RIGHT PUMPS WILL MITIGATE MINES’ RAINY SEASON RISKS

During the drier months of the year, it is easy to forget that the pumping equipment at mining sites or process plants might not be up to the demands that the rainy season brings. 

In fact, 90% of pump failures are from putting the wrong pump into the application. This is the view of Justin Bawden, Key Account Manager at Integrated Pump Technology, local distributors of Grindex submersible pumps. Being aware of the factors and influences of each application is vital to providing a suitable and lasting solution – which will mitigate the risk of flooding and consequent loss of life, equipment and production.

“Where dewatering activity is conducted, it is imperative that monitoring and forecasting of water inflows is done – whether on opencast or underground mines,” says Bawden. “This will allow for the necessary planning and specification of the correct capacity of pumping equipment, as well as hose sizes and materials.”

On one site, he says, a customer was able to meet dewatering requirements with just two 37kW pumps for most of the year. With the rainy season, they had to add another four of these units, based on their previous experience. He points out that Integrated Pump Technology understands these changing needs, and keeps the right pumps and quantities in stock.

“Another challenge is that mines will generally have multiple pumps located around their operations, and these are frequently moved from one location to another as needs change,” he says. “Personnel can lose track of which models and capacities are needed where – and the size and condition of the pipelines in place may not always suit the application.”

When responding to customer requests, Integrated Pump Technology is careful to ensure that the existing pipeline on site is suited to the scale of the pumping solution. This means being clear on the pipeline’s diameter, length, material of construction, age and condition – as well as valves or bends that may affect flow.

Technological innovation is also helping to mitigate risk of pump failure, he explains. The smart unit on Grindex pumps, for instance, protects them against overheating, phase rotation and phase loss. There is also the air release valve, making Grindex pumps capable of running dry for extended periods of time. 

He also recommends the regular performance testing of dewatering pumps to ensure they are still operating on their rated curve. This will give added peace of mind that these units will deliver the expected duty in critical dewatering functions. The tests should also confirm the energy efficiency of the pumps, to control operating costs. 

The long term benefit of such tests is significant, he explains, as timeous maintenance interventions will ensure a longer product lifecycle. As part of its service offering, Integrated Pump Technology can run these specialised tests for customers on a range of pumps. Keeping sites effectively dewatered needs quick service turnaround too, so critical parts and basic repair kits are readily available for Grindex submersible pumps, notes Bawden. 

ZENZELE PRECAST PRODUCTS CEMENTED WITH AFRISAM QUALITY 

Zenzele Pavers and Cladding, a family-run Pretoria-based manufacturer, credits its unwavering commitment to quality and its lasting partnership with leading cement supplier AfriSam for its successful growth. Today, the business serves both local homeowners in Pretoria North, Ga Rankuwa, Soshanguve and broader regions, as well as large developers and construction contractors.

Since its inception in 2007,Zenzele has specialised in precast products from concrete pavers and bricks to cladding, kerbs, blocks, and tiles. “The backbone of our success is high-quality cement, ensuring consistency in results and colour,” says Founder and Owner Wendel Krook. “Our enduring relationship with AfriSam, who mirrors our dedication to quality, reliability and consistency, plays a significant role in our growth.”

The company’s core principle of delivering a product that is ‘good enough for their own home’ has attracted a diverse clientele, ranging from local families to large commercial customers. Zenzele Co-Founder Hengelene Krook says, “Our loyal customer base is built upon quality, service and the trust that our products will pass the test of time.”

This commitment to quality extends to Zenzele’s workforce, marked by low staff turnover and retention of skills and experience, ensuring attention to detail in all business aspects. General Manager Jacqueline O’Kelly, Zenzele’s first employee, applauds AfriSam’s support and reliability in meeting Zenzele’s high-quality standards.

Sales and Marketing Representative Tinus Redelinghuys emphasises AfriSam’s vital role in the success of phased construction projects. “With AfriSam’s quick service, we maintain a consistent supply of cement, facilitating efficient production and ex-stock deliveries,” says Redelinghuys.

AfriSam’s consistent service and high-quality cement, including the 42.5R CEM II High Strength Cement, has notably benefited Zenzele’s inventory management and delivery efficiency. Wendel Krook comments, “AfriSam’s cement consistency and quality allow us to accurately predict our paver supply and promptly deliver to our customers.”

Praising the partnership, Hengeline Krook says, “AfriSam genuinely values our relationship, a sentiment we greatly appreciate as a smaller business.”

Adele Wentzel, AfriSam’s Sales Manager Manufacturing for Gauteng, further emphasises the importance of their collaboration. “We provide technical support, share information and interact regularly to strengthen our partnership. We are proud to be associated with such a caring and well-respected company.”

Zenzele’s collaboration with AfriSam continues to contribute significantly to its growth and success, underscoring the value of quality and service consistency in the precast product manufacturing sector.

Right Pumps Will Mitigate Mines’ Rainy Season Risks

During the drier months of the year, it is easy to forget that the pumping equipment at mining sites or process plants might not be up to the demands that the rainy season brings.

In fact, 90% of pump failures are from putting the wrong pump into the application. This is the view of Justin Bawden, Key Account Manager at Integrated Pump Technology, local distributors of Grindex submersible pumps. Being aware of the factors and influences of each application is vital to providing a suitable and lasting solution – which will mitigate the risk of flooding and consequent loss of life, equipment and production.

“Where dewatering activity is conducted, it is imperative that monitoring and forecasting of water inflows is done – whether on opencast or underground mines,” says Bawden. “This will allow for the necessary planning and specification of the correct capacity of pumping equipment, as well as hose sizes and materials.”

On one site, he says, a customer was able to meet dewatering requirements with just two 37kW pumps for most of the year. With the rainy season, they had to add another four of these units, based on their previous experience. He points out that Integrated Pump Technology understands these changing needs, and keeps the right pumps and quantities in stock.

“Another challenge is that mines will generally have multiple pumps located around their operations, and these are frequently moved from one location to another as needs change,” he says. “Personnel can lose track of which models and capacities are needed where – and the size and condition of the pipelines in place may not always suit the application.”

When responding to customer requests, Integrated Pump Technology is careful to ensure that the existing pipeline on site is suited to the scale of the pumping solution. This means being clear on the pipeline’s diameter, length, material of construction, age and condition – as well as valves or bends that may affect flow.

Technological innovation is also helping to mitigate risk of pump failure, he explains. The smart unit on Grindex pumps, for instance, protects them against overheating, phase rotation and phase loss. There is also the air release valve, making Grindex pumps capable of running dry for extended periods of time.

He also recommends the regular performance testing of dewatering pumps to ensure they are still operating on their rated curve. This will give added peace of mind that these units will deliver the expected duty in critical dewatering functions. The tests should also confirm the energy efficiency of the pumps, to control operating costs.

The long term benefit of such tests is significant, he explains, as timeous maintenance interventions will ensure a longer product lifecycle. As part of its service offering, Integrated Pump Technology can run these specialised tests for customers on a range of pumps. Keeping sites effectively dewatered needs quick service turnaround too, so critical parts and basic repair kits are readily available for Grindex submersible pumps, notes Bawden.

MORE DRY-TYPE TRANSFORMERS FOR BISIE FROM TRAFO POWER SOLUTIONS

It has been five years since Trafo Power Solutions supplied Alphamin’s Bisie tin mine in the Democratic Republic of Congo with two dry-type transformers; they have performed so well that another three of these modular substations equipped with dry-type transformers will soon be on their way, to keep up with the mine’s expansion.

“This latest order is testament to the operational performance of our dry-type transformers at Bisie mine over the past five years,” says David Claassen, Managing Director of Trafo Power Solutions. “There were numerous challenges that our design had to accommodate, not least of which is a very arduous section of road in the journey to the mine.”

The mine’s location in the Walikale Territory of DRC is remote, being about 180 km north west of Goma, and more than 30 km from the national route linking Walikale with Kisangani. Like the initial order, the three 3000 kVA, 400 V/11 kV substations will be supplied in standard six metre containers to facilitate transportation. However, specialised steel bracing is required – to withstand the challenging road conditions, especially over the last part the journey.

“These conditions make the road almost impassable by any vehicle other than a six-wheeled Unimog,” says Claassen. “There is intense vibration and tilting of the cargo on these trailers, so our design and bracing is done with this in mind.”

He notes that the mine had considerable foresight in specifying the first dry-type transformers, especially given the relative novelty of this option at the time. At that stage, it tended to be standard practice to use oil-filled transformers for this type of application. Apart from the logistics, the substation solution also had to withstand the equatorial climate and frequent lightning strikes.

“The region where the mine is located is ranked in the top five most vulnerable to lightning strikes, so there is a high risk of damage to equipment related to electrical surge,” he says. “We therefore designed robust surge protection solutions on both the medium voltage and low voltage sides of the substations, and for the transformers.”

Given the warm climate, Trafo Power Solutions designed a fully redundant N+2 cooling system for the transformers; this means that each transformer is cooled by two fans, with another two fans on standby. Among the advantages of dry-type transformers in this climate is that the MV winding is completely cast in resin, so is highly resistant to humidity. 

More Dry-type Transformers for Bisie From Trafo Power Solutions

It has been five years since Trafo Power Solutions supplied Alphamin’s Bisie tin mine in the Democratic Republic of Congo with two dry-type transformers; they have performed so well that another three of these modular substations equipped with dry-type transformers will soon be on their way, to keep up with the mine’s expansion.

Another three modular substations from Trafo Power Solutions, equipped with dry-type transformers, will soon be headed to the Bisie tin mine in the Democratic Republic of Congo (DRC).
Another three modular substations from Trafo Power Solutions, equipped with dry-type transformers, will soon be headed to the Bisie tin mine in the Democratic Republic of Congo (DRC).

“This latest order is testament to the operational performance of our dry-type transformers at Bisie mine over the past five years,” says David Claassen, Managing Director of Trafo Power Solutions. “There were numerous challenges that our design had to accommodate, not least of which is a very arduous section of road in the journey to the mine.”

The mine’s location in the Walikale Territory of DRC is remote, being about 180 km north west of Goma, and more than 30 km from the national route linking Walikale with Kisangani. Like the initial order, the three 3000 kVA, 400 V/11 kV substations will be supplied in standard six metre containers to facilitate transportation. However, specialised steel bracing is required – to withstand the challenging road conditions, especially over the last part the journey.

“These conditions make the road almost impassable by any vehicle other than a six-wheeled Unimog,” says Claassen. “There is intense vibration and tilting of the cargo on these trailers, so our design and bracing is done with this in mind.”

He notes that the mine had considerable foresight in specifying the first dry-type transformers, especially given the relative novelty of this option at the time. At that stage, it tended to be standard practice to use oil-filled transformers for this type of application. Apart from the logistics, the substation solution also had to withstand the equatorial climate and frequent lightning strikes.

“The region where the mine is located is ranked in the top five most vulnerable to lightning strikes, so there is a high risk of damage to equipment related to electrical surge,” he says. “We therefore designed robust surge protection solutions on both the medium voltage and low voltage sides of the substations, and for the transformers.”

Given the warm climate, Trafo Power Solutions designed a fully redundant N+2 cooling system for the transformers; this means that each transformer is cooled by two fans, with another two fans on standby. Among the advantages of dry-type transformers in this climate is that the MV winding is completely cast in resin, so is highly resistant to humidity. 

SEW-EURODRIVE IN SA LAUNCHES ONLINE PURCHASING FOR CUSTOMERS 

In an important digital initiative to make product selection and procurement easier for customers, SEW-EURODRIVE South Africa has launched an online purchasing feature on its website. 

According to Zander Claassens, Training Manager at SEW-EURODRIVE, the portal allows customers to not only order products or parts, but also to find support in the form of documentation and CAD data. To maintain the personal touch, there is even a dedicated person to assist customers with their online requests from 7am to 9pm every day. 

“The online purchasing portal offers users many useful tools and functions, valuable information and practical assistance,” says Claassens. “It is clear that many customers are embracing online procurement platforms, especially since the Covid-19 lockdowns, and we are excited to further enhance our sales and support channels in this way.”

He highlights that the very wide and dynamic range of configurations in SEW-EURODRIVE’s offering demanded that the functions of the shopping cart be specially developed to make it as user-friendly as possible for customers. 

“We have developed four different functions that customers can choose from when adding a product to the shopping cart,” he explains. “The first is through our product configurator, which guides customers in configuring their required equipment – using drop down options from our vast range.”

The next channel would be to use the spare parts or replacement product selection function, where one of two routes can be chosen. In the first, the customer can make use of the SEW-EURODRIVE serial number found on the product nameplate. Entering that serial number is a quick and simple way of request a replacement – and ensuring that the exact configuration is replicated.

“Another route enables customers to find an SEW-EURODRIVE replacement product for a third-party drive – in other words, which is not an SEW-EURODRIVE item,” he said. “Our online tool will not understand the non-SEW-EURODRIVE serial number, of course, but if the specific criteria are supplied, we will know what the customer needs and we will supply.”

Registered customers who have already been trading with SEW-EURODRIVE can also use a third option – a customer transaction overview – to help select what they are looking for. When they log into the online purchasing portal, they will be able to view their history of quotations and orders. This makes it simple to re-order a component that has been purchased before, as they can select the item from a previous transaction or quotation, says Claassens. 

“Lastly, customers can use the drive selection assistant – a smart online tool that guides the user through three simple steps to find the right drive,” he says. “The first step is to select the application, and the second requires more application-related information; the third step then presents the customer with product configurations and suggestions – from which they can choose.”

He reiterates that customers wishing to transact on the portal can find support from a real person behind the portal, who can provide hands-on advice and assistance. Customers can also rest easy that the security of the portal is world class. 

“Our cyber-security is handled by a dedicated IT team in our group headquarters in Germany,” he explains. “Our customer and transaction data are double-encrypted when working online, while the online support is run on hyper-text transfer protocol secure (HTTPS) and is backed up on a geographical redundancy cloud-based system.”

Another security precaution is that online purchasing is not permitted using credit cards, as the company still follows its normal payment protocols with customers once they have placed items in the online shopping cart. 

BOOYCO BEAMS: ENHANCING SAFETY AND PRODUCTIVITY IN MINING OPERATIONS

Today, modern technology has become an integral part of mining operations, ensuring safety and improving productivity. Booyco Electronics, a leading player in proximity detection solutions, is at the forefront of these innovations with its gamechanging offering – the Booyco Electronics Asset Management System (BEAMS) software solution.

Centralised Information Hub

According to Anton Lourens, CEO of Booyco Electronics, the pivotal key to enhancing operations lies in centralising information from various sources, including  the mine’s proximity detection system (PDS) assets data. “BEAMS acts as a single source of information, a comprehensive hub that consolidates data from both our PDS and CPS hardware and monitoring devices into a robust database,” says Lourens.

The software suite is a web-based application that not only links the PDS hardware products and the monitoring devices, but also transforms a vast amount of data into a single, comprehensible and manageable stream. This unification provides an opportunity for stakeholders to gain greater insight into various facets of the mining operation, paving the way for increased safety and productivity levels.

Detecting Patterns for Safety

One of the fundamental achievements of BEAMS is its ability to analyse data to detect patterns which could indicate unsafe behaviour. This functionality enables mining customers to understand potential risks and design appropriate interventions, mitigating the probability of future safety incidents.

“BEAMS helps paint a comprehensive picture of the working environment, uncovering operational issues that were previously unknown,” Lourens emphasises. By quantifying the working environment and its interactions, potential risks and bottlenecks can be identified, managed and reduced, ultimately leading to a significant boost in productivity.

By leveraging the data, BEAMS can feed a digital twin model with real-time, accurate information about the state of the mine’s assets and the environment. This comprehensive data enables a more precise and reliable digital twin that reflects the current and historical conditions of the mine. 

Lourens says this allows for predictive modelling, risk analysis, and better decision-making. “With the insights provided by BEAMS, digital twin models can be utilised to their fullest potential, making them an even more powerful tool for improving safety, efficiency, and productivity in mining operations.”

Easy Implementation and Adaptability

BEAMS is engineered for easy implementation and adaptability. It operates on web browser platforms and can conform to various information and infrastructure environments. This flexibility allows for seamless integration into existing systems and workflows.

In addition to improving safety and productivity, BEAMS can integrate with lamp room management systems in underground mines. This feature ensures legal compliance with lamp room requirements and helps mines to effectively locate critical safety equipment such as lamps, self-contained self-rescuers, and gas instrumentation.

Customisable Reporting

Lastly, BEAMS can be configured to meet the unique needs of each user, offering a standard set of reports or providing customised reporting to address specific requirements. This customisation enhances the user experience, enabling a mining operation to get the most from its data and ultimately improving safety and productivity.

“BEAMS is a powerful tool in the arsenal of any modern mining operation. By centralising information, detecting unsafe interaction patterns and providing easy implementation, adaptability, integration, and customisable reporting, it is redefining safety standards and productivity levels in the mining industry,” Lourens concludes. 

THE ROLE OF CUTTER FANS IN PUMP AGITATION

The integration of innovative features during pump design has significantly enhanced performance and efficiency, with significant benefits for lowering total cost of ownership. One such component, the cutter fan, plays a crucial role in achieving effective agitation and solids handling. 

Ruaan Venter, Business Development Manager at IPR – the official distributor of Toyo heavy duty slurry pumps in southern Africa, sheds light on the functions and applications of these components, offering valuable insights into their importance in pump systems.

Cutter Fans: Enhancing Agitation and Solids Handling

The cutter fan, also known as an agitator, has revolutionised heavy-duty submersible dredge pumps. Toyo Pumps was the pioneering manufacturer to incorporate this type of agitation into its designs. Venter says that their patented curved three-blade stirring attachment, threaded onto the pump shaft just below the suction inlet, became a gamechanger in handling solids-laden slurries.

The primary function of the cutter fan is to dislodge and re-suspend solids, creating a slurry. As fluid flows towards the pump suction, the cutter fan redirects a portion of the fluid away from the pump, generating a fanning effect. This redirection and cyclic process result in a concentrated “pocket” of high solids content slurry directly in front of the pump suction inlet. This maximises the pumping efficiency and effectiveness, making it an essential feature for dredge pumps.

To protect the cutter fan, a stand is attached to the bottom of the pump. For larger pumps, an additional stub shaft is placed between the pump’s main shaft and the cutter fan, providing extra protection and stability during operation.

Differentiating Between Cutter Fans and Other Components

During pump installation, it is crucial to differentiate the cutter fan from other components. Operating the pump with a reversed rotation can lead to unscrewing of components during operation, resulting in potential damages and costly repairs.

To identify a cutter fan correctly, it is advisable to consult the pump’s rotational arrow. The cutter fan is easily visible and recognisable, as it pushes fluid away from the pump for agitation purposes. Observing the marked arrow during pump wiring ensures the correct rotation and installation of the cutter fan.

Cutter fans have significantly contributed to the efficiency and effectiveness of pump systems, particularly in managing solids and enhancing agitation. With a deeper understanding of the roles played by the cutter fan’s ability to redirect fluid and maximise solids management exemplify the advancements in pump technology. By correctly identifying and using cutter fans, pump operators can ensure optimal performance and avoid unnecessary operational issues,” Venter concludes. 

The Role of Cutter Fans in Pump Agitation

The integration of innovative features during pump design has significantly enhanced performance and efficiency, with significant benefits for lowering total cost of ownership. One such component, the cutter fan, plays a crucial role in achieving effective agitation and solids handling.

Ruaan Venter, Business Development Manager at IPR – the official distributor of Toyo heavy duty slurry pumps in southern Africa, sheds light on the functions and applications of these components, offering valuable insights into their importance in pump systems.

Cutter Fans: Enhancing Agitation and Solids Handling

The cutter fan, also known as an agitator, has revolutionised heavy-duty submersible dredge pumps. Toyo Pumps was the pioneering manufacturer to incorporate this type of agitation into its designs. Venter says that their patented curved three-blade stirring attachment, threaded onto the pump shaft just below the suction inlet, became a gamechanger in handling solids-laden slurries.

The primary function of the cutter fan is to dislodge and re-suspend solids, creating a slurry. As fluid flows towards the pump suction, the cutter fan redirects a portion of the fluid away from the pump, generating a fanning effect. This redirection and cyclic process result in a concentrated “pocket” of high solids content slurry directly in front of the pump suction inlet. This maximises the pumping efficiency and effectiveness, making it an essential feature for dredge pumps.

To protect the cutter fan, a stand is attached to the bottom of the pump. For larger pumps, an additional stub shaft is placed between the pump’s main shaft and the cutter fan, providing extra protection and stability during operation.

Differentiating Between Cutter Fans and Other Components

During pump installation, it is crucial to differentiate the cutter fan from other components. Operating the pump with a reversed rotation can lead to unscrewing of components during operation, resulting in potential damages and costly repairs.

To identify a cutter fan correctly, it is advisable to consult the pump’s rotational arrow. The cutter fan is easily visible and recognisable, as it pushes fluid away from the pump for agitation purposes. Observing the marked arrow during pump wiring ensures the correct rotation and installation of the cutter fan.

Cutter fans have significantly contributed to the efficiency and effectiveness of pump systems, particularly in managing solids and enhancing agitation. With a deeper understanding of the roles played by the cutter fan’s ability to redirect fluid and maximise solids management exemplify the advancements in pump technology. By correctly identifying and using cutter fans, pump operators can ensure optimal performance and avoid unnecessary operational issues,” Venter concludes.

BOOYCO BEAMS: ENHANCING SAFETY AND PRODUCTIVITY IN MINING OPERATIONS

Today, modern technology has become an integral part of mining operations, ensuring safety and improving productivity. Booyco Electronics, a leading player in proximity detection solutions, is at the forefront of these innovations with its gamechanging offering – the Booyco Electronics Asset Management System (BEAMS) software solution.

The Booyco Electronics Asset Management System (BEAMS) software solution is a gamechanger.
The Booyco Electronics Asset Management System (BEAMS) software solution is a gamechanger.

Centralised Information Hub

According to Anton Lourens, CEO of Booyco Electronics, the pivotal key to enhancing operations lies in centralising information from various sources, including  the mine’s proximity detection system (PDS) assets data. “BEAMS acts as a single source of information, a comprehensive hub that consolidates data from both our PDS and CPS hardware and monitoring devices into a robust database,” says Lourens.

The software suite is a web-based application that not only links the PDS hardware products and the monitoring devices, but also transforms a vast amount of data into a single, comprehensible and manageable stream. This unification provides an opportunity for stakeholders to gain greater insight into various facets of the mining operation, paving the way for increased safety and productivity levels.

BEAMS operates on web browser platforms and can conform to various information and infrastructure environments.
BEAMS operates on web browser platforms and can conform to various information and infrastructure environments.

Detecting Patterns for Safety

One of the fundamental achievements of BEAMS is its ability to analyse data to detect patterns which could indicate unsafe behaviour. This functionality enables mining customers to understand potential risks and design appropriate interventions, mitigating the probability of future safety incidents.

“BEAMS helps paint a comprehensive picture of the working environment, uncovering operational issues that were previously unknown,” Lourens emphasises. By quantifying the working environment and its interactions, potential risks and bottlenecks can be identified, managed and reduced, ultimately leading to a significant boost in productivity.

By leveraging the data, BEAMS can feed a digital twin model with real-time, accurate information about the state of the mine’s assets and the environment. This comprehensive data enables a more precise and reliable digital twin that reflects the current and historical conditions of the mine. 

Lourens says this allows for predictive modelling, risk analysis, and better decision-making. “With the insights provided by BEAMS, digital twin models can be utilised to their fullest potential, making them an even more powerful tool for improving safety, efficiency, and productivity in mining operations.”

Easy Implementation and Adaptability

BEAMS is engineered for easy implementation and adaptability. It operates on web browser platforms and can conform to various information and infrastructure environments. This flexibility allows for seamless integration into existing systems and workflows.

In addition to improving safety and productivity, BEAMS can integrate with lamp room management systems in underground mines. This feature ensures legal compliance with lamp room requirements and helps mines to effectively locate critical safety equipment such as lamps, self-contained self-rescuers, and gas instrumentation.

Customisable Reporting

Lastly, BEAMS can be configured to meet the unique needs of each user, offering a standard set of reports or providing customised reporting to address specific requirements. This customisation enhances the user experience, enabling a mining operation to get the most from its data and ultimately improving safety and productivity.

“BEAMS is a powerful tool in the arsenal of any modern mining operation. By centralising information, detecting unsafe interaction patterns and providing easy implementation, adaptability, integration, and customisable reporting, it is redefining safety standards and productivity levels in the mining industry,” Lourens concludes.