The awarding of the operation and maintenance of a 25MW biomass power station to John Thompson illustrates how ACTOM is actively seeking opportunities to extend their service offering. Increasingly, customers are looking for accountability and integrity in business partners. ACTOM has developed a reputation for professionalism and innovative and reliable service provision and is ideally placed to provide end-to-end solutions.
ACTOM Electrical Machines’ new range of Airstream rated electric motors.
“Africa’s fast-growing population and increased urbanisation will require a significant investment in power generation capacity. This is where John Thompson will be very well placed with our ability to supply a complete power island. To illustrate the point, we have quoted two power generation projects, similar to Ngodwana, into Africa using John Thompson boilers and ancillary plant where we will be considered for the operating and maintenance of the plant. We believe that Ngodwana will be the start of many operating and maintenance contracts in Africa with the outsourcing of non-core activities and the lack of expertise driving these opportunities,” commented John-Paul Andre, Divisional CEO of John Thompson.
During 2020, Reid & Mitchell secured contracts outside of their traditional scope of business.
Sandile Nyembe, an Assembler with Reid & Mitchell checks a 788-wheel motor before it is dispatched.
They have been appointed to modify a 60 Hz dragline based in North America which is being relocated to a new site in North Africa and to convert the dragline to operate in a 50 Hz environment.
“This is new business for Reid & Mitchell, but our extensive experience of the mining sector enables us to easily and successfully diversify,” explained Mike Shaw, Divisional CEO of Reid & Mitchell.
John Thompson also diversified their service offering when they were awarded a contract to refurbish two cooling towers at Tutuka Power station. The refurbishment entails the removal of the current cooling tower packs, the distribution pipes as well as the drift eliminators, all of which contain asbestos. ACTOM is using the services of a local company specialising in the removal, and appropriate disposal of these components. The towers will then be washed down and declared asbestos free before the new components are installed. The new packs have been redesigned and are made of a durable polypropylene. They will be manufactured by a locally based contractor working with John Thompson on this project. The new distribution pipes and drift eliminators have been engineered by Hamon. Once all the components are delivered, John Thompson will install and commission.
Gladstone Mbili, General Manager of John Thompson’s Utility Boilers and Environmental Solutions explained how John Thompson got involved in this new line of work, “We have a technology co-operation agreement with Hamon and we partnered with them to tender for this business. Our partnership meant that we met the required technical and local regulatory requirements that were specified in the tender. We were successfully awarded the contract in July this year and the refurbishment is well underway.”
Many of the ACTOM businesses have developed new technologies or improved existing technologies that will extend the life cycle of products.
Reid & Mitchell are supplying components, on a unit exchange basis (UnX), to the off-highway vehicle (OHV) market.
“Our customers are always looking for cost effective ways in which to extend the lifespan of their older trucks. With the truck fleets equipment with 776-wheel motors reaching the end of their expected lifespan, it makes sense to sell complete refurbished components, that we issue with a guarantee, to keep them running. We believe that this service offering is of particular interest to our customers” said Mike Shaw.
With the success of the 776-wheel motor UnX programme, Reid and Mitchell has now developed the model to also supply 788-wheel motors and GTA22 alternators.
Another challenge Reid & Mitchell believe they have found a solution for relates to the cooling systems on draglines. Mike Shaw explains, “Increasingly we see larger buckets being fitted to draglines which means the motors are working harder and at higher temperatures. For every 10 degree increase in temperature, you potentially cut that motor’s lifespan by half. It is imperative that we find effective ways of keeping these motors cool and we believe that, together with TLT - Turbo, we have found a solution that will prove to be successful.”
Draglines are currently fitted with heavy centrifugal scroll fans. The newly developed composite axial fan has a number of advantages - it delivers more air flow which cools more effectively, it uses far less energy through the motor and it weighs a lot less which is helpful in reducing stresses on the cantilever mounting arrangement.
Reid & Mitchell have introduced two other innovative processes this year.
Equaliser rings are now being vacuumed after they have been epoxied and this takes out any air pockets resulting in higher product integrity. And, the spin seasoning plant was upgraded to an AC drive system resulting in a more modern and efficient plant. This has resulted in the successful reintroduction of spin seasoning to ensure the quality and durability of product.
ACTOM Electrical Machines launched its new range of Airstream rated electric motors. This new range, designated the PQ3, is a range of 3-phase, low voltage, aluminium PAD mount electric motors.
After extensive market research on potential customers, market size, price levels and product requirements a year-long R&D program was initiated. During this period, new patterns, tooling and samples were manufactured and approved. The result is a well-engineered, price competitive and high-quality range of electric motors. The PQ3 range will find application in domestic, commercial and industrial fan units.
The PQ3 range is available in frames sizes 71 to 132, with a power rating from 0.25kW to 9.2kW. It is available for 400V supply in 2, 4, 6 pole speeds.
Other businesses have further developed and tested technology that will come to fruition in the years ahead.
The final forming and alignment of equiliser leads.
One such concept is Centralised Substation, Protection, Automation and Control Systems (CSPACS). Although not a new concept (it was first proposed in the early 1970s), it is now only becoming a viable option as a result of the development of computer hardware and software and the communication technology able to support it.
With plans to connect renewable and intermittent energy resources to the grid, protection and control systems need to be more flexible and have the capability of reconfiguring quickly.
The IEC 61850 international standard defines communication protocols for intelligent electronic devices at electrical substations. These protocols can run over TCP/IP networks or substation LANs using high speed switched Ethernet, resulting in the necessary response times for protective relaying and is the basis on which centralised solutions are built.
ACTOM Protection and Control, together with a technology partner, have been evaluating various substation protection and control architectures and Herman Mare, General Manager designate for Protection and Control commented, “It is important that we stay on top of developments in this area in order to deliver these solutions as soon as possible. A centralised protection and control solution offers a number of benefits including increased flexibility and improved performance as well as an overall reduction in costs.”
ACTOM Turbo Machines used this turbulent year to expand their workshop, adding a further 300 m2 of floor space, that will house a horizontal boring mill as well as a vertical lathe. This extra-large machinery will increase their machinery handling capacity.
“These machines will put us in a different league as we will no longer need to outsource this work. This will improve our turnaround times and enable us to manufacture more cost effectively. I believe this will boost turbo machinery manufacturing not only in South Africa, but for the African continent,” Chris Bezuidenhout, Managing Director of ACTOM Turbo Machines proudly explained.
Chris also mentioned how important this upgrade to the factory and the purchase of additional equipment is to the Vaal area, “Having grown up here, it is important for me personally to be able to continue to provide employment and to develop the skills of the people from this community.”
ACTOM Turbo Machines is considered an essential service provider and operated throughout lockdown. Strict hygiene measures were adopted and included daily sanitising of all work areas. Chris explained their lockdown strategy, “We always look for the positive in every situation and we saw lockdown and the restriction on international travel as an opportunity to showcase what we, as a local OEM, are capable of. I believe that we have proven ourselves and I hope to build long-term business partnerships with those companies we worked with this year.”
Jack Mofokeng, CNC Machinist, Chris Bezuidenhout, Managing Director and Mark Gulbis, Business Development Manager with the horizontal boring mill recently acquired by ACTOM Turbo Machines.Jack Mofokeng, CNC Machinist, Chris Bezuidenhout, Managing Director and Mark Gulbis, Business Development Manager with the horizontal boring mill recently acquired by ACTOM Turbo Machines.
ACTOM Turbo Machines was recently awarded a service contract with Illovo Sugar and also recently became a vendor to Engen Refinery, Impala Platinum and Tongaat Hulett Sugar.
There is still a great deal of uncertainty around how South Africa will recover from the enormous economic impact of Covid-19. However, it is encouraging to hear how the various ACTOM businesses are seeking opportunities and using this time to plan for an uptake in business in the future.
@JackMofokeng @ChrisBezuidenhout @MarkGulbis @JohnPaulAndre @MikeShaw