BHT: Sep 2010

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3/40BULK HANDLING TODAY September 2010

September 2010

ContentsCover Story5 Taming Conveyor Problems

Power Transmission

9 ComingFull Circle13 More for the Conveyor Industry

Conveying17 FightingWear

21 Whats in a Pulley?

Harbours & Ports25 Container Terminal Leads in Productivity

27 Not Your AverageWatchdog

31 Market Forum

Endorsing Bodies

CMA (Conveyor Manufacturers

Association)

HCASA (Hydraulic ConveyingAssociation of SA)

LEEASA (Lifting Equipment Engineering

Association of South Africa)

RFA (Road Freight Association)

SAIMechE (SA Institution of Mechanical

Engineering)

SAIMH (SA Institute of Materials Handling)

Proprietor and Publisher:

PROMECH PUBLISHING

Tel: (011) 781-1401

Fax: (011) 781-1403

E-mail:

[email protected]

Website: www.promech.co.za

Managing Editor:

Susan Custers

Advertising Sales:

Surita Marx

DTP: Zinobia Docrat and

Sean Bacher

Printed by:

Typo Colour Printing

Tel: (011) 402-3468

Our e-mail address [email protected]

Visit our website on www.promech.co.za

The monthly circulation

is 4 016

CopyrightAll rights reserved. No editorialmatter published in Bulk Han-dling Today may be reproducedin any form or language withoutwritten permission of the publish-ers. While every effort is made toensure accurate reproduction, theeditor, authors, publishers andtheir employees or agents shallnot be responsible or in any wayliable for any errors, omissions orinaccuracies in the publication,

whether arising from negligence orotherwise or for any consequencesarising therefrom. The inclusionor exclusion of any product doesnot mean that the publisher oreditorial board advocates or rejectsits use either generally or in anyparticular field or fields.

Featured on the cover:

KetaflexTel: 072-421-6459

Email: [email protected]: www.ketaflex.co.za

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CONVEYOR MANUFACTURERS ASSOCIATION

The weekend kicked off witha cocktail hour followed by asuperb table dhote dinner. Alively and closely contested

quiz evening was next up and won bythe Melco team with 39 points andchased home by two teams from Re-maDunlop (Free 38 points) and (Dom37 points). The golfers were off to an

early start the next morning with thebowlers soon following for an excel-lent mornings bowls. The standard ofthe bowls is improving every year andIm sure that there are some buddingchampions hiding among the numbers,if only they would play more regularly!A mixed team from Afripp, Nepean and

Sandvik beat last years winners Fenner in the finalsto win the Bowls trophy and Dunlop triumphed overa mixed team (Shaw Almex and RemaDunlop) towin the Plate.

Points amassedTo get back to the golf, we had 6 fourballs andDanie OConnell (Melco) amassed 42 points towin the Wolhuter trophy. Clive Dicks of Hansen(38 points) and Jay Pillay of Brelko (34 points)were the runners up. Knox Ngema of Bauer andWillem Niemandt of Bosworth saw more of thecourse then the other 22 players and Willem wasfined for swimming, after falling in water whileattempting a recovery shot!!!

From the Chairmans DeskI am delighted to once again report that the AGM and Industry Interact weekend held at Hunters Rest 13 to

15 August was a huge success.

Then it was time to don costumes weird and won-derful for the Gala Dinner and Fancy Dress party;the theme being book titles. Wow the costumesget better and better each year! Notable coupleswere Lady Chatterleys Lover (Dave and LyndaPitcher), Men are from Mars and Women are fromVenus (Gavin and Lynette McKenzie). There weresome outstanding individuals, too the DevilsAdvocate (Jay Pillay) won the best male award,

and War and Peace (Janet Skeen) was adjudgedthe best female. The prize for the best group wentto Bosworth for their Alice in Wonderland and aspecial award was made to Damon Oliver (ShawAlmex) for his IT. Our entertainer, Wez Mayo,who attends many fancy dress parties, is firmly ofthe opinion that the CMA is easily the best thathe has seen.

Well done to you all the level of creativity istruly amazing.

For a good cause

As custom dictates, prize giving wrapped up theIndustry Interact weekend in lively fashion withthe Bearings International Trophy being awardedto RemaDunlop and the Seawest Trophy going toGavin Hall of Melco, enjoying his first CMA AGMand Interact weekend. The Fines Master managedto extract R4 817 in fines for misdemeanoursover the weekend, admissions of guilt for thosehe couldnt pin anything specific on, and straightdonations for our favourite charity, the SA GuideDog Association. Thank you all!

Simon Curry

Chairman

Was fined for swimming, after falling in water whileattempting a recovery shot!!!

After the golf, it was time to don costumes weird and wonderful for

the Gala Dinner

Notable couples were Lady Chatterley s Lover (Dave and Lynda

Pitcher)

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COVER STORY

There just isnt anything like it in thecountry and to best describe thesoftware package in one sentence,it can be compared to zooming in on

a digital map on the internet. As you wouldin Google Maps, you zoom in from a graphicof the whole earth right down to an actualpicture of your front gate at street level, thisnew software allows you to zoom in froma global view of several plants in variouslocations, to a single component such as a

conveyor belt, idler or gearbox on any oneof the plants and get specific informationabout it.

Imagine what this means for the chief main-tenance engineer of a power station or mine? Hedstart off with a picture of all the mines in the groupand is able to zoom in on a specific gearbox on aspecific conveyor system at a specific mine and isnot only able to see its current condition, but alsoits full history in terms of maintenance records.Hell be able to retrieve all the specifications interms of shaft sizes, couplings fitted, when it wasinstalled, by who and even under what condi-tions, including any personal notes made by theengineer on site at the time. All at the click of amouse button.

Where it startedIt all began when Ketaflex started an Eskomcontract to do the inspection and monitoring ofmaterials handling systems at its Duvha powerstation, explains Lord. This service comprisesteams of specially-trained beltsmen from our com-pany going through the plant on a daily basis tophysically inspect conveyor belts, idlers, gearboxes,motors and pulleys for wear and faults. They havea checklist on which they log the condition of each

component so that we can compile a report for themaintenance engineer at the power station.

As we progressed with the collection of data, itjust kept on growing so much that we soon realisedthat it all needed to be recorded in a computerdatabase and Eskom did not have anything suitablein place, says Lord. We then started developinga dedicated SAP Business One software modulethat can interface Eskoms SAPR3 system so thatwe can log data from all the conveyor systems inthe finest detail in order to build up a profile ofeach system.

More functionsOver the last two years, this conveyor softwaremodule has kept on growing in functionality in thatengineers could start plotting trends in terms ofidler wear and replacement, gearbox temperaturevariants and so on. We then also started buildingstrong graphic capabilities into the software suchas actually mapping a conveyor belt to show thecondition of the belt in a graphic interface, saysLord. One of their conveyors, for instance, has15 000 idlers and through this interface we can

graphically show the engineer exactly which areasto pay attention to in terms of the condition of theidlers. From this he can clearly see exactly howmany idlers need to be replaced.

AdaptabilityThe beauty of this system is that it is adaptable toany materials handling plant, complete with theunique codes, specifications and standards for eachindividual company. Since our manual systemhas been implemented, the unexpected failuresand breakdowns at this power station have beenreduced dramatically. With the software module

in place this has been reduced even more as theengineers can now do something about problemareas before they have a breakdown, Lord adds.

ReferencingInitially the function of the Conveyor Module only

Taming ConveyorProblems

Its not everyday that you talk to an engineer

about something new he developed and you

walk out the interview in stunned awe having

heard about a development that is bound tochange things forever. But, this is how Bulk

Handling Today felt after talking to Lord Le-

buru of Ketaflex about a sof tware module he

is developing for the bulk materials handling

industry.

Lord Leburu

The software can be compared to zooming in on a digital

map on the internet

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addressed the inspection side of monitoring andrecording data, but Lord realised that such acomprehensive database could be utilised evenfurther. If each single component in the materi-

als handling plant is not properly referenced it isdifficult to clarify exactly which component at aspecific location youre referring to when reportinga fault, he says. In addition, without a referencesystem, any specification that has changed is notrecorded and over time, engineers lose track of anychanges made to a specification.

This prompted us to then build a referencing func-

tionality into the module as well, Lord explains.Here we will literally spec the entire plant toproduce 3D models representing the actual plant.If something breaks down, the engineer simplygoes to the module, delves into the area of thebreakdown and pulls out a drawing with all thelatest specifications of the specific component thathas failed. He can then order the right replacementpart immediately, without having to go out to theplant to dismantle it to find out what he needs.In fact, the engineer can be at head office, milesaway from the plant and address the problem im-mediately through the Conveyor Module.

Preserving knowledgeAnd, theres more, Weve also added a functioncalled knowledge resource, says Lord. Over timeengineers can add to this resource so that certainfacts and experiences on a specific component dontget lost as is usually the case when the engineer

The beauty of this system is that it is

adaptable to any materials handling

plant

leaves the company. For instance,he may learn certain aspects aboutan installation during a repair andby storing his notes, someone else

can later benefit by reading his com-ments and avoid making mistakesrelated to that specific component,he comments.

The future

As the development of the ConveyorModule stands right now, it is beingused and can be implemented onany materials handling plant, butLord is stoked-up on even morefunctionality that will enhance thissoftware solution to be the ultimate

tool for any materials handling plant.Were working on ways of integrat-ing vibration monitoring or thermalgraphic monitoring into the inspec-tion side of the module, he saysin conclusion. Such functionalitywill be a great aid in trending theextent of a problem as it develops.The aim of the module is to givethe maintenance engineer a holisticview, not only of one plant, but allthe companys installations. Yet, hewill also be able to go down into

each single component and readits current state.

Lord Leburu, Ketaex, Tel: 072-421-

6459, Email: [email protected],

Website: www.ketaex.co.za

COVER STORY

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SAIMH NEWS

Diarise!

The format will be a 4ball alliance stableford, 2scores to count and there will also be prizes fornearest the pin and the longest drive.

The entrance fee of R300 per person includesgreen fees and supper. Advertising banners will be R1000 each either at a tee, a green on the course or onthe practice putting green. The same fee will apply towatering holes.

Proceeds will be donated to the Avril Elizabeth Home.

Bookings can be made by phone to Graham Downing at082 372 5150, email: [email protected] orFax: 086 550 0291. To book a golf cart, please contact

the Pro Shop on (011) 826-2466 or (011) 383-9920no later than 7 October 2010.

At the same time, please advise players names, handicap(use your club handicap), otherwise off 18 and whetheryou are able to sponsor a watering hole or provide uswith prizes. Because the event creates tremendous in-terest each year, it is very important that you book your4ball early.

Payment can be made electronically (or if preferred bycheque) to: Institute of Materials Handling, Nedbank -Bedford Gardens, Branch No: 176105, Account number:176 100 1450

(Kindly fax copy of deposit slip to 086 550 0291)

Yours sincerely

Graham Downing

It is that time of the year again so we have

great pleasure in inviting you to participate

in our annual Golf Day, to be held at the

ERPM Golf Club on 14 October 2010

(Tee-off time will start at 11.00).

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Continuously transmitting power from one shaft to another

through chain running over a sprocket wheel affixed to each

shaft dates back to designs Leonardo da Vinci penned in the

16th century. Today the same principle is widely used to trans-

mit power in industrial drive systems. Even modern highly-

sophisticated car engines still utilise the sprocket and chain

principle inside the engine for the high precision opening and

closing of valves.

Coming Full Circle

POWER TRANSMISSION

Amodern drive train, depending on the ap-plication, can consist of any combination

of chains, pulleys, sprockets, clutches,motors, gearboxes and couplings, engi-

neered to deliver the optimum transfer of torque toachieve a specific objective. Power transmission

specialists, Sprockets & Chains in JetPark near Johannesburg, has extended their

product range over the years to now offerthe South African and African marketall the components needed for sucha total drive solution from under

one roof.

Specific requests addressedBulk Handling Today speaks to Shaun Bennett,technical sales manager at Sprockets & Chains, tocatch up with the latest additions to the companyscomprehensive power transmission product range.Besides adding a full range of shaft mountedspeed reducers as well as a full range of electricmotors under our Challenge brand, we have also

been appointed as a FAG/Ina distributor in SouthAfrica, he says.

Although we have always had a premium bearingin the Challenge range, some customers specifi-cally requested FAG bearings and this range nowcomplements our offering with a choice betweenboth premium quality brands.

More bearingsThe Schaeffler Group and the FAG brand is well-respected for their precision rolling bearings in theautomotive, mechanical engineering and aerospace

industries and has been for many years, adds Shaun.The INA brand stands for the development andmanufacture of rolling bearings, plain bearings andlinear systems as well as precision components forthe automotive industry for engines, transmissionsand powertrains worldwide.

A highlight in this range is the special X-life designwhich provides development engineers with totallynew design perspectives. New manufacturing tech-nologies enable a more uniform and comprehensivecontact surface between the rolling elements andraceway.

A-brandAs a result, under identical load, there is a

significant reduction in the stress conditionsimpacting on the rolling elements and

raceway. This means there is reducedfriction and lower bearing temperatures,less strain is placed on the lubricant, ahigher basic dynamic load rating canbe achieved and there is an increased

basic rating life.

These bearings are high-precisionA-brand bearings giving us yet anothertop-quality product line in the wholepower transmission offering, saysShaun. In addition, we also haveaccess to FAGs engineering servicesin terms of monitoring systems to

manage condition monitoring of bear-ings in drive systems.

Since moving into new premises bordering theJet Park Lake, east of Johannesburg, Sprockets

& Chains has also added shaft mounted speedreducers (SMSR), worm gear units and electricmotors to the product range.

AwarenessAfter taking on the full range of shaft mounted

Under identical load, there is asignificant reduction in the stress

conditions

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POWER TRANSMISSION

commonly found in many lightconveying systems.

Specialist in chargeRounding off the product range,there are all shapes and sizesin keyless clamping, taperbushes and hubs, shaft cou-plings, torque limiters, pulleysand V-belts and a wide rangeof sprockets and chains. Our

standard policy is to develop andpromote quality products through

dealerships and resellers as wellas OEMs on a countrywide basis

in order to service the diversifiedindustry of South Africa, Shaun says

in conclusion.

Each one of our products is overseen by a special-ist with many years experience in that particularfield and, as a team, we aim to bring completesolutions to the market.

Shaun Bennett, Sprockets & Chains, Tel: (011) 397-5115,

Email: [email protected]

speed reducers for conveyor drives. the demandhas grown steadily as more and more people be-come aware of the product, says Shaun. Thisprompted the move to also bring in the standardelectric motor range to complement our offeringfor conveyor applications.

We launched the Challenge SMSR range with thearrival of over a million rands worth of stock, addsShaun. These SMSRs are fully interchangeablewith other leading brands and provide a conve-nient method of reducing speed. They come in anumber of different sizes including B through toJ in both 20:1 ratio and 13:1 ratios while allunits include a torque-arm. Naturally we keep acomprehensive range of spares in order to be ableto provide a repair service to the industry.

MotorsAll Challenge products are branded and are thustraceable, says Shaun. Our ironware products arebranded using laser technology. The advantage isthat your staff can easily identify the product for

storage and dispatch and this in turn reduces thenumber of packing and picking errors.

The Challenge-branded electric motors are 3-phaseasynchronous AC electric motors and comply withthe international IEC standard. The motors aremanufactured from high grade die cast aluminiumalloy and unlike most makes, come with multi-mount detachable feet as standard, allowing forvarious mounting positions to be achieved easily,says Shaun.

Also for conveyor applications, the company hasadded a versatile range of worm gear units. We

keep a complete range of worm gear units in tensizes, adds Shaun. Each size comprises 11standard ratios allowing for numerous outputspeeds and it uses standard IEC electric motorsup to and including 7.5Kw. The units are generallyinterchangeable with other leading brands and are

Unlike most makes, the motors come with multi-mount

detachable feet as standard

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MOSTPRODUCTIVE

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When it comes to your crushing and materials handlingrequirements, you need reliable equipment that performsin the toughest conditions.

Joy Mining Machinery offers STAMLER feeder-breakers and reclaim

feeders, and CONTINENTAL conveyors and conveyor equipment.They are at work in some of the worlds most productive materials

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STAMLER PRODUCTS are engineered to cut operating costs and increase

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CONTINENTAL CONVEYOR PRODUCTS are a perfect fit to meet todays

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Complete crushing and conveying systems integration is available

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your materials handling system will work together as designed.

And, we stand behind our design and equipment with unsurpassedcustomer service and support.

THIS IS

Longwall Systems Bolting Cutting Haulage Crushing & Conveying

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So its now becoming a caseof, the more a supplier

can provide, the morecustomers will order from

the company as a single inter-face rather than having to shoparound among multiple suppliers.A company who recognised thistrend is Zhous Enterprise basedin Jet Park near Johannesburg.Bulk Handling Today speaks toHennie Pieterse who heads upthe power transmission sectionof the company.

For years weve supplied general power transmissioncomponents for conveyor systems and, therefore,its natural to extend our product range so we canfulfil more and more customer requirements, hesays. We, therefore, commenced a global searchfor products that meet the high quality requirementswere known for in the South African market.

Carefully selectedUnder the power transmission division well soonhave a complete range of flange-mounted gearboxesas well as a full range of electric motors manufac-tured by carefully-selected reputable manufacturersin China, Hennie emphasises. With China recentlyovertaking Japan to become the second largesteconomy in the world after the United States, it is

a clear indication that this country has a lot to offerfrom a wide range of manufacturers competing in

the world market.

Of course you do get the cheap and nastiesemanating from China but there are as manygood quality ones. In order to maintain our qual-ity standards, all the products well be importing,such as the gearboxes and motors, first undergostringent quality tests, explains Hennie. Apartfrom literally taking the gearbox apart to check thequality of components and its assembly, we alsoget someone locally to test the product for us inan actual installation. Only when were satisfiedthat it conforms to world standards, will we take

on the product.An old handIn addition, Zhous will stock conveyor beltingand associated products, including a belt splicingservice as part of their offering to the conveyorindustry. Although conveyor belting is new to thecompany, Hennie is an old hand in this industry.My background is with Goodbearing & Beltingwhich I ran for many years before joining Zhous,explains Hennie.

The belting division will now be run through thiscompany and well be covering all requirementsfor conveyor systems, from design, right through to

structures and installation of a complete conveyorsystem. This will include belt splicing utilising in-novative imported clips. Several of the big mininggroups have already shown a keen interest to dealwith us due to previous dealings over the last fifteen

POWER TRANSMISSION

More for the

ConveyorIndustry

With South Africa being mining country, itis expected that the country ranks among

the top in the world when it comes to con-

veyor installations. This creates healthy

competition in the market in terms of sup-

pliers of power transmission components,

each vying for a slice of the cake in a highly

active industry.

Hennie Pieterse

Only when were satisfied that it conforms to world

standards, will we take on the product

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Our drive is your performance.

Hgglunds Drives South Africa (Pty) Ltd

P.O.Box 2851, 1610 Edenvale, Johannesburg

Phone: + 27 (0)11 454 4933, Fax: +27 (0)11 454 5088

E-mail: [email protected], www.hagglunds.com

Tough demands havemet their match.

Visit us at Electra Mining 4-8 October 2010,

Hall 8 stand no. C18, MTN Expo Centre, NASREC.

Let us know your demands.

8/7/2019 BHT: Sep 2010


The new motor from Zhous

years with Goodbearing & Belting.

Smart isnt the wordIn terms of design and specification, weve alsoinvested in a software programme of which thereare very few in South Africa, adds Hennie. Aclient simply provides us with his or her conveyorrequirements and, with this programme we cancalculate their specifications in the finest detail.The programme is so smart we can even tell thelife expectancy of each bearing.

Hennie is a hands-on man and personally inves-tigates any problems clients may have with anyof their power transmission applications. Werefocused on assisting our clients in finding solutionswith regards their power transmission requirementsin addition to providing training to ensure correct

installation and operation.Blaming the equipmentAn example is where a steel processing plantstarted picking up problems with their conveyorsystem, explains Hennie. On closer investigationwe found that they have been increasing productionover the years without making any changes to thedrive system, designed 20 years ago. Although thebelt could handle the increased tonnages, the drivesimply wasnt coping and they started blaming theequipment, rather than the fact that productionhad increased dramatically. We audited the plant,

POWER TRANSMISSION

Of course you do get the cheap and nasties emanatingfrom China but there are as many good quality ones

made certain rec-ommendationsand they haventhad a problem

since.Generally peopleacross the worldare realising thatnot everythingthat comes outof China is belowpar just becauseit costs less,Hennie says inconclusion. Likesome of the well-

known manufacturers who now have componentsmade at factories in China, we also critically se-lect the good quality manufacturers to supply thebroad range of products we put our name to. Theconfidence people have in our selection is clearlyreflected in our ever increasing sales.

Hennie Pieterse, Zhous Enterprise, Tel: (011) 397-7788,


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CONVEYING

Rubber is steadily becoming the material ofchoice to protect these systems, but itsnot just any rubber, its a highly specialisedindustry, where rubber compounds are

scientifically mixed to suit each and every uniqueapplication. Tega Beruc South Africa is a companythat specialises in protective systems for conveyor

systems and mills, and to find out more Bulk Han-dling Today speaks to Wayne Johnstone, productmanager at Tega.

Its all in the compoundGetting the right rubber compound for an applica-tion is like baking cake, there is a specific recipe foreach type of cake, but even so, some people make

Fighting

Wear

Of all the machinery on a mine there is probably noth-

ing that takes more punishment than the materials

handling system in terms of wear and corrosion. The

conveyor system, chutes at transfer points, crushers

and mills are constantly bombarded with chunks of

abrasive rock and chemical substances as ore is

carried through the various stages of processing.

It is a flame-retarded material that can handle up to

160C

Wayne Johnstone

Tegas Spill-Ex Universal Support System

a better chocolatecake than others,he says. Similarlythere are hundredsof different rubbercompounds, eachmixed scientifically

by our rubber tech-nologists, for eachand every applica-tion under specificconditions. Each oneof our mill liners, forexample, is customdesigned to suit theduty application.

With more than 30 years experience in the fieldof rubber lining systems, we have firmly estab-lished the use of rubber liners in grinding mills

and conveyor applicationsin the ore processingindustry, Wayne says.With our technology anda huge database, Tegaliners have been able toout-perform and replacetraditional steel liners toa large degree in manyapplications.

Conveyor systemsTega has become well-known across the globe

for their mill linings, buta large part of the com-panys business comefrom the wear compo-nents they manufacturefor conveyor systems.Our range of conveyorproducts include all impactbed requirements, wearprotected parts at load-ing and transfer points,protection in chutes andour unique belt spillage

control system called Spill-Ex, says Wayne. Wealso do pulley lagging ina variety of rubber andceramic combinations.

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The skirting system

CONVEYING

The only parts we dont do are idlers and thebelting itself.

All of these systems have been thoroughlytested in typical South African applications,adapted from Tega technology from elsewherein the world specifically to suit local condi-tions. A particular challenge we recentlyfaced was at a chrome plant where they hada huge problem with rubber due to the veryaggressive nature of chrome ore, explainsWayne. We came up with a special rubbercompound that exceeded even our expecta-tions. It was our standard Spill-Ex skirtingsystem, but the actual skirting was rubberblocks made out of this new compound. Theclient is now getting four times the life out ofour system than the previous rubber protec-

tion they had.

Flame-proof rubberA product fairly new to the South Africanmarket is a rubber compound developed byTega in India, specifically for high temperatureapplications as found in the cement industryand coke production plants. It is a flame-re-tarded material that can handle up to 160C,says Wayne. This rubber is also known as aself-extinguishing material and is popular inunderground application in the coal mining

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Scania Southern Africa

Angola, Botswana, Malawi, Mozambique, Namibia

South Africa, Tanzania, Zambia, Zimbabwe

Scania. Destined to Lead.

Just add Diesel.

Scania is the leadingsupplier in South Africaof Euro 4 products, with

EGR technology.

For more information contact

your nearest Dealer. Details available

on www.scania.co.za

8/7/2019 BHT: Sep 2010


industry. If the rubber does overheat, forinstance, it will not ignite into a flame asis the case with ordinary rubbers.

For coke production plant applicationwhere youre dealing with very high tem-peratures weve taken it a step furtherand embedded ceramic materials into theflame-retarded rubber, adds Wayne. Theceramics provides the necessary flow char-acteristic required while the rubber wontburn from the material that is almost in asintered state.

Consultancy serviceDue to the complex specialised nature ofwear protection in conveyor systems aswell as mills, Tega has teams of specialistswho analyse each situation on its particularmerits and will assist in taking a projectfrom design and specification all the waythrough to installation and commissioning.We have a dedicated consultancy side ofthe business where, founded on a largeknowledge base, we do surveys of an entireplant to solve all the wear problems on theplant, Wayne says. Were not only hereto sell a product, we physically go out tothe mines and well survey the plant inrelation to operations. We consider theamount of downtime spent on replacingproducts that dont last or fail prematurelyand, if we dont have a solution in terms ofa specific wear product, well even assistin re-designing a system to try and solvethe problem.

Very often it is not a problemwith the wear material as such,but rather the whole design of a

system, Wayne says in conclu-sion. With Tega experts in 26countries world wide, we haveaccess to a huge knowledgeresource, not only on rubberproducts but also in experienceof materials handling systemsof all kinds. In addition, werealways willing to try and findnew solutions in terms of differ-ent types of rubber compoundsfor particular challenges, result-ing in Tega bringing new rubber

wear solutions to the market allthe time.

Wayne Johnstone, Tega Beruc South

Africa, Tel: (011) 421-6761, Email:

[email protected]

CONVEYING

Often it is not a problem with the

wear material as such, but rather

the whole design of a system

8/7/2019 BHT: Sep 2010


process that distinguishesa premium pulley from the

rest, he says. Every singlepart of a Bosworth pulley, forinstance, is made in-houseand each phase of assemblyis fully controlled by ourpeople.

Although it isnt generalpractice to stress relievepulleys, every single hightension pulley we manufac-ture is stress relieved righthere in our factory as part ofour strict quality assurance

programme, adds Mark. This philosophy has alsobeen extended to welding and every weld is thereforetested ultrasonically as well. What differentiatesa good pulley from an inferior one really dependson what goes on behind the scenes. We only usecertified plate and all our welders are coded as to allextras we add onto our pulley, which is not alwaysthe case with some of the pulleys in the market.

Pulley designApart from using improved materials, the designof a pulley has changed substantially over time,he explains. Through finite element analysis (FEA)

we now have a better understanding of where thestress points are in a pulley which has enabled usto design a pulley where those stress points aremoved away from the usual failure areas.

Originally, pulleys were of the boss-type design

CONVEYING

Based on this principle, throughout its sixtyeight years in business in South Africa,Bosworth has built its pulley manufactur-ing business in Alrode to become known

throughout the local and international miningindustry as a manufacturer of superior conveyorpulleys. Bulk Handling Today visits managingdirector, Mark Tarboton, in the companys newly-built offices to catch up on developments in thisspecialised industry.

More than meets the eyeWhen you look at one make of pulley against an-other, they pretty much look the same, but theresa lot that actually goes into the manufacturing

in aQuality assurance can only be provided if the

manufacturing company has full quality control

of the manufacturing process. One sure way

of achieving this is to manufacture as much as

possible in-house. Relying on others to maintain

the specific quality standards associated with

a well-established product is often more cum-

bersome than just doing it yourself in the first

place.

An assignment of pulleys ready for shipping

Mark Tarboton

Whats

Pulley?

What differentiates a good pulley from an inferior one

really depends on what goes on behind the scenes

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where the pulley was shrunk onto a shaft as a perma-nent fixture. This proved to be unsatisfactory as oncethe pulley or pulley shaft became worn or damaged,repair was difficult and sometimes impossible, leadingto the replacement of the whole pulley. Now the shaftis locked onto the pulley by a locking element arrange-ment which is removable and when either the pulley orshaft is damaged or worn out, just the damaged partcan be replaced.

LaggingThe life of a pulley has also been extended throughlagging methods with rubber or ceramics, explainsMark. This has two main advantages, the first is thatthe rubber or ceramic becomes the wearing surfaceas opposed to the pulley shell and the second is theimproved efficiency of friction to allow for better trac-tion on a drive pulley. Failures that used to occur, veryseldom happen these days if the pulley is designed andmanufactured correctly. The pulleys have developed tothe current series where all components are computerdesigned. We developed a 3-D modelling drawing sys-

tem using Solid Works and have added an in-house FEAdesign onto this package.

Unique featuresBosworth has always been at the forefront in pulleydesign and was the first conveyor pulley manufacturer

CONVEYING

A ceramic lagged pulley

Every high tension pulley we manufacture is

stress relieved

Many companies have their own specifications which have

to be strictly adhered to when fabricating a pulley

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in South Africa to obtain an ISO 9002 listing. Today the in-dustry has matured to a point where pulley design has been

optimised to almost as best as it can be, says Mark. Youllfind that the reputable manufacturers all work to similar designtheories. As applications vary for different conveying systems,for instance, there is sometimes a request for pulleys of anunusual or unique size, but we can readily custom designand manufacture.

In pace with general developments in the materials handlingindustry where mines are increasing production with largerthroughput, pulleys have increased in size to cope with big-ger conveyors systems being built. Weve just done someextremely large pulleys weighing fifteen tonnes each for an ironore mine in Brazil, says Mark. It was a unique project in thatthe pulleys had very special design requirements. Locally wealso supplied large pulleys to the BKM iron ore mine upgradeproject near Sishen as well as a long overland conveyor systemfor the new DMO project near Middelburg.

StandardsClearly, pulley manufacturing is not just a case of churningout off-the-shelf components. In spite of an industry-widestandardisation in pulley design, many companies have their

own specifications which have to be strictly adhered to whenfabricating. Although we have our own Bosworth standards,there is a SABS standard to formalise the basis of a pulleydesign. In addition each major company has a standard thatsuits their operations best and the pulley has to conform tothose specific standards, says Mark. These specs can varysubstantially in areas such as shell thickness, shaft sizes andturn-down ratios. The amount of turn-down determines thesize bearing that has to be fitted and as the bearing makesup to between 30-40 percent of the value of a pulley, thisbecomes a serious factor to consider.

Bosworth is the oldest conveyor pulley manufacturer inSouth Africa and we pride ourselves on being able to supply

an economical, well engineered pulley which is reliable andof the best quality available, Mark concludes.

Mark Tarboton, Bosworth, Tel: (011) 864 1643, E-mail: markt@

bosworth.co.za, website: www.bosworth.co.za

The rubber or ceramic becomes the wearing surface as opposed

to the pulley shell

CONVEYING

Pulley manufacturing is not just a case of

churning out off-the-shelf components

8/7/2019 BHT: Sep 2010


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With an achievement of 24 gross crane

moves per hour (GCH) on averageduring July 2010, the Cape TownTerminal enjoyed a 9% improvement

from Junes recorded average of 22 GCH. Theoverall Transnet target is 26 GCH.

Improved performanceVelile Dube, the new Regional Terminal Executivefor TPTs Western Province operations, attributedthe improved performance in July to a reduction

Container Terminal Leads

in ProductivityBetter planning and streamlining of operations has given Cape

Towns container terminal the lead in productivity among the

five container facilities operated by Transnet Port Terminals

(TPT) in South Africa

in force majeure disruptions caused by inclementweather, as well as improved employee skills asoperators become more proficient in handling thenew equipment procured as part of the terminalsfive-year capacity creation project.

The equipment includes new Super Post Panamaxship-to-shore (STS) cranes and rubber tyred gantry(RTG) cranes. Decreased stack congestion in theterminal has encouraged a smoother operational flow.Velile says, We have managed to strike a balancein the availability of resources to meet operationaldemand and have also systematically improvedproductivity in our RTG crane operations.

New cranesThe new STS cranes give the terminal a competi-tive edge because they are faster than the oldercranes and boast twin lif ting capability, where twosix metre containers are handled simultaneously.This minimises the crane cycle time and increases

the cycle frequency. Also contributing to improvedproductivity in July was Ship Working Hours (SWH),which were maintained at an average of 41 moveson all vessels. Ship Working Hours is the numberof containers moved by the cranes working on avessel in one hour.

Better housekeepingTruck turnaround time was 26 minutes on averageagainst a target of 30 minutes maximum, whilestack occupancy was an average of 46% againsta ceiling figure of 65%. Further plans to improvelandside operations are advanced and even greaterproductivity is expected. Greater emphasis has beenplaced on housekeeping compliance, which ensuresconducive landside operations.

The terminals ongoing refurbishment has extendedthe quay wall by 10 metres and increased the draftby 15.5 metres on the high productivity Berth 601and the first 40m of Berth 602.

Equipped with four of the latest Super Post Panamaxship-to-shore cranes, the terminal is now able toservice 305 metre vessels along Berth 601 andthe first 40 metres of Berth 602. In addition, theincreased berth and increased height capacity ofthe cranes allow for the efficient handling of Super

Panamax vessels.

Transnet Port terminals, Ayanda Mantshongo, Cell: 083 301

2975, Email: [email protected] Towns container terminal leads in produc tivity among

the five container facilities operated by Transnet Port Ter-

minals (TPT) in South Africa

Truck turnaround time was 26 minutes on average

against a target of 30 minutes maximum

HARBOURS & PORTS

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HARBOURS & PORTS

The Port is Londons major gateway, handlingsignificant levels of diverse cargo including

the importation of paper, containers, grain,and various bulk handling facilities, all of

which are handled at a number of berths both indock and on river facilities. The Ports Grain Terminalfacility handles around 1.5 million tonnes per year,making it one of the biggest in the UK.

The ship-unloaders, in the form of marine legs arethe main component of two rail-mounted, mobilemarine towers which were installed on the quaysidein the 1960s. Although the equipment is over 40years old and has, since installation, handled manymillions of tonnes of grain, it is still in excellentworking condition and is a key element of the grainoperations at the port.

Major overhaulFollowing a major overhaul of one of the marinelegs in 2003/2004 it was decided to bring thecondition monitoring right up to date and the 4BBraime Watchdog Elite system was chosen to beinstalled on the marine tower.

The marine leg is an extremely heavy duty, purposebuilt, bucket elevator, designed to be deployed intoa ships hold in order to dig into and unload graincargos to shore. Raising and lowering of the leg,together with luffing, is achieved through a winchand rope system controlled by an operator in acabin, mounted in the marine tower.

The 35 metre long marine leg elevator operates ata capacity of 860 tonnes per hour, is fitted with4B Braime HDPE CCS elevator buckets bolted to acontinuous 1 120mm wide belt and runs at a speedof 3.5 metres per second. Although 4B BraimeWatchdog Elite elevator monitoring systems have

been around since 1984 and over 2 000 systemshave been installed, this is the first to be fitted tosuch a mobile device.

Why a monitoring system?Fundamentally all bucket elevators are at risk during

normal operation, regardless of the product beingconveyed, because of a number of issues. These

include possible bearing and drive faults, misalignedhead and tail pulleys, belt slipping and rubbing andbucket damage and rubbing.

Together with the potential for inlet and outletchute blockages common with any conveyor andthe prospect of poor maintenance and housekeep-ing due to inaccessibility or lack of personnel, itis clear why comprehensive monitoring solutionsare necessary.

If, in addition to this, the product being conveyedis combustible or even explosive then monitoringis absolutely essential. The installation cost of the

system is insignificant when compared with the

Not Your Average

WatchdogThe manufacturer of materials handling and electronic components, 4B Braime Elevator Components, has

supplied its condition monitoring equipment to one of two veteran ship-unloading system located at the Port

of Tilbury on the River Thames.

The Port of Tilbury Marine Tower

The 35 metre long marine leg elevator operates at a

capacity of 860 tonnes per hour

8/7/2019 BHT: Sep 2010


consequences if workers, plant and equipment arenot adequately protected and a failure occurs.

The system

The Watchdog Elite effectively mitigates these risksby constantly monitoring a number of conditions.These include belt speed, belt alignment, bear-ing temperature, pulley alignment, blocked chutedetection and acceleration.

Up to 4 digital and 6 analogue parameters can bemonitored and all data is collated at the WatchdogElite Control Unit and monitor. The control unitis usually mounted adjacent to the conveyor or

is sometimes positioned in the operators controlroom.

The IP 66 rated unit has a LCD screen that dis-plays machine status messages (available in fourlanguages), and a LED display that shows beltspeed. Calibration and set-up parameters are ac-cessed via the front panel buttons. An optional PLCinterface is available.

The Tilbury implementationBelt under speed and misalignment are monitoredby WDA High Power sensors which detect movingferrous material, in this case bucket bolts, since

non-ferrous elevator buckets are being used. This isa non-contacting extended range sensor, designedto detect targets which are up to 100mm away.Sensors mounted on either side of the marine legcasing monitor belt alignment.

Alarms for under speed are set at >10% for 180 plusseconds and immediate shutdown at > 20%.

Furthermore, all four main conveyor shaft bearings

Over the six years, a number of potential incidents have

been avoided due to the early detection and quick

response capability

The open-cage elevator boot showing the triple row 4B Braime

HDPE elevator buckets

HARBOURS & PORTS

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WDA sensors are mounted either side

of the marine leg

are monitored for temperature with trips set at80C and alarms for 180 seconds and real-timereadouts are given from 50C - 120C.

Blocked chute detection is provided in the infeedchute by the installation of a Binswitch capacitancestyle sensor that can detect plugs. All WatchdogElite systems are approved for use in hazardousenvironments including Atex Zones 21 and 22 inEurope, CSA in the USA and Canada and IECEx ona worldwide basis and the WDA sensor is approvedfor use in Atex Zone 20.

Unforgiving environmentThe system at Tilbury was installed in 2004 andhas, to date, been reliable, even though most com-ponents are constantly exposed to an unforgivingmarine environment and no components have been

replaced during this period.Over the six years, a number of potential incidentshave been avoided due to the early detection andquick response capability of Watchdog Elite. Theseoccur maybe three or four times per year and aremainly due to belt misalignment. This has giventhe operator the opportunity to re-align the elevatorbelt without incurring further damage.

Whilst the Watchdog Elite is a Guardian system,constantly monitoring for a change condition

indicating a potential per-formance failure, the Portof Tilbury actually uses theinformation in a sophisti-

cated way.Andy Lamb, EngineeringManager at the TilburyGrain Terminal, explains,When the Watchdog givesus a first indication of beltslip and raises an initialalarm, we use this as atrigger point to deployour planned maintenancescheme. There is a strongcorrelation between that very early, slight out oforder condition and the timing of a service.

By doing this, our maintenance regime is tied tohours of machine usage not absolute time andtherefore we only service when necessary. Thissaves valuable manpower resources and obviouslymoney.

4B Braime Elevator Components, email: 4b-uk@go4b.

com, www.go4b.com

HARBOURS & PORTS

We use this as a trigger point to deploy our planned

maintenance scheme

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Market ForumTrue readingsRainbow Reservoirs has launched the Yaktek, a leadingAustralian line of liquid-level indicators for storage tanks

and reservoirs.The gauges are simple, robust, effective and guaranteedfor five years. The indicators are made from corrosion-proofmaterials and early local buyers include Rand Water andN3 Toll Concessions.

Yaktek level indicators differ from the majority of competi-tors products in that the read-outs are actual and true,with the indicator exactly matching the level of the liquid.There is no need to interpret the read-out.

The underlying mechanism comprises a simple, mechani-cal float-weight-pulley system needing no power sourceand the weighted float and external indicator are both

connected by separate chords to a counterweight locatedbetween the two. Everything is in balance and level whenthe reservoir is half full. A rising liquid level will lift thefloat, lowering the counterweight which in turn raisesthe external indicator. A falling liquid level will cause theweighted float to pull the counterweight up, lowering theexternal indicator.

There are three Yaktek variants of this basic mechanism,any one of which will fit any tank of any manufacture,whether plastic, fibreglass, galvanised iron, steel, con-crete or timber.

All Yaktek indicators are made of polished aluminiumfitted with reflective red bands for maximum visibility.They can easily be seen from a helicopter and at night,making them suitable for applications such as fire-fight-ing reservoirs.

Yaktek level gauges areavailable ex-stock fromRainbow Reservoirs andtheir authorised agents.

Rainbow Reservoirs, Wayne

Thompson, Tel: (015) 297-

7640, Fax: (015) 297-7646,

Email: skywater@mweb.

co.za

Increasing fleetMkulu Plant Hires latestorder to High Power Equip-ment (HPE) Africa for fouradditional yellow metalearthmoving machines willbring its Hyundai fleet to atotal of eight.

Mkulu Plant Hires latest order to High Power Equipment (HPE) Africa brings its Hyundai fleet to a

total of eight

The order, which includes the addition of two wheeled 20tonne excavators, a 50 tonner and the an 80 tonne trackedexcavator all signify key additions to Mkulus growing planthire fleet.

Determination and uncompromising commitment has re-alised Mkulus expansion from a humble beginning of justone grader in 2006, to a fleet commanding more than 45plant hire machines today. Wheeled excavators work muchfaster than tracked excavators when used in the correctapplication, they are able to move around on site easier,thereby resulting in a significant time saving advantagefor clients.

We currently have four Hyundai machines operating inour fleet, explains Mkulu Plant Hire owner, Pierre Kok.This includes the recent delivery of a 30-tonne excavatorwith a Soosan hammer attachment that Mkulu has work-

ing on one of the worlds largest open-cast iron mines atSishen, near Kathu in the Northern Cape.

Our 20 tonne wheeled excavator has found an applicationwith a large contractor, and is working on a significant gaspipeline construction operation in KwaZulu-Natal. Mkuluslargest machine is the Hyundai 50 tonner (R500LC-7),which never saw Mkulus yard as it was delivered straightto site for a large mining company, he says.

In addition to the new order, Mkulu is purchasing a Hyundai80 tonne machine. The heavy-duty R800LC-7A excavatorwill be much more than just a high-performance work-horse, adds Pierre. It will be one of the few of its size inthe country, and will give us the ability to move more than800 tonnes an hour.

Mkulu Plant Hire, Tel: (011) 425-0073

8/7/2019 BHT: Sep 2010


Market ForumLargest crawler crane in South AfricaJohnson Crane Hire has introduced the new Liebherr 750tonne lattice boom crawler crane, the only one of its kindin Africa, to the South African industry.

Johnson Crane Hire is recognised as the largest mobilecrane fleet operator in Africa and according to Peter Ya-man, general manager of Johnson Crane Hires Heavy LiftDivision, the acquisition of this new lattice boom crawlercrane establishes the company as the leader in the heavylift sector of the market.

Peter says the Liebherr LR 1750 has a 750 tonnelifting capacity and being a crawler crane offers themajor advantage of being able to pick up a load andtravel with it.

Another advantage which will have cost saving im-plications for customers is the flexibility the machine

offers in terms of being able to move while fully as-sembled and rigged from one location to the next.This eliminates the need for multiple mobile craneson one site. In addition, the ability to carry a loadfrom the first lift location to a second position whereit will be placed removes the need for additionaltransportation between lift locations on site.

The LR 1750 has the further benefit of being able tohandle higher lifts and heavier loads to further radiithan any other crane currently available locally.

It is equipped with a 245 tonne machine counter-weight and an additional 195 tonne central ballast

counterweight. When used for lifts requiring itsmaximum capacity, the crane is fitted with a 400tonne super-lift counterweight which is mounted ona suspended super-lift tray.

The Liebherr LR 1750 lattice boom crawler is equippedwith a 133 metre main boom, however when in luff-ing fly-jib configuration it has a main boom length of84 metres, a luffing fly-jib length of 70 metres andis able to reach a height of 150 metres. With tracks1.5 metres wide and the use of specialised cranemats, ground pressures are substantially reducedand the crane can perform single lifts up to a heightof 130 metres. It is powered by a Liebherr eight

cylinder turbo-diesel 400 kW engine and can travel The Liebherr 750 tonne lattice boom crawler crane

at a maximum speed of 1.65 km per hour.

The crawler crane, being specifically designed for heavy-dutyindustrial applications, is ideally suited for applications inpower stations, refineries and petro-chemical plants, miner-

als processing and smelter plants, large civils and bridgeconstruction sites and the assembly of wind power plants,Yaman says.

Johnson Crane Hire , Yvonne Macnab, Tel: (011) 455 9203, www.

jch.co.za

8/7/2019 BHT: Sep 2010


Market Forum

Lifting coal to great heightsAustralian company, Sedgman has placed an order with Con-dra for the first of several high-lift overhead cranes quotedfor the Benga coal handling and preparation plant, near Tetein Mozambique. Sedgman, is managing design and supplycontracts worth US $63-million at the Benga project.

The contracts relate to the projects US $270-million firststage, which will allow 5,3 million run-of-mine tonnes peryear to yield approximately 1,7Mtpa of high quality cokingcoal and 0,3Mtpa of export thermal coal. Sedgman Australiaand Sedgman South Africa are delivering under a tripartitecontract with Riversdale Mozambique, the developmententity owned jointly by Riversdale Mining and its partnerTata Steel.

Condras 10-tonne high-lift overhead crane is earmarked forthe coal handling and preparation plant, which will have aninitial throughput of 800 tonnes per hour, expandable in stagesto 3 000 tonnes per hour. The cranes two-fall K-Series hoistincorporates a lift height of 32 metres. Travel and lift speedsare 8,0m/minute and 2,6m/minute respectively.

Condra is acknowledged as South Africas market leaderin very high lift crane applications, a niche in which the

The Condra 10 tonne high-lift crane for Sedgman

Split bearings the way to go

Split bearings originated in the United Kingdom and havebeen on the market for many years. As a result, many Britishand colonial built industries used these bearings extensivelyon conveyors. One such example is the Konkola copper minesin Zambia where the concentrator now has split bearings onall the conveyor pulleys.

Much of the equipment that was imported from the UK wasfitted with split bearings, however many local companiesin the conveyor industry still opted for locally availablebearings.

Split bearings were generally fitted to conveyors only on abreakdown basis and even this was seldom done due to thebolt holes and centre height being different.

A split bearing offers a superior sealing arrangement which

companys K-Series hoists have proveddependable, durable and robust underconditions of increased mechanical strain.The modular design of the K-Series allows

rapid modification to the specific require-ments of any high-lift application.

Motor reliability in the high-lift role is en-hanced by the use of silumin motor cores,while variable speed control levels on thedrives have been developed to enable pre-cise load positioning, even on lifts greaterthan 100 metres. The crane can providehigh-lift hoist speeds of between zero and18 metres per minute, and travel speeds ofbetween zero and 100 metres per minute,depending on the requirement.

Condra, Josef Kleiner, Tel: (011) 021-3712, Fax:086 669-2372, Email: [email protected]

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Market Forummeans the split bearing in many cases outlasts the originalplummer block between 5 and 30 times. An example isBotswana Ash, where a bearing was replaced every 3 to 6months, whereas a split bearing lasted 7 years.

Split Roller Bearing (SRB) a division of Revolvo a specialistbearing manufacturer in UK took a good concept and madesome significant improvements such as using stronger castiron. Split Roller Bearings (SRB) pioneered the developmentof a range that was compatible with the standard SN andSD plummer block, this range made the conversion to splitbearings very simple, which led to new plants being speci-fied with split bearings.

Now many companies such as Lonmin Platinum, AquariusPlatinum, Portnet, Assmang, Anglo Plats, Impala Plats andSasol specify split bearings on new plants.

An added advantage of a split bearing is that it takes about

an hour to replace, compared with around five hours witha conventional plummer block, the cost of the downtimesaved covers the original cost of the split bearing manytimes over.

Based on the above, Revolvo has decided to offer a two yearguarantee on SRB which makes this bearing the only bearingwith a two year warranty.

OE Bearings, Dennis Cooney, Tel: (011) 493-4463, Fax: (086) 502

6433, email: [email protected], www.oebearings.co.za

A successful dome liftTarget Cranes has completed a precedent setting heavy liftfor Active Mechanical Services Group (AMS) in the WesternCape.

The contract called for the lifting of a 37-tonne geodesicdome and placing it atop a recently-refurbished oil storagetank. The aluminium dome, with a 54 metre diameter, willserve as a covering for the oil tank to protect its contentsfrom the elements. The geodesic shaped dome allows anycondensation or rainwater to flow to the edge of the domeand down the sides of the oil tank.

Target Cranes was selected to perform the lift because ofits expertise with similar, complicated lifts. In addition, thecompany has the most comprehensive mobile crane fleet inSouth Africa, totalling more than 70 modern, mobile craneswith lifting capacities from 8 to 600-tonnes.

The number and size of the crane fleet enables Target Cranesto provide a turnkey service for substantial projects, BernettLaufs, national operations manager at Target Cranes says.

Aluminium was the chosen material of construction as op-posed to steel for its anti-corrosion and light-weight proper-ties. However, because of the lighter aluminium which ismore flexible than steel, the dome had a tendency to distortwhen lifted, says Bernett.

In addition to supplying the six Liebherr mobile cranes forthe lift, Target Cranes was also responsible for undertakingthe rigging study and supplying a rigging team. We haveperformed rigging on numerous contracts and are actively

expanding the capabilities and scope of this offering, hesays.

This service is a value added benefit to our customers asthey can now source all the elements required for a l ift fromone service provider. This, in turn, allows continuity andquality of service, Bernett continues.

Target Cranes elected to use a 275-tonne LTM 1250 craneon one side of the tank and a 245-tonne LTM 1225 craneon the opposite side to lift the 24.7 metre long spreader

beam weighing 6.5-tonnes. Four 30-tonne slings were used to attach thespreader beam to the crane hooks.

Below the spreader beam, 24 slingswere attached to the domes outercircumference.

Placed at intervals between the twolarger cranes were two 66-tonne LTM1060 cranes, one 95-tonne LTM1090 crane and one 77-tonne LTM1070 crane. The dome was attachedwith four slings to each of thesesmaller cranes. Target Cranes usedthese additional cranes to providemore precise and complex lifting asopposed to the sheer lifting strength

of the larger cranes.Prior to the lift, a comprehensive rig-ging study indicated exact placementof each crane and its slings.

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Market Forum

THT managing director, Sampie Swanepoel, seen with three of the Hino 700 Series 28-45

in his fleet

Crane hire serviceHeavy Transport (THT), which was es-tablished more than 40 years ago, hasrecently extended the services it offers customers with theacquisition of a HIAB Pesci SPE 350/4 that is mounted onthe rear of a Hino 700-Series 28-48 rigid. The crane canlift up to a 17-tonne load and is the largest crane mountedon a Hino in South Africa.

The Italian-made crane is one of only three of this model inthe country and it was selected by THT managing directorSampie Swanepoel for i ts versatility and manoeuvrability. Itcan lift a 17-tonne load with a 2 metre reach and a 5-tonneload at a 6 metre reach. The current maximum reach of 8metres enables it to lift up to 3.7-tonnes, while the reachcan be extended even further to handle lighter loads.

The clearance between the dome andthe tank wall was a maximum of 250mm, which meant there was no roomfor error.

The time taken from the start of prepara-tion to the point of fastening the last nutwas 41 hours. The lift was characterisedby stringent safety precautions, extremeattention to detail and ongoing commu-nication and cooperation between theTarget Crane and AMS teams, Bernettconcludes.

Target Cranes , Jan Lourens, Tel: (011) 827

9227, Fax: (011) 827 9688, E-mail: Jan@

targetcranes.co.za, www.targetcranes.co.za

The big advantage of is that it can both lift and drag loads,which makes it ideal for rigging tasks, while the trucks freightcarrier body enables it to carry a load of up to 14-tonnes,including the weight of the crane, says Sampie, who addsthat it was an expensive piece of equipment, costing (withthe Hino truck) R1.7 million, but has found an immediate

market and is almost continually in use.

The Hino 28-45, which was supplied by Hino East Rand hadits chassis extended by TFM to facilitate the rear mountingof the crane.

Hino, Ignatius Muthien, Tel: (011) 809 2064/2255, Fax: (011) 809

9064, Email: [email protected]

8/7/2019 BHT: Sep 2010


Market Forum

Tracked screeners

rebranded

Coinciding with the relocation ofMetso Minerals mobile screeningfactory to the companys existingcrusher plant in Tampere, Finland, isthe 2010 launch of the re-brandedLokotrack ST track mounted screenseries, which comes with a host ofnew technological enhancements.

Within the southern African market,the new ST range will complementa growing population of MetsoMinerals mobile units already per-forming sterling service on mining,

quarrying and construction sitesacross the region. Locally, the Metso mobile range is soldand supported by Barloworld Equipment, which is also theexclusive southern African Caterpillar distributor.

One of the major new developments on the ST range is MetsoMinerals decision to fit Caterpillar C4.4 Tier 3 engines as astandard OEM item across the series, explains Trevor Garden,general manager: Metso, at Barloworld Equipment.

The well-proven Metso ST358 and ST458 models have nowbeen re-named as the ST3.8 and ST4.8, which best describesthe tasks which these machines are designed to perform. Forexample, on the ST3.8, S stands for Screen, T for tracked,

3 indicates the number of discharge conveyors, and 8 thearea in square metres to the nearest whole number.

Best grab ever builtSince its inception in Durban in 1966, Arlona Engineer-ing, specialists in fabrication, machining, proofloading andmaintenance of bulk handling and stevedoring equipment

has made a significant contribution to the efficiency of SouthAfrican ports.

The companys fully computerised fabrication facility isequipped to design and manufacture grabs, hoppers, containerspreaders and lifting equipment, and a wide range of cargohandling equipment, all to exact specifications.

Arlonas lat-est grab, witha unique 12mhook-on, remoteopening, dumpingdesign, which has

been describedby customers asthe best grabArlona has everbuilt, is generat-ing quick returnsfor local steve-dores, says SteveChristy, managingdirector of ArlonaEngineering.

The new genera-tion of grabs, with

a unique lockingmechanism that is simple and reliable, has advanced designfeatures over conventional units. These include reduced taremass, superior sealing and enhanced reliability.

By employing the latest design technology, the 12m capacitygrab weighs only 7 000 kg. This has been achieved withoutany reduction in strength or loss of closing forces, a problemgenerally associated with lightweight grabs.

In addition, the capacity of these buckets can be quicklyreduced in 2m increments down to 6 m. This means thatdepending on the commodity being handled, the grab can beused on cranes with a safe working load as low as 15 tonnes.

This flexibility is especially useful in South Africa where age-ing bulk vessels call into ports on a regular basis.

Arlona Engineerings new 12m grabs discharging soya in Durban.

High closing forces generated by robust chains which closeand suspend the grab, are complemented by serrated dustseals and an under-hanging lip, making the grab both robustand environmentally-friendly. As a result of these advanced

design features, leaking grab buckets are now an unusualsight in South African ports.

Arlona Engineering , Steve Christy, Tel: (031) 205 5991, Fax: (031)

205 9835, Email: [email protected], www.arlona.co.za

8/7/2019 BHT: Sep 2010


Improved conveyor loadingMartin Engineering has introduced custom-engineeredtransfer chutes, helping to deliver material control from thetime it leaves the conveyor discharge pulley until it reachesthe receiving belt. By managing the material speed and di-

rection, Martin Inertial Flow Transfer Chutes can minimiseimpact and wear on liners and belts, while containing dustand spillage.

The engineered flow chutes employ special geometries thatcapture and concentrate the material stream as it travels

A Metso Minerals Lokotrack ST358 mobile screening unit in operation on a site in Namibia. The next generation ST3.8 will be fitted

with a Cat C4.4 Tier 3 engine as a standard OEM fitment

Technological enhancements include improved bearing qual-ity and remote greasing. Additional protection is now alsoprovided for the hopper skirts to improve skirt life, while arevised adjustable covered discharge chute design furtherincreases material flow efficiencies. On the main and finesconveyors, additional rollers have been added to reduce therisk of spillage to a minimum.

Barloworld Equipment, Tel: (011) 929-000, Website: www.barloworld-

equipment.com

through the chute. Every design is tailored to suit the specificmaterial characteristics and conveyor systems of the individualcustomer, rather than using stock products and attemptingto make them work. Inertial Flow Transfer Chutes providethe dual benefits of minimising aeration and preventing buildup within the chute.

Transfer points should never be a production bottleneck,comments Martin Product Development Engineer JustinMalohn. By testing the customers specific bulk materialand applying those properties as the initial step in chutedesign, we can develop a transfer that meets capacity whileminimising the potential for build-up and chute plugging,he says.

The transfer chutes also incorporate replaceable liners, allowingoperators to unbolt the enclosure for simplified replacementof worn components without confined space entry.

Engineered chutes typically employ a hood and spoontransfer, with the hood discharge chute at the top of thesystem and a spoon receiving chute to place material onto

the belt being loaded. Martin Engineering components arecustom-designed to suit the characteristics of the conveyedproduct and the materials used for chute construction.

The hood minimises expansion of the material stream,directing it downward, he explains. The spoon provides

Market Forum

8/7/2019 BHT: Sep 2010


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a curved loading chute for a smooth line of descent, consis-tently feeding the material at a specific speed and directionto minimise impact in the loading zone, explains Justin.

The goal is to confine the material stream and reduce airentrainment, while directing the moving material onto thereceiving belt with minimal impact.

Martin Engineering, Tel: (013) 656 5135, Fax: (013) 656 5129, Email:

[email protected], www.martin-eng.co.za

By managing the material speed and direction, Martin Inertial

Flow Transfer Chutes can minimise impact and wear on linersand belts

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