Tag Archives: Zest WEG Group

Client Focus

GROWING INTEREST IN SA FOR STEAM TURBINE SELF-GENERATION

Steam turbines provide a valuable opportunity for many industries in South Africa to self-generate more of their own power requirements – and often from alternative fuels produced as a by-product of their processes.

According to Rudolf van Pype, Steam Turbine Manager Energy Systems at WEG, this technology offers benefits including energy cost reductions, more stable supply of power and a lower carbon footprint.

A leading South African firm taking advantage of these opportunities is Sappi Saiccor. Its mill at Umkomaas in KwaZulu-Natal is one of the world’s largest producers of dissolving pulp for viscose staple fibre – used mainly in the production of textiles but also in other household, industrial and pharmaceutical applications. Gas produced from this process represents a fuel source which generates steam for electricity production.

“A 45 MW extraction backpressure steam turbine from WEG will be adding to Sappi Saiccor’s energy generating capacity at its MgO3 plant,” says van Pype. “The power generated will be used for internal consumption.”

Steam turbine technology is also becoming increasingly versatile, to accommodate the specific requirements of the facilities they serve, he explains. At the Sappi Saiccor mill, for instance, there is the need to have 15 different load points served by the turbine – where in the past it was usual to have just two or three load points.

“It is now possible to provide many more load points – each one with its own inlet steam flow conditions,” he says. “The steam turbine design can cater for a steam flow range that varies considerably. For the new unit at Sappi Saiccor, this range will be from 75 t/h to 300 t/h.”

As the leading manufacturer of steam turbines in Brazil, WEG has supplied a number of units of this turbine model to customers in the market there, he says. The company’s factory in Brazil will design and manufacture the new unit bound for South Africa, and WEG will conduct the installation, commissioning and ongoing maintenance next year. The Sappi Saiccor mill will also use a 50 MVA, 11 kV WEG alternator, which will be coupled to the steam turbine.

Van Pype highlights that there is significant interest in steam turbine technology among South African companies who produce steam as part of their industrial processes – especially those who have alternative fuel sources. He notes that loadshedding has limited the productivity of many firms, who are now looking for longer term solutions.

“We receive regular enquiries from companies who operate boilers for their operations, looking for opportunities to reduce their operating costs while raising their production levels through a more reliable supply of electricity,” he says. “We are able to conduct an assessment of their steam flows and pressures, to advise on the most suitable turbine size and the amount of energy they could generate internally.”

He adds that WEG also has a depth of local expertise and supporting infrastructure to service steam turbines of various makes, and can provide maintenance contracts to give customers peace of mind. In addition to this, WEG offers its customers access to a complete set of spare parts, all of which promote high equipment availability levels.

Client Focus

A REBRANDED WEG SET TO MAKE POWERFUL DEBUT AT ELECTRA MINING AFRICA

WEG has maintained a formidable presence on the African continent for over four decades, consistently demonstrating its industry-leading capabilities at Electra Mining Africa under the Zest WEG brand. This year, a rebranded WEG is poised to make a powerful debut with a renewed focus on innovation and sustainability. 

Eduardo Werninghaus, CEO at WEG Africa, says a strong belief that a more efficient and sustainable tomorrow starts today will underpin the company’s participation at this year’s Electra Mining Africa. The company will showcase its latest advancements in hybrid power solutions encompassing renewable energy and energy storage, along with premium efficiency electric motors and drive technology. 

“With our continued commitment to supporting our customers’ decarbonisation projects, WEG aims to update the industry on cutting-edge technologies designed to reduce energy consumption and carbon footprints, while driving continuous growth and sustainability,” Werninghaus says. 

Visitors to the WEG stand at Electra Mining Africa can expect to explore hybrid power generation solutions including solar, wind, gas, and diesel powered options as well as battery energy storage systems (BESS). With an established reference base in Brazil and other countries across the globe, all these WEG technologies ensure a continuous, stable and reliable energy supply.

Werninghaus emphasises that the WEG team will be on hand to discuss specifics about all the options, and to provide further insight into the company’s extensive experience and expertise when it comes to providing sustainable energy solutions. 

On display will also be the WEG W23+ Ultra IE6 and WEG W22 IE4 electric motors, which push the boundaries in efficiency. These motors offer mines reduced operating costs, lower noise levels and increased reliability.

Another highlight will be the WEG MTW05 medium voltage switchgear, which is locally assembled and tested in South Africa for voltages ranging from 2.3 kV to 36 kV. This switchgear has been developed to meet stringent standards, including IEC 62271-200, without losing its convenience assembly and maintenance features. It also has the flexibility to be adapted to the different requirements of the market.

“We will also use Electra Mining Africa to engage visitors on our WEGSEE+ platform for calculating potential energy savings achievable by replacing motors, gearboxes, and inverters,” Werninghaus explains. “With accurate analyses and strategic indicators, our tool generates valuable data for making smart decisions to optimise resources, again speaking to sustainability. It will also measure return on investment periods and evaluate the potential to avoid or reduce GHG emissions.”

“With these innovative offerings, WEG continues to set the benchmark in the industry, reinforcing our commitment to sustainability and efficiency,” he concludes. 

With a legacy of excellence and a forward-looking approach, WEG is set to make a significant impact at Electra Mining Africa, highlighting technologies that are not only innovative but also pivotal for a sustainable future.

Visit WEG in the Red Zone Stand P01

Client Focus

WEG AFRICA’S GHANA BRANCH MARKS 15 YEARS OF SERVING WEST AFRICA

Set up in 2009, initially to provide parts support to the growing installed base in West Africa at the time, WEG Africa’s Ghana operation has transformed into a fully-fledged branch. Through an expanded network of Value Added Resellers (VARs), the branch has boosted its capacity to deliver tailored and responsive solutions to a diverse customer base in West Africa. 

In its 15 years of existence, WEG Africa’s Ghana branch has placed customer success at the centre of its operations. To meet diverse customer needs, the branch offers customised solutions that speak directly to market requirements in West Africa.

Foster Yeboah Owusu, Regional Manager – West Africa – Sales at WEG Africa, says VARs play a pivotal role in ensuring customer satisfaction. To this end, the branch has a total of eight VARs in key markets such as Nigeria (two), Ghana, Côte d’Ivoire, Burkina Faso, Mali, Senegal and Mauritania. 

As a commercial office for WEG Africa, the Ghana entity can offer a complete range of WEG solutions across the different product families – industrial electric and electronic equipment, power generation and transmission and commercial and appliance motors. Currently, however, the facility has a major focus on industrial electric and electronic equipment, catering largely for oil and gas, and mining markets. 

The main product line includes electric motors, variable speed drives and controls, softstarters, switchgear, geared motors, distribution boards and customised E-houses, among many other products. This is complemented by a selected range of power generation and transmission products such as oil-cooled and dry-type transformers as well as mobile substations.  

Owusu reiterates the importance, in a culturally diverse region of 16 countries, of understanding the unique infrastructural challenges and regulatory requirements in each market in order to develop suitable products. For example, he says, several countries in West Africa have varying levels of grid power infrastructure and voltage compatibility, which makes product customisation and adaptation a major requirement to meet unique market needs. 

Armed with the globally renowned WEG product offering, coupled with a strong support regime that entails technical support, training and high spare parts availability, WEG Africa’s West African business has seen substantial growth in recent years. The growth, says Owusu, has largely been driven by a thriving West African mining sector. 

“We have in recent years executed some flagship projects in the region,” says Owusu. “For example, between 2019 and 2020, we supplied and commissioned major electrical equipment for a large oil and gas project. This comprised six WEG electric motors – four 9,5 MW and two 7 MW units. Of note is that this project was successfully executed during the Covid-19 pandemic.”

Commenting on emerging trends in the market, Owusu highlights the accelerated move towards energy efficient solutions. In Ghana, for example, the government has introduced Minimum Energy Performance Standards (MEPS) for about 20 different electrical products including transformers, electric motors and air conditioners, amongst others.

As a key industry stakeholder, WEG Africa was part of the electro-mechanical technical committee that prepared the standards on which the MEPS for electrical motors are based. Through this process, the government of Ghana has set MEPS for electric motors at IE2, up from IE1. The industry, however, is already moving to IE3 and IE4 efficiency standards. Given that electric motors consume 50% of global energy, Owusu says the adoption of higher MEPS is a welcome development. Making electric motors more efficient not only reduces power consumption, but also minimises carbon emissions and improves sustainability. 

“Governments in West Africa have a big focus on sustainability and environmental management. On the back of rapid industrialisation, there is a growing renewable sector in the region. To cater for this market, we intend to expand our offering with WEG’s other existing solutions such as solar systems, hydro and wind turbines,” says Owusu. 

In addition, says Owusu, there is a lot of interest in increasing partnerships and collaboration. “The plan is to have local service partners in at least every country in the region to ensure faster parts and service turnaround times for our customers,” he concludes.

Client Focus

WEG AFRICA’S NEW CAPE TOWN PREMISES REFLECT 30 YEARS OF GROWTH

Starting out 1994 to serve the metropolitan area with a range of low voltage electric motors, WEG Africa’s Cape Town branch has grown in its size and its offerings, according to Branch Manager Marthinus Greeff.

Testament to this is the fact that it has again outgrown its premises, and last year relocated to larger, well-equipped facilities in Richmond Business Park – enhancing its service capability while making life easier for its customers.

“The branch had humble beginnings 30 years ago, with three staff members – the manager, an administrative assistant and a storeman,” says Greeff. “Our dedication and commitment to customers soon put us on a growth path which has continued to this day; the experienced staff complement at Richmond Park now stands at 35 people.”

Another sign of success is the geographical area that the branch now covers – from Cape Town upwards to the north as far as Upington and east to the town of George. Similarly, a wider range of industrial sectors reach out for solutions from WEG Africa’s Cape Town branch. These include mining, cement, petrochemical, water and wastewater as well as building, food processing, materials handling and heating, ventilation and air conditioning (HVAC). He notes that a particularly exciting recent development has been in agriculture, where the branch serves farmers who want to use more renewable energy.

“Perhaps the most exciting aspect of our growth over the years is that we have become a real solutions provider to our customers – not just a supplier of products,” he explains. “We also make an important contribution to reducing our customers’ carbon footprint and energy costs.”

In terms of the company’s comprehensive product range, it covers low voltage electric motors from 0,18 kW to 500 kW. These are available in energy efficiency categories from IE1 to IE4. The branch provides high voltage electric motors up to 11 kV and up to 6,000 kW – for demanding applications such a mill motors on mining operations. 

“We expanded into variable speed drives (VSD) quite early on, and offer low voltage VSDs from 0,18 kW to 500 kW,” he says. “Our medium voltage VSDs range from 1 MW upwards, in 3,3/6,6 kV and 11 kV.”

Another advance made by the branch was to open an Electrical Panel Division a decade ago. This facility manufactures solutions by combining the wide range of quality WEG components. These are supplied to customers across the Western Cape in enclosures which are electrical type tested and non-type tested.

“We are also able to supply starters, VSD boxes and motor control centres (MCCs) – all custom-made to the required specifications,” explains Greeff. “Our motor workshop facilities allow us to conduct many motor modifications including fitment of space heaters and temperature monitoring devices such as thermostats, thermistors and Pt-100 (RTD) temperature detectors as well as the fitment of special bearings as required by the customers’ application, ensuring we can deliver a high standard of quality in our value-added offerings.”

This in-house capability also reduces lead-times and optimises cost effectiveness for the customer, he points out. The branch has its own in-house repair facility for all WEG drives and softstarters, staffed by three dedicated technicians. 

“This enables us to do all the repairs locally, without the need for these products to be sent to our head office in Johannesburg,” he says. “Similarly, this gives customers the advantage of fast and efficient turnaround times.”

In the new premises, the sales counter area has been enlarged to facilitate quicker collections; Greeff notes that even the location of the new offices will please customers – as the road design and planning means much better traffic conditions. 

“Training remains a key value-add for our customers, so we designed our Richmond Business Park building with an even bigger training room,” says Greeff. “With our technology advancing constantly, and our range of solutions growing, there is always considerable demand for us to train our customers’ employees.”

He highlights that the training provided by WEG Africa in Cape Town is fully certified, and is presented by the company’s dedicated training officer. Trainees and customers receive this training at no cost, as a service from the company.

“Our new training facility includes training benches for VSD and softstarter training, where we can accommodate 12 to 18 trainees at a time,” he says. “Training on motors will, of course, continue and we can have 22 trainees per session.”

In keeping with the WEG’s global commitment to sustainability and a low carbon future, the WEG Africa Cape Town office has been recognised by the Green Buildings Council South Africa as achieving Level 1 building emissions. Roof-top photovoltaic panels reduce the carbon footprint and energy costs, while keeping operations powered during loadshedding.

Client Focus

UNDERSTANDING STANDBY, PRIME AND CONTINUOUS GENSETS

The increasing reliance of South African businesses on generator sets (gensets) to mitigate power disruptions highlights a crucial need for proper selection based on specific operational demands. Despite their growing usage, there’s still widespread confusion about how to choose the appropriate genset, often leading to inefficient and costly decisions. 

Understanding the differences between standby, prime and continuous applications is essential to optimise genset performance and longevity. This is according to Craig Bouwer, Senior Manager Gensets at WEG Africa, who explains that many customers mistakenly select gensets based solely on nameplate rating. 

“Understanding the specific application of the genset is crucial for the right selection, and the first step is knowing that genset applications are broadly categorised into standby, prime and continuous, each with distinct operational requirements,” he says. 

Standby gensets are seldom used, typically kept for emergency situations. These units have a limit on operational hours per year and a specific load factor. In South Africa, due to frequent load shedding, few gensets are used solely for standby purposes.

Prime and continuous applications are more common in the country. Prime gensets can run unlimited hours annually with variable loads, maintaining an average load factor below their maximum rating. Continuous gensets also operate unlimited hours, but with a constant and predetermined load.

Damian Schutte, Engineering Manager at WEG Africa, explains that understanding the difference between prime and continuous ratings is also critical. The load factor is a key differentiator and not the unlimited time requirement, with prime applications having variable loads and continuous ones having fixed loads.

Schutte uses a vehicle analogy to illustrate the differences: a continuous genset is like a car on cruise control operating at a steady speed within its capacity on a long-distance trip, while a prime genset is akin to a vehicle driving in the city. Standby can be perceived as racing between traffic lights. 

The choice of genset rating impacts its expected lifespan and maintenance needs. For example, continuous power may be required in mines during load shedding to supplement limited grid power, while industrial applications like workshops, with variable loads, would need a prime-rated genset.

Bouwer notes that standby power remains vital in essential service sectors for health and safety reasons, especially in environments like mines, hospitals, and data centres.

WEG Africa, as an Original Equipment Manufacturer (OEM), uses these categories to guide customers in their genset choices, aiming to match their specific needs and expected service life. They caution against oversimplifying the selection process by just matching the total load with a genset’s nameplate rating, as this can lead to premature failure and additional costs.

“To ensure the correct choice, we work closely with customers assessing their load requirements, usage frequency and operational conditions and through this process ensure optimal genset selection,” Bouwer concludes. 

Client Focus

WEG MOTORS AND DRIVES ARE KEY PLAYERS IN SOUTH AFRICA’S ENERGY SOLUTION STRATEGY

With the continued energy poverty being experienced in South Africa, motors and drives are set to play an ever more crucial role in industry’s energy solution strategy. The manufacturing and processing sectors, which include minerals processing plants, are energy-intensive industries, and finding ways to reduce energy consumption while increasing efficiencies is essential for both economic and environmental reasons. 

This is according to Jaco Brits, Projects and Technical Manager at WEG Africa, who says that the company has the knowledge and expertise as well as the technology solutions to assist operations in reducing their operating costs and increasing their productivity while guarding their energy security.

“Electric motors and drives are used across industries to operate pumps, mixers, conveyors, vibrating screens and feeders, crushers, and other machinery including automated packaging systems,” Brits says. 

“Advancements in motor and drive technology, underpinned by WEG’s extensive research and development, have seen substantial improvements in energy efficiency, both equipped with advanced control algorithms to optimise motor performance based on real-time conditions,” he explains. “These algorithms assist in ensuring motors operate at peak efficiency levels, even in complex processes.” 

“By upgrading to newer technology and installing higher efficiency motors such as the WEG IE3 or IE4 electric motor, customers can significantly lower their energy consumption. In addition to this,” he adds, “by combining high efficiency motors with WEG variable-speed drives (VSDs), better control and optimisation of equipment can be achieved. This ensures that equipment operates at its most energy efficient speed and power level, and will reduce operating costs significantly.”

Commenting on the use of VSDs, Brits explains that traditional fixed speed motors run at a constant speed regardless of the actual load requirements. In contrast, VSDs are most effective in controlling the speed and torque of motors based on the actual load requirements. This level of precision facilitates the adjustment of the motor’s speed to match the load, thereby ensuring that equipment operates only as needed. VSDs also have faster reaction to load changes and better integration with equipment. “All these factors reduce unnecessary energy consumption during periods of low demand and enhances overall equipment efficiency and performance,” says Brits. 

Unpacking advancements in drive technology, Brits points to the WEG CFW11 VSD line, which incorporates some of the most advanced technology in the world for alternating-current three-phase induction motors. 

“Incorporating WEG Vectrue™ technology, these new generation WEG drives combine variable frequency, sensorless and closed-loop vector (with encoder) control techniques in a single product. This facilitates high torque and a fast dynamic response with the self-tuning function allowing automatic configuration of the drive to adjust it to the motor and load in vector modes,” Brits says. 

With most industries looking at sustainable energy resources including renewables such as wind and solar, motors and drives will continue to play an important role in facilitating the integration of such systems. VSDs can be used to balance power supply and demand, and ensure stable operation in hybrid energy setups. 

“Substantial efficiency improvements are possible by leveraging the latest motor and drive technology, and the significant savings in energy consumption more than justify the capital cost of replacing old technology equipment with higher efficiency technology,” Brits concludes. 

Client Focus

PETROK SUPPORTS WEG GROWTH IN UGANDA

WEG, as part of its drive to expand the WEG footprint in East African markets, is taking significant steps to increase its presence in Uganda by partnering with company Petrok as its Value-Added Reseller (VAR). Petrok’s local presence and technical expertise, along with the popularity and reliability of WEG products in the market, will likely facilitate this expansion.

Theodul Mwema, WEG’s Regional Sales Manager for East Africa, says the anticipated economic growth from projects like the East African Crude Oil Pipeline (EACOP), along with the existing strength of sectors such as agriculture, manufacturing, utilities, cement and oil and gas in Uganda, offer potential opportunities for WEG to  offer their products and solutions. 

“This is an exciting step as we look forward to reaching more customers in Uganda with WEG’s range of electric motors as well as medium and high voltage solutions,” he says “We have been supplying customers in Uganda for over a decade, and this appointment builds our support for them and opens new markets for us. Our commitment to delivering efficient, reliable products with a low total cost of ownership, as exemplified by our W22 IE3 motor, shows our customer-centric approach which is appealing to businesses in Uganda.”

Mwema highlights that the coffee sector already has a strong reference base, for instance, as many coffee factories used Brazilian processing machines which are fitted with WEG motors, drives and soft starters.

With agriculture being the biggest contributor to Uganda’s economy, other significant sectors include manufacturing, utilities, cement and oil and gas, he explains. There has also been considerable investment in power and water projects in East Africa, notably from Asian countries. 

Commenting on the EACOP, Mwema says when completed this major project will see the transportation of Uganda’s crude oil almost 1,450 km from Kabaale in Uganda to Tanga in Tanzania.

“Petrok was selected as our VAR following a stringent vetting process, and we are confident they will deliver the high standard of support to our customers that we expect,” he says. “The company has the necessary experience in our field of operation, with a strong technical team of engineers and technicians with the right product knowledge.”

He says Petrok’s premises in Kampala allows for local warehousing of WEG Low Voltage products such as electric motors ,drives and others, as well as workshop facilities for small works. The company’s sales team and customer base across Uganda also ensures customers will be well served and distribution channels expanded. 

“With the quality and reputation of WEG products, we can ensure players in the Ugandan market will benefit from the same low total cost of ownership as our customers everywhere,” says Mwema. “This includes the five-year warranty on our popular WEG W22 IE3 motor, a promise of reliability that few of our competitors can match.”

Client Focus

WEG PARTNERSHIP WITH PANACO STRENGTHENS PRESENCE AND BOOSTS GROWTH IN THE DRC

The strengthened presence of WEG in the Democratic Republic of Congo (DRC) through its strategic alliance with Panaco, its Value-Added Reseller (VAR), has proven to be highly successful. 

Thierry Kakese, WEG’s Regional Manager – Central Africa, attributes this success to the alignment of business models between the two companies. “As a major player, WEG has long been dedicated to establishing and nurturing a robust VAR partner network in the Central African region, ensuring sustainable growth and expanding our installed base of products and solutions,” he says. 

Panaco was appointed as WEG’s VAR in the DRC four years ago, and plays a vital role in the region. The company was one of the first electrical subcontractors operating in that country and today with more than 40 years’ experience, Panaco possesses the experience and capability to meet the escalating demand for WEG motors, drives and other products in the country. 

The company’s reputation and established operations in the key mining centres of Lubumbashi and Kolwezi ensure efficient stockholding allowing easy access to WEG products. This significantly reduces lead times for complete motors and drives, as well as spare parts in case of breakdowns.

Apart from the mining sector, Panaco and WEG also serve other industries such as power and water utilities as well as cement. Kakese emphasises that partnering with Panaco facilitates essential market feedback, enabling WEG to make informed decisions and maintain its position as a leading provider of electrical products and solutions.

Recognising the significance of the DRC and the Copperbelt region, WEG’s team, in collaboration with Panaco, regularly visits end user operations to closely comprehend specific challenges and requirements. 

Financial Operations Director at Panaco, Khalid Patel shares that to support the growing installed base and increased demand in the DRC, Panaco and WEG will establish a support centre in the Katanga province. This facility will conduct technical assessments, offer local maintenance and repair services for Low Voltage drives, and enhance overall support for our customers. 

“The enduring success of the WEG and Panaco partnership stems from our shared technical expertise,” Patel says. “Ongoing support is provided via the South African-based WEG operation which is bolstered through comprehensive training for our sales and technical teams.” Training sessions take place both in the DRC and at the WEG drives training centre in Johannesburg, enabling Panaco to deliver excellent customer service.

Kakese highlights an increasing demand for motor and drive combinations in the DRC and neighbouring regions. “This demand is not merely due to WEG’s extended warranty but primarily because of the superior performance and compatibility offered by correctly matched motor and drive combinations,” he explains. “End users who have embraced this trend experience improved reliability and better performance.”

“Furthermore, the energy saving benefits of WEG’s IE3 and IE4 motors have made them highly sought after, as major miners strive to reduce energy consumption and reduced operating costs.” 

WEG transformers have also gained popularity in the region, with them being locally manufactured in South Africa with capacities of up to 40 MVA. Kakese highlights the logistical advantages of sourcing such equipment from South Africa instead of from overseas. The close collaboration between the support teams in South Africa and Panaco ensures that transformers are precisely specified to meet technical application requirements, guaranteeing reliability and optimal performance.

Recognising the increasing power demand in the DRC, particularly in the mining and other sectors, Panaco has decided to augment its product offering by also stocking generator sets. “Initially, the market is expected to favour standard WEG gensets, manufactured in South Africa with convenient logistics. However, this expansion also opens doors to supply custom-engineered gensets tailored to specific applications,” Patel says.

“This strategic partnership in the DRC has yielded remarkable results, and we look forward to significantly increasing the installed base of WEG products as well as expanding the level of sale and aftermarket support we offer to our customer base,” Patel says. “The shared business vision, technical expertise and commitment to customer satisfaction have paved the way for sustainable growth and the provision of premium products that enhance reliability, performance, and cost-effectiveness for end users in the region.” 

Client Focus

ZEST WEG HELPS POWER KIPUSHI’S NEW DAWN 

As part of Ivanhoe Mines’ refurbishment of the historic Kipushi Zinc-Copper Mine in the Democratic Republic of Congo (DRC), Zest WEG will be supplying a range of electrical and energy solutions. Ivanhoe Mines acquired its 68% interest in the Kipushi Project in November 2011; the balance of 32% is held by the DRC’s state-owned mining company, Gécamines. 

According to Luveshen Naidoo, Business Development External Sales Engineer for Mining and Industrial at Zest WEG, this includes a 14 MW power plant, motor control centres (MCCs), WEG medium voltage (MV) variable speed drives (VSDs) and a WEG 1,200 kW MV motor for the mine’s ball mill. The company is also the preferred supplier of low voltage (LV) motors, and will supply these to a range of mechanical Original Equipment Manufacturers (OEMs) servicing the mine. Delivery of the equipment is expected to begin in the third quarter of 2023.

“Our diesel powered plant, which will provide the mine with backup energy, has been designed to comprise 12 generator sets – each rated at 1,587 kVA and 400 V,” says Naidoo. “Assembled at Zest WEG’s specialised Cape Town facility, the plant includes MV switchgear, six 3150 kVA ONAN type 400V / 6.6 kV step-up transformers, a 40,000 litre fuel tank and an automated fuel system”

He highlights that splitting the plant design into smaller generating units ensured engines and alternators were readily available, securing a quicker delivery time. The configuration of the plant in this way also gives the mine greater energy security in the case of maintenance or breakdown. The gensets can also be transported to site using conventional trucking, without the need for abnormal load vehicles. 

The MCCs are being supplied for use in an established substation on the Kipushi Zinc-Copper mine, as well as for a containerised substation elsewhere on the site. To accommodate space constraints, the MCCs are designed for a back-to-back configuration with a compact bucket size, he explains. 

“This ensures that the equipment will fit in the available space while still meeting the client’s specification and stringent IEC standards,” he says. 

For the mine’s SAG mill, Zest WEG is providing the WEG W60 MV motor rated at 1,200kW – a robust unit for the demanding applications and aggressive environments found in the mining sector, says Naidoo. The reduced motor weight holds distinct benefits, he notes, including a compact base plate or plinth onto which it is mounted – and lower installation costs. The motor’s IP55 rating ensures the motor is well protected from dust or water ingress. 

To meet the client’s needs for the MV VSD to drive the ball mill motor, WEG’s MVW3000 unit is being supplied – a compact design with an integral dry-type transformer. To facilitate the dissipation of heat, Zest WEG designed a ducting system for this 1,200 kW VSD which will reduce the need for cooling of the substation. 

As the client’s preferred brand of LV motors, the WEG W22 motor is being made available to Kipushi’s mechanical supply OEMs. Among the key benefits of this WEG IE3 motor is its energy efficiency, he says. This preferred brand strategy makes it more cost effective for the mine to keep the necessary consignments of spares for maintenance and servicing. 

In putting together its proposals for the client, Zest WEG worked closely with the engineering consultant METC Engineering in the detailed design stage. 

First-line support for Zest WEG’s equipment will come from Panaco, the company’s Value Added Reseller (VAR) in the DRC. The Panaco team can conduct site visits and technical investigations, and has a substantial in-country stockholding to ensure rapid availability of key equipment.

“Our partners at Panaco can generate technical reports to share with Zest WEG to ensure we can provide accurate and necessary specialist support,” he says. “We have an aftersales team who can deliver support and solutions remotely or by travelling to site.”

He concludes that Zest WEG’s ISO9001 quality management systems underpin the high quality standards in all its products, and the company is audited annually to maintain this compliance. 

“We also constantly work at reducing the environmental impact of our production processes, with regard to our usage of natural resources and the generation of waste and emissions,” he says. 

Client Focus

TREND IS TOWARD LARGER  POWER PLANT SOLUTIONS, SAYS ZEST WEG

Whether companies need power to survive loadshedding or to raise their production output, the trend is for these power generating systems to get bigger.

Bernard Mitton, Business Development Consultant at Zest WEG.
Bernard Mitton, Business Development Consultant at Zest WEG.

According to Bernard Mitton, Business Development Consultant at Zest WEG, it is becoming more common for customers to request proposals for power solutions that exceed 10 MW. In South Africa, this appears to be mainly a response to rising levels of loadshedding. In other parts of Africa, says Mitton, it is economic growth that drives demand.

“For many companies who want to grow their output, it is vital to have continuous and reliable power supply,” he says. “In recent years, Zest WEG has been designing and installing more of these large power plants for customers across Africa.”

It is Zest WEG’s depth of in-house engineering expertise and technical capability that earns it these contracts, he explains. From the generator sets themselves to the transformers, switchgear and containers, the company can provide customers with a full turnkey solution.

Generator installed in a 40ft high cube container.
Generator installed in a 40ft high cube container.

“We often propose a modular system that allows the customer to execute their project in phases,” he says. “They can begin with the most cost effective solution, and then expand the plant as the power demand grows.”

In one of these 10 MW systems, there will usually be eight to 10 generators installed within a containerised solution or a dedicated power plant room. They can generate power at 400 V, to be stepped up by transformer up to 11 kV – or power can be generated directly with an alternator output up to 11 kV.

“For a typical 10 MW power plant, we connect the generators to a common switchboard up to maximum 22 kV, to distribute power to the various on-site loads,” he says. “The switchboard solution can be installed in a container, an E-house or a plant room.”

The generating units are custom engineered, built and fully tested in Zest WEG’s Cape Town generator facility. Testing includes a step load test and the synchronisation of generators to each other –  verifying all setpoints, engine performance and efficiency indicators.