at AfriSam sites.”

He also emphasises that AfriSam staff adhere closely to regulations when making deliveries to customer sites. This includes the wearing of masks at all times, sanitising and maintaining appropriate social distance.

“We understand that these are difficult and challenging times for the industries we serve, and are doing what we can to support the economy’s partial recovery after the first phase of the lockdown,” he says.

“At the same time, we will be keeping all other visits to customer sites by AfriSam employees to an absolute minimum. These will only take place if they are critical, and if they are permitted under Alert Level 4 restrictions.”

Client Focus

ICONIC MSIKABA BRIDGE TO BE BUILT BY CONCOR-MECSA JV

Destined to be the longest cable-stayed bridge in Africa according to www.highestbridges.com, the Msikaba Bridge is being constructed by Concor Infrastructure in a joint venture with Mota Engil Construction. Significant work has already been done on the establishment infrastructure to support the construction works. Work on the approach roads and the significant pylon foundations and anchor blocks for the bridge are currently under construction.

Being built over the Msikaba Gorge near Lusikisiki in the Eastern Cape, the Msikaba Bridge forms part of the N2 Wild Coast project being undertaken by the South African National Roads Agency Limited (SANRAL).

When completed this spectacular bridge will also be the second longest main span bridge crossing ever built on the continent with a tower to tower distance of 580 metres. Its two pylons will be 127 metres high.

With a bridge deck at 194 metres above the valley floor, the Msikaba Bridge will be the third highest bridge in Africa, eclipsed only by the existing Bloukrans Bridge with a height of 216 metres and the Mtentu Bridge which, when completed, will be 223 metres high.

According to Eric Wisse, managing director of Concor Infrastructure, what is important is that that Joint Venture has overcome the initial community challenges through significant community engagement strategies with the various community stakeholders and businesses on board.

Concor has a strong legacy in the construction of iconic bridges, having constructed the Bloukrans Bridge back in 1983. At the same time, the company also built the Grootrivier and Bobbejaansrivier Bridges in the Eastern Cape.

The Msikaba Bridge itself will require 43,000 m3 of concrete, 2,700 t of structural steel and 1,090 t of cables and 3,100t of steel reinforcing.

Not to be overshadowed by the bridge is the balance of works contained in the contract which includes construction of 1,5 km of approach roadworks on either side of the bridge. Expressed in quantities, this will include 650,000 m³ of bulk earthworks of which 430,000 m³ is hard rock, a conventional three span bridge and four in-situ concrete culverts crossing some of the tributaries. A significant amount will be spent on projects to benefit of the wider community, including upgrading or repairing gravel roads in the district.

Wisse explains that due to the remoteness of the project as well as the logistics travelling from the northern side to the southern side (a three hour drive), a cable way will be installed as part of the temporary works. Due to the specialist nature of this installation, a company from Switzerland has been appointed to install the cable way. It is anticipated that the cableway will be complete and operational by May this year.

“The cable car system will be used to transport people and small amounts of material from one side to the other,” he says.

Work on the project was suspended following the declaration of the National State of Disaster, but has been resumed under the Level 4 restrictions with all the necessary measures having been put in place to ensure the health and safety of all stakeholders.

Client Focus

CONCOR WINS ASH DUMP PROJECT AT KENDAL

Concor Infrastructure’s order pipeline has received a further boost with the awarding of a contract to extend the ash disposal facility (ADF) at Eskom’s Kendal power station near Ogies in Mpumalanga.

According to Concor Infrastructure managing director, Eric Wisse, the work focuses on the construction of a continuous lined ash dump and its associated infrastructure. The extended facility will be capable of accommodating the ash generated by Kendal until the year 2032.

The 24-month project will commence on 1 July and also includes the construction of two dams, a stream diversion and site services, as well as the lowering of the wall of an existing Farm Dam. The Kendal award comes just months after the company signed another Eskom contract in January– for the ADF at Majuba power station near Amersfoort.

“News of the Kendal ADF award has certainly been most welcome given the uncertainty and disruption related to the Covid-19 pandemic in recent weeks,” says Wisse. “It is also encouraging that contracts of this type and scale are coming available for our civil engineering and construction sector, which has faced difficult trading conditions for many years.”

The project will require about 109 hectares to be cleared and grubbed,  almost 1,5 million cubic metres of excavation and approximately 1million cubic metres of fill / layerworks to be processed. To ensure adequate environmental protection, over 750,000 square metres of 1,5 mm HDPE liner will be used, with the same amount of 1,000 gram-per-square-metre geotextile. Concrete works will require 39,000 cubic metres of concrete, and there will be 4,400 metres of pipeline laid.

Wisse highlights that the Kendal contract will be conducted in a fully-integrated joint venture with partner company Lubocon Civils. Having previously worked as a subcontractor to Concor Infrastructure, Lubocon Civils has proven the quality and reliability of its work. The JV is an indication of Concor Infrastructure’s commitment to empowering younger firms to grow their contribution in the sector, he says.

“Among the attributes that Lubocon Civils brings is its relationships with QSE and EME contractors, where they can assist the JV to effectively award the relevant portions of work to local firms, to manage subcontractors and to develop small enterprises,” says Wisse.

He notes that the two ADF projects won by Concor Infrastructure, in their JV partnership with Lubocon Civils, is an indication of the company’s strong capacity and broad range of expertise in the civil engineering and construction space.

Client Focus

BOT MODEL CAN BOOST EMERGING CONTRACTORS, TRANSFORM MINING

Opening the doors of the mining sector to junior miners and emerging contractors can be boosted by partnerships based on the build-operate-transfer (BOT) concept, according to B&E International.

Experts in integrated crushing, mining and mineral processing solutions, B&E International brings its experience of not just operating crushing plants but designing and manufacturing its innovative equipment locally, according to the company’s director of plant and engineering, Ken Basson.

“As a committed Level 1 BBBEE contributor, we understand the importance of transforming our industry, by building local expertise and capacity,” says Basson. “We have therefore partnered with junior miners and emerging contractors to assume some of their initial risk in mining projects and giving them a firmer basis for sustainable growth.”

He highlights that new entrants to the mining sector face both financial and technical hurdles. Sourcing a fit-for-purpose processing plant is frequently a ‘bridge too far’ in terms of capital expenditure. Financial institutions usually require a strong balance sheet, which many young companies do not have. There is also the risk that a new plant may not run smoothly or to specified capacity, demanding a depth of technical expertise not yet developed by a new contractor.

“With our experience of running plants, combined with our in-house design and manufacturing capabilities, we shoulder a large portion of this initial risk for the smaller players,” he says. “We design and build the plant to suit our BOT partner’s operational needs, and then run the plant ourselves. The partner pays us only for the final saleable product from the plant.”

The arrangement is a close collaboration with the partner, who must be assured of meeting their contractual obligations to the end-customer – in the case of a coal-producing operation, for example. The production experience in B&E International – which has for decades run crushing and screening operations for its own account – is what puts their BOT partners’ minds at ease.

“The ‘transfer’ aspect of the BOT contract is also an important step in growing a new generation of miners and contractors in South Africa,” he says. “This allows for our BOT partners to take ownership of the plant after an agreed period of time, should they wish to take over the operation of processing activities.”

This allows a junior miner to build its balance sheet and skills base over a manageable timeframe, while mitigating its operational risk and ensuring a sound growth trajectory. Basson also emphasises the value of B&E International’s local manufacturing experience, especially given the steady deterioration of the Rand against the US dollar and Euro – the currencies in which most mineral processing equipment is sold.

“Our Rand-based manufacturing capability has always been cost effective, and is becoming increasingly so,” he says. “This further improves the economics of our plants’ performance and maintenance.”

Client Focus

BARGAINING COUNCIL FOR THE CIVIL ENGINEERING INDUSTRY GETS GREEN LIGHT FROM CCMA

The ongoing success of the Bargaining Council for the Civil Engineering Industry (BCCEI) has led to its accreditation by the Commission for Conciliation, Mediation and Arbitration (CCMA) being extended for another three and a half years.

“This is a great achievement, especially for a relatively young bargaining council and we are very proud,” says Merle Denson, dispute manager at the BCCEI. Denson notes that this is the second consecutive accreditation by the CCMA – demonstrating the BCCEI’s capacity to deliver on its mandate.

The CCMA’s accreditation allows the BCCEI to continue performing its dispute resolution functions, either by conciliation or – if the dispute remains unresolved – through arbitration. The green light from the CCMA follows the recent extension by the Minister of Labour of the BCCEI’s dispute resolution collective agreement, allowing its decisions to be binding on non-parties.

“The stringent accreditation process demands that we meet a range of targets and standards, as well as efficiency indicators, to ensure a standardised and optimal performance of our duties,” she says.

“Our services have consistently met CCMA standards in terms of targets like conciliation and arbitration turnaround times, zero late arbitrations awards, settlement rates and quality control measures.”

She says this shows that the dispute resolution centre of the BCCEI is “on the right track” as far as both the CCMA and the Labour Relations Act requirements are concerned. The CCMA’s latest accreditation will run from 1 April 2020 to 31 August 2023.

Detailed reporting of the BCCEI’s operations is required on a regular basis for various bodies, highlighting everything from the number of referrals, outcomes of processes, cases scheduled and analysis of the types of cases being referred. Reports also track specific efficiencies on a monthly basis.

“Reporting documents must be submitted to the CCMA each quarter, for instance,” says Denson. “We are constantly monitoring ourselves in terms of efficiency and performance through the statistics that the BCCEI system generates.”

Among the CCMA’s other requirements is that the commissioners used for conciliation and arbitration – who must be CCMA-accredited in their own right – are all independent and qualified. Their performance is also monitored by the BCCEI in line with a specific code of conduct.

Signatory parties to the BCCEI are the National Union of Mineworkers (NUM) and Building Construction and Allied Workers Unions (BCAWU) from the trade unions, and the Consolidated Employers’ Organisation (CEO) and South African Forum of Civil Engineering Contractors (SAFCEC) from the employers.