Monthly Archives: September 2022

Client Focus

LEADING THE PDS AND CPS EVOLUTION IN COAL MINING

With a strong understanding of the coal mining industry, proximity detection system (PDS) and collision prevention system (CPS) specialist Booyco Electronics continues to steer the evolution of PDS and CPS solutions that meet specific requirements for both surface and underground collieries. 

In line with the mining industry’s quest for zero harm, a stringent safety culture has held a much more prominent role in safety management in coal mines. One of the enabling factors has been the advent and increased take-up of PDS and CPS solutions, an industry where Booyco Electronics has taken a leading role since its inception in 2006, says chief sales officer Graeme Jardine. 

From the onset, explains Jardine, Booyco Electronics had a good grasp of the safety challenges faced by the coal mining industry, which informed the development of its PDS and CPS solutions. “With a solid background in coal mining, Anton Lourens, founder and CEO of the company, had a first-hand understanding of the requirements of both surface and underground coal operations,” says Jardine. “Consequently, right from the start we were able to develop fitting solutions from an informed position.”

Some 16 years later, coal mining remains a critical commodity area for Booyco Electronics, constituting about 25% of the company’s PDS and CPS installed base, with a formidable client base ranging from large coal mining groups to junior miners. 

From CWS to CXS

Informed by changing industry requirements, Booyco Electronics has evolved its offering from its first-generation technology, the Collision Warning System (CWS), to the new generation Booyco CXS system.

Based on the technology available at the time, the Booyco CWS found favour within the coal mining sector due to its reliability. Leveraging Very Low Frequency (VLF) technology, the Booyco CWS set the benchmark in the early days, especially in the underground mining environment. Use of VLF technology enabled sensors on pedestrians and on trackless mining machines (TMMs) to communicate through rock walls for optimal safety.

Fast forward to 2022, the latest generation Booyco CXS consolidates the learnings of the past 16 years, leveraging technology to achieve new levels of safety in both underground and surface mining environments. It is a best-of-breed system providing a comprehensive and integrated response to Level 7, Level 8 and Level 9 requirements, as stipulated by Earth Moving Equipment Safety Round Table (EMESRT).

“Over the years, the technology has evolved from simply a PDS solution, to incorporating many other functions such as tracking and data management. In addition to the safety capabilities, our solutions are now able to provide customers with the bigger operational picture, which includes information such as machine standing time, idling times and cycles times,” says Jardine. 

Key differentiators 

A key differentiator is the intrinsically safe nature of the Booyco Electronics solution, which bodes well for the coal mining environment. Due to the presence of flammable gases, coal mines, especially underground operations, are susceptible to explosions. One spark and a split second are all that it takes for disaster to happen. The common industry alternative to intrinsically safe solution is for suppliers to supply a flameproof enclosure to house the PDS, which tends to be expensive, heavy and impractical. 

“Because they are intrinsically safe, our products are designed within specific system specification to allow them to be deployed in hazardous areas such as coal mining,” explains Jardine. “Typical benefits of this approach compared to flameproof enclosures include cost savings in installation and maintenance of the equipment.”

In addition, Booyco Electronics is one of few companies that can offer PDS and CPS solutions for both surface and underground environments. “Some of our competitors only focus on either underground or surface. By contrast, our solutions and system architecture are by design suited to all facets of coal mining, making us a one-stop provider for operations with both surface and underground environments,” he says. 

Customer relations

Every product is as good as its support, stresses Jardine, who firmly believes that the relationship between the supplier and the customer is key to the success of any PDS installation. A key enabler is the company’s strong support footprint in the coal mining regions of South Africa. 

Its fully-fledged branch in Witbank supports the Mpumalanga coalfields, while the Richards Bay branch looks after the Vryheid/Newcastle coal mines. Each branch has a large aftermarket team of technically skilled and competent field staff, assisting customers to optimise uptime and productivity.

“We have always prided ourselves on the fact that of our 330 employees, 190 are technicians, which speaks to our commitment to provide unparalleled aftermarket support to customers. It also enforces our partnership approach to all our PDS installations because we have the technical means to ensure hassle-free operation for our customers,” he concludes.

Client Focus

UPGRADES BRING NEW LIFE TO CRUSHERS

In today’s market customers have to maximise their return on investment to stay competitive, and companies like Pilot Crushtec partner closely with customers to ensure equipment will continue to produce at the lowest cost per ton. This is according to company sales manager Charl Marais who says Pilot Crushtec, together with Metso Outotec, recently delivered and installed a world first upgrade to older Metso Outotec mobile crushing equipment.

“In doing this we created an opportunity to breathe new life into older machines in a way never done before in the industry,” he enthuses. “In this particular case the upgrade, which was done on site, was to a Lokotrack® LT300HP™ cone crusher with a belt feeder, which has now been upgraded to include a vibrating grizzly feeder. This upgrade significantly increases production capacity and decreases wear on the cone crusher.”

Migrating to the TK feeder option on Metso Outotec Lokotrack® LT300HP™ cone crushers assists in maximising productivity, increasing throughput and reducing costs per tonne for several of Pilot Crushtec’s mining and aggregate producing customers. 

Marais says these upgrades are particularly exciting for Pilot Crushtec as it is the first time this type of upgrade has been conducted within the international Metso Outotec community.

“The majority of Lokotrack® LT300HP™ cone crushers we have in the field use a belt feeder,” he explains. “However, applications changes due to market demands and customer expectations resulted in our working with customers to take their equipment to the next level.”

The Lokotrack® LT300HP™ – an efficient and flexible mobile cone crusher for secondary and tertiary stage crushing – has always been available with either of the two feeder options. The TK feeder includes the advantage of a vibrating pan feeder with a grizzly. Local customers have historically opted for the belt feeder, largely due to the lower upfront capital cost of this option. 

A belt fed cone crusher comes with a feed hopper at the back of the machine. Material from an excavator feed is received and directed onto the belt conveyor, which then carries the material to the cone crushing chamber. 

With a belt feeder, the cone crusher is fed with a high proportion of fine material. This adds to the load in the crushing chamber but does not contribute to the high value output that the crusher produces. In contrast, the vibrating feeder and grizzly bars in the TK feeder allow the fine material in the feed to bypass the crusher and go straight to the stockpile or further in the process. 

“Bypassing the fines and only crushing material that needs to be crushed increases your throughput,” says Marais. “A cone crusher is a volumetric machine by nature, and by taking out fines, you create more crushing volume in the chamber. For instance, if you bypass 20% of fines in your feed material, your production rate will increase by 20%.”

Pilot Crushtec has been able to assist several customers to upgrade their existing Lokotrack® LT300HP™ cone crushers with TK feeders. A mid-tier miner has already gone the TK feeder route for two of its units operating at two different sites. A further unit has just been commissioned for another customer running a Lokotrack® LT300HP™ cone crusher in an aggregate operation. 

Marais highlights other benefits of the TK feeder, including reduced wear. Limiting the amount of fine material that reports to the crushing chamber increases the life of wear items, particularly crusher liners. This also reduces the machine’s power draw as the cone crusher’s closed side settings are maintained, translating into lower cost per tonne of material produced. 

“As customers seek increased efficiencies and ways to reduce their bottom-line costs, we believe the trend towards upgrading machines as opposed to replacements will gain traction in the next few years,” concludes Marais. “Pilot Crushtec is committed to working closely with customers to find the best possible solution for their operations.” 

Client Focus

MINE PROJECT TAKES STAFF MEMBER FROM LABOURER TO BOILERMAKER

Murray & Roberts Cementation is excited to announced that its Venetia Underground Project (VUP) project has produced its first boilermaker. 

Thibi Jerry Phala has just completed his apprenticeship, which he began in 2019 after joining Murray & Roberts Cementation a few years earlier as an engineering assistant. Phala says he has been passionate about engineering since he was a child.

“Being part of Murray & Roberts Cementation’s VUP project inspired me to apply for an apprenticeship with the company,” he says. “Working with our experienced boilermakers – and being exposed to various engineering activities – really motivated me to develop my skills further in this field.”

The journey so far has included learning the skills of a plater – handling thick metal plates – as well as understanding steel structures, drawing and design. The apprenticeship involved studying boilermaking theory at Harmony Engineering Training Centre in Orkney for three years. The practical aspect of the apprenticeship was done on the VUP site, where experienced artisans supervised and mentored Jerry for 11 months. This achievement is only the beginning, he says. 

“I am planning to continue working hard and gaining more experience in this important occupation,” says Jerry. “This will give me a good starting point to work towards becoming an engineer.”

He urges any person with ambition to look seriously at the engineering field for a career – and to pursue this goal with commitment, hard work and resilience.

Client Focus

BCCEI CALLS FOR PARTNERSHIPS IN ROLLING BACK CONSTRUCTION CRIME

Taking an important step in addressing systemic extortion in the construction sector, the Bargaining Council for the Civil Engineering Industry (BCCEI) has signed the Anti-Corruption Pledge and set up a platform for joint action. 

Working in support of Public Works and Infrastructure (DPWI) Minister Patricia de Lille’s and Special Investigating Unit Advocate Mothibi’s Infrastructure Built Anti-Corruption Forum, the BCCEI is calling on all affected parties to be part of a collaborative solution. 

“It has been encouraging to see government and media expressing growing concern about how the construction mafia is impacting South Africa’s future,” says BCCEI operations manager Lindie Fourie. “After many months of consultation and planning, the BCCEI has an action plan in place that reaches out to all parties involved.”

Construction sites have been disrupted country-wide by criminal gangs often presenting themselves as business forums. As far back as 2020, it was estimated that the resulting losses suffered by the economy had reached over R40 billion. Representing employers and employees in the civil engineering sector, the BCCEI has been proactive, says Fourie.

“In addition to engaging with our own stakeholders, we have put our full support behind the Infrastructure Built Anti-Corruption Forum set up by Minister De Lille and the Special Investigating Unit (SIU),” she says. “We are now looking forward to building practical partnerships to roll back the lawlessness that threatens our sector.”

She highlights that the minister called for a risk analysis focusing on key threats to the execution of projects. This would include identifying high priority projects where these risks were delaying successful completion. 

“Our action plan deliberately aligns with the efforts of government departments and agencies, so that the energy of all affected parties can be harnessed,” she says. “The focus has often been on the South African Police Service to do more about stemming this criminal activity; but the long-term solution really needs everyone’s involvement.”

She highlights that the BCCEI action plan includes macro level engagements with government, as well as support mechanisms at the micro level where construction projects are planned or being conducted. The BCCEI council has approved the appointment of a resource to co-ordinate input from project stakeholders including contractors, clients, employees and communities and offer guidance to contractors when sites are disrupted by construction mafia or communities. This will include working closely with the responsible persons within SAPS mandated to address extortion incidents. 

“To help our members to execute projects safely and smoothly, we are creating a centralised database with key contacts at regional and national level,” says Fourie. “This includes unions, government departments, police, private security, community leaders and even taxi associations.”

The BCCEI is also reaching out to credible specialists who may be able to assist in resolving site disruptions. At project level, she says the plan would see engagement between clients and contractors on how to systematically deal with criminal and other disruption. 

“The aim is to equip both parties with guidelines to prevent and respond to external interference – with the support of SAPS and a national policing strategic plan,” she says. “Importantly, we would like to see every project having contact details of a nominated mobile policing unit.”

Projects should also have local contacts in the trade unions, municipalities, emergency services and Department of Employment and Labour – who will be able to provide support. Fourie emphasised that it was not enough just to react to project interference; proactive steps need to be taken to prevent it. This, she says, needs to take place within a framework of acceptable behaviour that all parties formally accept. 

“Awareness needs to be built around the value that civil engineering projects are adding to communities, and community expectations must also be carefully managed,” she says. “Reacting to disruption will need more effective collaboration and intervention – with careful monitoring and recording of information on each incident.”

She is hopeful that momentum is building in the national response to construction mafia disruption and violence. The safety of employees on site remains the key concern. A key aim must be to create a stable environment where law-abiding communities and capable local sub-contractors can benefit fully from construction works, she explains.

Client Focus

HIGH-TECH DRIVE SOLUTION MAKES ITS DEBUT AT ELECTRA MINING

One of the star attractions at SEW-EURODRIVE’s stand at the Electra Mining Africa 2022 exhibition was the company’s new-generation MOVI-C® all-in-one modular drive solution, which had its African launch at the show.

In essence, MOVI-C® is a suite of products that automates drive applications, whether they be simple or very complex. It is ideal for optimising or expanding existing automation systems or for rapidly implementing new automation projects where flexibility, rapid deployment and cost-effectiveness are key.

A true 4IR solution that offers huge productivity benefits to users, MOVI-C® can be used in a wide range of applications where processes and operations need to be automated – for example, production lines or packaging operations. “It can be applied to any situation where the speed, acceleration and torque and position of drives needs to be regulated and controlled,” says Dylan Enslin, SEW-EURODRIVE’s MAXOLUTION® engineer.

He adds that MOVI-C® can be used to implement standards-based single-axis or multi-axis applications or customised and/or particularly complex motion control applications or automation solutions.

“Generation C is a big step up from its predecessor Generation B, with better control, higher efficiency, added flexibility and a much-improved interface,” he says. “It represents the future of automation and we see it having a big future in South Africa, and further afield on the African continent.”

MOVI-C® has four main components – the requisite engineering software (MOVISUITE®); advanced control technology (MOVI-C® Controller); cutting-edge inverter technology for motor control (MOVIDRIVE®); and decentralised drive technology (MOVIGEAR® and MOVIMOT®). Together these components represent a single end-to-end modular automation system, all available from SEW-EURODRIVE with no necessity for any add-ins from third parties.

All the components can be fully integrated into any automation design, fieldbus technology or network standard. There is complete freedom of configuration when it comes to the communication technology as MOVI-C® is compatible with protocols from Profibus and Industrial Ethernet through to Modbus, Profinet and EtherCat. Another benefit is the EtherCat CiA402 protocol.

SEW-EURODRIVE's geared motors.
SEW-EURODRIVE’s geared motors.
The new range of SEW-EURODRIVE's MOVIGEAR®.
The new range of SEW-EURODRIVE’s MOVIGEAR®.
SEW-EURODRIVE's MOVI-C® modular automated system.
SEW-EURODRIVE’s MOVI-C® modular automated system.

SEW-EURODRIVE has used MOVI-C® to automate operations at its brand new Aeroton facility in Johannesburg, which now acts as the hub for its African operations. The complex includes a factory which significantly expands SEW-EURODRIVE’s manufacturing capability and which will ultimately assemble most products in the SEW-EURODRIVE range. 

The main production conveyor at the new facility is based on MOVI-C®. The installation includes the MOVIGEAR® mechatronic drive system. The MOVIGEAR® units – which combine an energy-efficient IE5 motor, gear unit and corresponding drive electronics in a single housing – control and drive a conveyor line used in the assembly of gearboxes. The modular nature of the installation means it can easily be extended in the future should the need arise.

Installation of MOVI-C® at the Aeroton facility has resulted in a 40 % productivity gain compared to the less advanced, more manual systems for assembly used in the past, says Jacques Kemp, SEW-EURODRIVE’s Geared Motor Production Manager. “This increase in productivity stems from MOVI-C®’s ability to eliminate ‘wasteful’ activities, which were previously carried out manually but which are now being done by machines.”

Kemp points out that automation should not be seen as a means of reducing employee headcount. “We have not replaced a single worker – quite the opposite, in fact. Instead, we’ve empowered our existing employees to be far more productive. This is what MOVI-C® does.”

The installation not only demonstrates SEW-EURODRIVE’s confidence in MOVI-C® but it will also allow the company to show its customers the system in operation in a ‘real world’ application. 

As Enslin says: “It showcases our abilities very effectively. It will allow customers to see MOVI-C® in action and judge for themselves the efficiencies that can be achieved when SEW-EURODRIVE’s advanced drive technology is installed in a production environment.” 

Client Focus

CONCOR’S TREVENNA PROJECT SECURES TOP SAFETY RATING PLUS 1ST PLACE IN 2022 MBSA NATIONAL SAFETY COMPETITION

Concor, a diversified infrastructure and services construction company has earned a Five Star Safety Grading from the Master Builders South Africa (MBSA) and also secured first place in the National Safety Competition in Category G for projects between R250M and R450M. Both these accolades are in relation to Concor’s construction of the Trevenna Basement project in Sunnyside Pretoria commissioned by the Public Investment Corporation (PIC). 

Both the award and the Five Star Safety Grading from the MBSA reflect the highest level of safety compliance by this leading black-owned construction company. The results are based on a stringent audit process including an on-site audit at the Trevenna site, where Concor began construction early this year. According to Martin Muller, Concor contract manager, the 11-month contract comprises a five level, 68,000 square metre super basement with all services, lobbies and finishes.

“We have deployed five tower cranes on the site to fast track the project, ensuring the safe movement of steelwork, formwork and other construction material,” says Muller. Readymix concrete is being used for the in-situ construction of post-tensioned slabs, with space at a premium due to the busy urban location.

“The exciting results of this compliance audit and the MBSA National Safety Competition hold great credibility as we have been audited and rated in relation to our peers in the sector,” he says. He notes that Concor also conducts its own internal safety audits during the life of the project in line with the Occupational Health and Safety Act and other related regulations.

Concor health, safety and environment (HSE) coordinator Margaret Dube says the MBSA audit included a detailed physical inspection of site activities, housekeeping, cranes and equipment. Aspects such as temporary formwork are also required to be signed off by the responsible engineer. 

“It also checks that all our documentation is compliant with legal requirements,” says Dube. “After scrutinising the condition of our cranes, for instance, the audit team will also check that this equipment has been inspected by a qualified lifting machinery inspector (LMI).”

She highlights the importance of the company’s HSE awareness philosophy: Stop.Think.Act! By applying this culture through visible felt leadership, safety is prioritised among staff and subcontractors alike. 

“Wherever we work, it is vital for Concor managers and supervisors to lead from the front, providing an example for the whole site,” says Muller. “This leadership must apply as much to safety as to production.”

“Concor will continue to elevate health and safety at all its sites, while delivering on projects on behalf of its clients,” Muller concludes. 

Client Focus

DRY-TYPE TRANSFORMERS’ LOW RISK CAN CUT INSURANCE COSTS

Dry-type transformers have long been known for their high levels of safety, as they are cooled by air rather than oil; insurers recognise this too, and it affects their risk ratings. 

“We see a trend in commercial buildings and shopping centres, for instance, where insurers themselves are insisting on dry-type transformers,” says David Claassen, managing director of Trafo Power Solutions. “This exposes them to less risk in their coverage of these properties, and can reduce the insurance premiums paid by their clients.”

A specialist in dry-type transformers and mini-substations, Trafo Power Solutions supplies equipment with an F1 safety rating – due to its self-extinguishing and flame-retardant features.

“The fire hazard is significantly reduced by using dry-type transformers, as there is no oil that could ignite,” says Claassen. “There is also less environmental risk, as there is no oil which can potentially leak out into soil or groundwater.” 

He highlights the ways developers can reduce the insurance element of their cost-per-square-metre to construct and operate their buildings. Installing a safer transformer will not only reduce risk levels, but can reduce the costs of associated fire detection and suppression systems.

“An insurance evaluation of a building will typically include a strong focus on fire risk, especially in warehouses where valuable stock could be vulnerable,” he says. “Where insurers detect a high fire risk, they many stipulate a range of mitigation measures, the costs of which must be borne by the client.”

Indeed, the lack of specialised systems for detecting and suppressing fires may raise premiums substantially, or even render a property uninsurable, he notes. A direct and effective way of reducing the fire and environmental risk is to install a dry-type transformer. These have been proven to be safe enough to use on ships, in confined spaces inside buildings, and in areas close to human traffic. 

“By offering our customers a technical solution with close to zero risk, we open the door to tangible savings from an insurance point of view,” he says. “In addition to being flame-retardant and self-extinguishing, the F1 rating that applies to our transformers also reflects that they will not emit harmful gasses in the event of being affected by a fire in the vicinity.”

He adds that Trafo Power Solutions also offers a specialised assessment service to insurance companies and developers. Where these firms may not have in-house experts in electrical power systems, Trafo Power Solutions can conduct a formal assessment on current installations and apply their technical expertise to advise on future installations. 

“This will allow clients to achieve an appropriate, fit-for-purpose solution with high safety levels and low maintenance requirements,” says Claassen.