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IMDEX BOLT bridges the gap between success and failure underground

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If the maxim in building is measure twice, cut once, then the underground mining equivalent would be to measure production hole deviation and analyse before blasting. Underground mining is challenging and the environment unforgiving of mistakes that often carry cost and safety implications.

IMDEX Commercial Manager – Underground Survey Applications Mike Ayris has been promoting the importance of surveying blast holes since he founded Downhole Surveys in 1989. DHS was majority owned by directional drilling specialists Devico and became part of the IMDEX group when IMDEX acquired Devico earlier this year.

For Mr Ayris, the process is not Drill and Blast; it’s Drill, Measure, Analyse, and Blast. IMDEX is developing a new system for the job: IMDEX BOLT TM , a production hole survey tool for underground applications measuring blast hole deviation using a north seeking gyro.

IMDEX BOLT 

BOLT TM is in the commercial prototype phase and has been installed at four sites with two trials underway. Recent design changes have reduced the weight, making it easier to deploy overhead, thereby solving one of the key challenges of working in an underground environment.

Zambia Airways Flies To New Heights With Boeing 737-800 Acquisition

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Zambia Airways has marked a significant milestone in its journey of growth and expansion as it welcomes a Boeing 737-800 aircraft, a move aimed at boosting its international flight operations.

The latest aircraft, which touched down at Kenneth Kaunda International Airport on Wednesday, September 27, 2023, is a testament to Zambia Airways’ commitment to enhancing its services and increasing its global reach. This acquisition also signifies the airline’s dedication to providing a superior travel experience to its passengers and boosting Zambia’s presence in the aviation industry.

The Boeing 737-800 is recognized worldwide for its popularity and advanced technology. It features state-of-the-art technology that not only enhances fuel efficiency but also extends its flight range. This fuel-efficient aircraft is poised to be a game-changer for Zambia Airways as it seeks to explore new horizons in international travel.

One of the notable advantages of the Boeing 737-800 is its longer fuselage, which translates into a more spacious interior for passengers and increased cargo capacity. With a two-class configuration that includes Business and Economy class, the aircraft can accommodate approximately 160 passengers comfortably.

Transport and Logistics Minister, Hon Frank Tayali, who was present to welcome the aircraft alongside IDC Acting CEO Ms Leya Mtonga-Ngoma, expressed his enthusiasm for Zambia Airways’ growth. He highlighted that the airline’s progress has defied skeptics and demonstrated the government’s ambition to establish Zambia as a prominent player in the aviation sector.

“The addition of this new aircraft will take us a step further in enhancing our local and international aviation footprint, opening up new routes and connecting more cities,” Minister Tayali said. “It will facilitate trade and tourism and allow citizens to explore the world with ease.”

Mr. Cosam Ngoma, the acting Managing Director of Zambia Airports Corporation Limited, emphasized the airline’s significant achievement at a time when aviation passenger traffic is rebounding following the challenges posed by the COVID-19 pandemic. He reported remarkable growth in both international and domestic air travel, with passenger numbers soaring by 106% and 133%, respectively, as of August 2023 compared to August 2019.

“The growth of domestic air travel has been faster than international travel because of local airlines such as Zambia Airways,” Mr. Ngoma added.

Abiy Asrat Jiru, CEO of Zambia Airways, reiterated the airline’s commitment to delivering top-quality travel experiences at the most competitive prices. He emphasized that the efficient Boeing 737-800 aircraft would enable Zambia Airways to explore new markets and reach new heights in the aviation industry.

Currently, Zambia Airways – jointly owned by the Industrial Development Corporation (IDC) and Ethiopian Airlines, operates routes to Harare and Johannesburg in addition to its domestic routes to Livingstone, Ndola, and Solwezi. With the acquisition of the Boeing 737-800, the airline is poised to expand its network and offer passengers an even more exceptional travel experience.

The US and EU jointly support a new African railway line between Zambia and Angola

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The European Union and the United States are joining forces to support the development of a new railway line between Zambia and Angola, initiating the technical and economic justification

This is part of the Trans-African Corridor development, connecting the southern part of the Democratic Republic of Congo (DRC) and northwestern Zambia to regional and global trade markets via the Lobito port in Angola.

CRRC unveils a new railway train

The project was announced on the sidelines of the Global Infrastructure and Investment Partnership (GIIP) event at the G20 in India.

The Lobito Corridor presents an alternative strategic route to the export markets of Zambia and the DRC, offering the shortest path connecting the key mining regions of these two countries to the sea.

The partnership between the EU and the US will revitalize critical infrastructure in Africa south of the Sahara to unlock the “vast potential of this region,” according to a joint statement.

“We are pleased to join forces to realize economic benefits with our partners in Angola, the Democratic Republic of Congo, and Zambia.”

The partnership will pool financial resources and technical know-how to accelerate the development of the Trans-African Corridor, including investments in digital access and value-added agricultural value chains, enhancing regional competitiveness.

According to the EU, this represents a “powerful evolution of the Global Infrastructure and Investment Partnership approach to collaboration, which can be replicated in other strategic corridors around the world.”

Namibia Plans $2.1 Billion Port Expansion for Oil Boom

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Namibia’s state-owned Namibian Ports Authority (Namport) has announced plans for a $2.1 billion port infrastructure expansion project to support the southern African country’s burgeoning energy industry.

The expansion project will involve the construction of new berths and quay walls at the country’s major port of Walvis Bay and the construction of a new port in the town of Lüderitz.

Under the plan, Namport will set aside roughly 350 hectares of land for development and will collaborate with the private sector through public-private partnership agreements, allowing companies to establish operations under a landlord port model.

“We are hoping to commence with the operation in the last quarter of next year, which will take about three years at most,” stated Namport CEO, Andrew Kanime, adding, “We are seeking private companies with technical expertise and financial resources to invest in this space.”

With offshore activity in Namibia accounting for approximately 13% of rigs working on African waters, the project will be designed to support drilling services at the country’s primary port of Walvis Bay. Meanwhile, a port at Lüderitz is poised to provide market access for the mineral-rich Northern Cape Province of South Africa.

The announcement comes after significant oil discoveries were made by supermajors, Total Energies and Shell, in Namibia’s offshore Orange Basin in 2022 and 2023, resulting in an estimated resource base of 7 million barrels of oil equivalent for the country. Namibia is expected to reach its first crude production by 2029 and is poised to become Africa’s fifth-largest oil producer by 2030.

MV Switchgear awarded SIS switchgear contract for DRC mine’s underground substations

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MV Switchgear, which executed two large contracts over the past two years involving manufacture, supply, and installation of numer­ous air-insulated switchgear (AIS) panels for 11kV substations at the extensive new Kamoa-Kakula cop­per mine in the Democratic Republic of Congo (DRC), has subsequently been awarded a further contract for GELPAG solid insulated switchgear (SIS) units for more underground substations at the mine.

A total 233 of MV Switchgear’s well-known and widely used SBV4E brand of AIS switchgear panels were produced and supplied by the division to equip surface and underground substations at the new mine. They comprised 140 panels for eight surface substations and 93 panels for five underground substations.

Specialised switchgear

The latest contract for 149 GELPAG SIS units for eight underground substations, awarded late last year for delivery in August this year, came about as a result of having to address changes in underground conditions at the mine as mining operations progressed.

“Harsh environmental conditions such as high levels of humidity and dust were found to be present in these underground sections, necessitating having to introduce more specialised switchgear equipped to cope with these conditions,” said Rhett Kelly, MV Switchgear’s Design & Development Manager.

“In such a situation the choice is typically between fixed pattern gas-insulated switchgear (GIS) and solid-dielectric-insulated switchgear (SIS). We were confident in recommending to DRA Global of South Africa, the engineering consultants for the Kamoa project, our GELPAG SIS product for this purpose.”

With MV Switchgear experiencing growing demand for GELPAG since introducing it into the local market in late-2020, it recently arranged in collaboration with its overseas-based OEM partner to commence local manufacture of some of the product’s ancillary components.

“By taking this step we’ve substan­tially shortened the production lead times, as we can now manufacture the agreed locally produced components in parallel with the OEM’s production of the main product, thereby speeding up both final assembly of the product in our plant as well as delivery to the end-user,” Rhett said.

The Kamoa mine will be the first recipient of GELPAG panels in terms of the new arrangement. Johan Jordaan, the division’s Technology Development Specialist, said: “The components being manu­factured locally now and in the future are the LV compartment, internal arc ducting and the drop-down boxes for the cable terminations.

“While not normally required for the GELPAG product range, custom drop-down boxes have been designed to accommodate the 3-core cable terminations with core balance CT’s specified by the customer. To further speed up and simplify production and delivery, we’ve devel­oped an LV connector system which allows the panel’s circuit-breaker, disconnector and earth switch wiring to interface with the LV control wiring via a standard multi-pin plug-and-socket system,” he added.

MV Switchgear has also developed a wiring test rig to enable it to test and verify the wiring of each LV compartment before the GELPAG panels they are to be connected to arrive from abroad.

The evolution of mining infrastructure and EPCM collaboration

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As the demand for raw material continues to surge, the spotlight has turned to the mining sector, bringing both greenfield and brownfield mining projects into focus.

Ensuring these ventures are efficiently executed without compromising on time or budget necessitates a tailored strategy. Often, this means relying on the expertise of an Engineering, Procurement, and Construction Management (EPCM) contractor.

Successful partnerships

David Claassen, Managing Director of Trafo Power Solutions, firmly believes in the importance of partnering with adept EPCM professionals and says the key to successful partnerships lies in comprehending the EPCM domain. Established in 2017, Trafo Power Solutions specialises in dry-type transformers and has established robust collaborations with EPCM contractors globally, especially across South Africa, Africa, Australia, and Canada.

According to Claassen, Trafo Power Solutions’ consistent successes hinge on several principles, which include understanding project complexities, fostering effective communication, flexibility in adjusting to evolving project scopes, access to proven technology and products, and delivering timely results.

“It’s vital to understand that each project has its uniqueness, and our team successfully navigates this by adopting an “understanding strategy”, emphasising the importance of collaboration to manage the complexities,” he says. “Our deep comprehension of the project process helps us pinpoint and provide the most suitable solution tailored to customer needs.”

EPCM contractors handle intricate tasks such as detailed engineering and design. Trafo Power Solutions contributes by suggesting alternate solutions, ensuring efficient procurement, avoiding redundancy and ensuring the best outcomes for every project.

Communication is the cornerstone of successful project execution. With various EPCM entities employing different communication tools and software, Trafo Power Solutions prides itself on its adaptability. “Our flexibility allows us to mesh with any project team, irrespective of their chose software,” Claassen notes. He emphasises that this adaptability optimises project management processes, contributing to each project’s success.

Integrity and collaboration remain at the core of Trafo Power Solutions’ operations. Their dedication to understanding project requirements and prompt responses ensures minimal risks and streamlined operations. As Claassen aptly puts it, “The collective goal of stakeholders is the successful execution of a project. “Trafo Power Solutions, in partnership with TMC Transformers from Italy, offers top-tier dry-type transformers, emphasising quality and reliability. As the world shifts towards rapid infrastructural developments, such collaborations and expertise will only become more invaluable,” Claassen concludes.

Technequip knife gate valves a cut above

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Long regarded as a leading brand in abrasive slurry applications, KREBS® Technequip® knife gate valves now allow less stockholding of spares through the enhanced interchangeability of components.

Most of the components are standard across the range, explains Herman Britz, Regional Product Line Manager for Pumps, Cyclones and Valves at FLSmidth. The upgrade of the legacy products has ensured that customers need to keep a smaller variety of parts in their inventory.

“While the bodies of the flange-type valve and the wafer-type valve will differ, for instance, other components like the gate, actuator and wiper blades are standard,” says Britz. “This means that the components for a 200 mm flange valve, for instance, will also fit on the 200 mm wafer-type valve.”

This benefits the supply chain and helps customers to reduce their stockholding. With an extensive footprint in mineral processing, the KREBS® Technequip® valves are used across a range of commodities and materials – from phosphates to the platinum group metals.

Design

“The focus of our design was for harsh, abrasive applications – where these valves have proved their worth globally,” he says. In sizes from 50 mm up to 1,3 m in diameter, the valves match the pipe sizes in the market and are designed to deal with a wide range of pressures and process conditions. He highlights the ‘full port’ nature of the valve, reflecting that the valve’s inside diameter will be the same as the pipe when the valve is fully open.

“This reduces any pressure loss as the material passes through the valve, and ensures that there is no turbulence, which also reduces the wear rate,” he explains. “The gate removes itself completely from the flow of material, which is a key differentiating factor.”

He also points to the valves’ push-through or self-cleaning design. This is essentially a self-flushing function which eliminates the need for a packing gland. As the gate closes during actuation, material is ejected out of the bottom of the valve, ensuring that there is full closure of the gate and a reliable seal is created. Another vital contributor to the valves’ durability and performance is the internal wear sleeve.

“The wear sleeves on our knife gate valves are the only surface that is in direct contact with the slurry,” says Britz. “By protecting the other parts from wear and tear, the sleeves reduce the need for replacement of parts.”

A bubble-tight seal ensures that there is no spillage, whether the valve is open or closed. Importantly, the sleeves can also be replaced in the field, so there is no need to take the valve to a specialised workshop.

“On our flange-type valve, a technician can simply remove the retainer flange and take out the sleeve, replacing it with a new part and returning the retainer to its position,” he says. “This is certainly a stand-out feature when compared to most products on the market, and helps our customers avoid undue downtime.”

High-pressure jetting trailers assist with tailings dam maintenance

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Tailings, the waste products from mining, can be liquid, solid or a slurry, and may contain toxic substances. To avoid these substances from contaminating water sources or polluting the environment, mines contain them in tailings dams and are required to maintain and monitor them to ensure they remain safe.

When tailings dams fail, the consequences can be lethal, which is why it’s important that drainage systems remain operational and function efficiently. High-pressure jetting equipment can be used to ensure this is the case.

“The way most tailings dams work is that a slurry of mining waste is piped into the dam, and the solids then settle to the bottom. The water is recycled to be used in the separation process again,” explains Sebastian Werner, MD of Werner Pumps, leading manufacturer of high-pressure jetting equipment in South Africa.

“Aside from ensuring that the dam walls are sound, it’s also important to monitor drainage. If the drainage system gets blocked, it can pose major safety risks.”

If the drainage system gets blocked, it causes flow restriction and can affect safety factors such as the degree of saturation in the dam, and phreatic surface levels. Blockages can be caused by anything from algae build-up to mineral deposits.

“To avoid or deal with blockages, regular jet-rodding is recommended,” says Werner. “This entails using high-pressure water jetting equipment to scour the walls of the drainage system to allow water to flow freely by unclogging the pipes. It can also assist in identifying damaged pipes.”

Werner Pumps supplies trailer-mounted high-pressure jetting units, which can be used for cleaning domestic sewer lines, as well as water sandblasting. The units are high-quality, 100% locally manufactured, and customisable for every customer’s specific requirements, with models available for every need. They range from 8 litres per minute to 500 litres per minute, with pressures from 50 Bar to 2800 Bar and power from 2.5kW to 500kW, while the ultra-high-pressure units (such as those used in the tailings cleaning applications) offer 1000 Bar and are also suitable for applications such as rubber and scale removal.

Extras available include a Werner low-water inlet switch, high-pressure jetting hose (20m, 30m or 50m), a high-pressure gun with lance, nozzle holder and fan nozzle, and the Werner small hose reel for smaller diameter hoses, for cleaning of household lines.

“We initially designed the trailer units for domestic applications and smaller sewerage clearing operators and municipalities who were looking for a more cost-effective option than investing in a truck unit, but we’ve found that because they are so easy to transport, they are much lighter and they can get into tight spaces, they are ideal for other niche applications,” says Werner. “We have a customer who uses one of our trailers not only for tailings dam maintenance on the mines, but also for clearing out piping in the boreholes they drill too. The trailer-mounted unit continues to be one of our most versatile offerings.”

About Werner Pumps

For over 30 years, Werner South Africa Pumps & Equipment (Pty) Ltd. has been designing, manufacturing, supplying and maintaining specialist high-pressure jetting equipment. The company has built a reputation as a local industry leader through its focus on delivering high-quality, low-maintenance, 100% South African manufactured products that last, all while considering clients’ budgets.

Aside from its in-house manufacturing capabilities, Werner Pumps specialises in the supply and maintenance of high-pressure jetting equipment, German high-pressure pumps, high-pressure sewer cleaning hoses, Swiss-engineered Nozzles by ENZ, and high-pressure guns, lances and cleaning equipment.

The High Cost of ‘Clean‘ Coal Power Plants

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Despite their envisaged benefits, adopting Clean Coal Technologies (CCTs) in new coal-fired power entails bearing a significant cost burden. Are organisations willing to bite the bullet?

By Nick Barnes

“To keep global warming to no more than 1.5°C – as called for in the Paris Agreement – emissions need to be reduced by 45% by 2030 and reach net zero by 2050.”

This is the pledge by the United Nations’ Net Zero Coalition on Climate Change.

It is a clarion call for everyone to play a part in reducing greenhouse emissions from their respective activities.

However, there is a huge burden on industries that utilise huge volumes of fossil fuels, as they are classified as the biggest producers of emissions.

Coal-fired power plants

Coal-fired power plants are one of the biggest producers of greenhouse gases. Greenhouse gases emitted by coal-fired power stations include but may not be limited to SOx, NOx, CO2, and particulate matter (PM). And so, industries that utilise or own coal-fired power plants should adopt measures to reduce emissions.

The reality

In an ideal world, industries should ditch coal and adopt the cleaner options of renewables and nuclear. Nonetheless, the reality is that coal constitutes a big part of the current sources of electricity (currently 29 of the world’s electricity sources).

Based on the state of affairs, coal will remain a significant source of electricity in the foreseeable future. This is not least in South Africa where coal-fired power plants supply baseload electricity.

On the role of coal, the World Coal Association could not have put it more perfectly by stating: “It is not the use of coal but the way coal is used that should be the focus of attention.“ In other words, the world has to use coal responsibly with minimal impact on the environment.

It is now or never.

Currently, in many countries, South Africa being one of them, coal-fired plants are approaching the end of their life about to be decommissioned. As a replacement, new plants will be developed. Thus, there should be more urgency.

Clean Coal Technologies (CCTs)

Thanks to recent advances, in new coal-fired power plants Clean Coal Technologies (CCTs) can be incorporated, where applicable, to minimise emissions. In the power generation context, CCTs refer to technologies that meet the need for a maximum amount of energy with minimum waste production while increasing the overall plant efficiency.

But the question is: Are industries willing to go the extra mile for the sake of achieving the collective good in the long term? Would economics allow them?

First of all, it is important to analyse the options available, and the commitment to adopting them entails.

Available CCT options

So far, three main CCTs deployed and operational globally are High-Efficiency, Low-Emission, or HELE, pollution abatement, and carbon capture utilization and storage (CCUS) technologies.

  1. HELE

The scope of ‘clean coal’ has been extended to include supercritical and ultra-supercritical coal-fired plants. Also known as High-Efficiency Low-Emission (HELE) plants, characteristically, these are without CCTs and run at 42-48% thermal efficiency.

Compared with a subcritical unit, typically, HELE plants typically cost more than a subcritical unit on average. For instance, the capital cost of ultra-supercritical (USC) HELE technology is 20-30% more than a subcritical unit.

However, this is offset by higher efficiency which reduces emissions and fuel costs to about 75% of subcritical plants. Usually, a supercritical steam generator operates at very high temperatures and pressures (above 22Mpa). This is a stage where the liquid and gas phases of water are no longer distinct.

Countries that demonstrate that supercritical and ultra-supercritical plants are workable are South Korea and Japan. In these countries, about 70% of coal-fired power comes from supercritical and ultra-supercritical plants.

  1. Abatement

There are several techniques employed in the abatement of coal. These include:

  • Washing coal

Cleaning coal by washing aims at reducing emissions of ash and sulfur dioxide when burning coal.

  • Electrostatic precipitators and fabric filters

Electrostatic precipitators and fabric filters can remove 99% of the fly ash from the flue gases

  • Flue gas desulfurization

The process of Flue gas desulfurization aims to reduce the output of sulfur dioxide to the atmosphere by up to 97%. This is dependent on the level of sulfur in the coal and the extent of the reduction.

  • With Low-NOx burners

With Low-NOx burners, coal-fired plants can reduce nitrogen oxide emissions by up to 40%. When used together with re-burning techniques, Low-NOx burners can reduce NOx by 70%. Furthermore, when used with selective catalytic reduction, low NOx burners can clean up 90% of NOx emissions.

  • Integrated gasification combined cycle (IGCC)

Integrated gasification combined cycle (IGCC) and pressurized fluidized bed combustion (PFBC) enable higher thermal efficiencies still up to 50% in the future.

  • Pulverised coal Ultra-clean coal (UCC)

Pulverized coal Ultra-clean coal (UCC) from new processing technologies reduces ash below 0.25% and sulfur to very low levels. This implies that pulverised coal might be used as fuel for very large marine engines, in place of heavy fuel oil. So far, there are at least two UCC technologies under development. However, wastes from UCC are likely to be a problem.

  1. Carbon Capture Utilisation and Storage (CCUS)

Carbon Capture Utilisation and Storage (CCUS) encompasses gasification and sequestration.

Using steam and oxygen, gasification, including underground coal gasification (UCG) in situ, turns the coal into carbon monoxide and hydrogen.

Sequestration refers to the disposal of liquid carbon dioxide, once captured, into deep geological strata.

Cost burden

It is tempting to ask: Why doesn’t industry go all out in embracing these CCTs considering the urgency?

Well, as with any business, in adopting the CCTs, the first consideration is cost and benefit – The board would be thinking: “What impact will it have on the bottom line? What is in shareholders Return On Investment?”

The fact: based on evidence from projects, well-meant efforts to implement the CCTs may not always have the much-desired end. The World Coal Association notes this in its review: “Some of these (CCTs) impose operating costs and energy efficiency loss without concomitant benefit to the operator.“

Specifically, there is concern that in the quest to adopt the CCTs, the cost of achieving low, near-zero emissions would negate the economic competitiveness of coal. Generally, CCT technologies are both costly and energy-intensive.

Slow uptake

Small wonder, in its Energy Perspectives, the International Energy Agency (IEA) laments the slow uptake of CCS: “CCS is advancing slowly, due to high costs and lack of political and financial commitment.“

Meanwhile, as the world dithers to adopt CCTs, coal emissions worsen global warming. Unquestionably, the sooner commercial-scale technologies are embraced, the better.

Realistic option

Accordingly, the IEA urges timely interventions, especially the available CCTs.

While owners of coal-fired power plants doubt the commercial viability of adopting CCTs, the IEA sees a realistic option in CCUS. The body hopes to see owners of coal-fired power plants embracing CCUS to put the world on the path to net-zero emissions. In a report on CCUS in its Energy Technology Perspectives 2020 series, it explains: “It is the only group of technologies that contributes both to reducing emissions in key sectors directly and to removing CO2 to balance emissions that cannot be avoided” (i.e. including direct removal of CO2 from the atmosphere).“

Enabling environment

More importantly, governments have to play a pivotal role by creating an enabling environment for industry to fully embrace CCTs. One of the options is through tax breaks. To offset the financial losses due to the perceived liability of compliance, governments can incentivise industries by providing tax breaks for companies adopting CCTs.

 

Get set for better bearing life – without supply chain difficulties and holdups

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The importance of correct bearing installation is paramount in industrial machinery. And this is particularly important where major plant is subject to arduous and continuous use in demanding industries, including food, beverage, primary processing, timber, sugar, mining, energy, and oil and gas.

All these industries cannot afford downtime caused by 16% of all bearing failures, which specifiers attribute to incorrect installation. Maintenance specialists say this is likely to be a big contributor to shorter service life and maintenance safety hazards, says hydraulic tensioning specialist, Technofast Americas.

But an obstacle to eliminating bearing setting problems in recent times has been restricted supply of proven, cost efficient bearing setting equipment, either because it is not available because of production lapses in the industrial gearing up following Covid, or because delivery has been delayed in stretched supply lines, says Technofast Americas Founder and CEO John Bucknell.

In response to these challenges, the company has boosted its capabilities to meet tight maintenance deadlines globally, while also lowering the competitive cost of the wider range of bearing setters it is producing to meet demand for cost efficient proven product.

“The big plus of a specialist and agile company like ours it that we can respond to changing market conditions and needs sooner and better than slower older suppliers. This is winning us more markets for our proven technology, including Technofast EziTite bearing setters, which we can manufacture to all sizes for precisely mounting or dismounting typical elements such as bearings, shaft couplings, through to specialist items such ships’ propellers, and rudder pintles,” says John Bucknell.

“When a new bearing is incorrectly mounted – be it by way of poor fitting, brute installation force, or incorrect tools – it can lead directly to premature and sometimes very swift bearing failure,” says Bucknell. A poorly installed bearing is not only a pending production liability in terms of service life, but also in terms of expensive downtime and the OH&S factors involved in getting the worn part out again when it fails prematurely,” he says.

“Crude approaches may be quick, but they can be nasty and dangerous, risk damage to machinery shafts, and make subsequent bearing failure analysis either difficult or impossible,” says Bucknell, whose safety-engineered and money-saving hydraulic tension solutions are used in time-critical fastening and service applications.

Bearing sleeve withdrawal example

These same qualities of speed, precision and avoidance of downtime while ensuring worker safety were demonstrated in service with a bearing sleeve withdrawal operation when assembling a new mobile crusher and conveyor. It was being commissioned on-site to make road-base gravel for applications such as new highways and worksite infrastructure.

The newly imported machine – purpose-built to be assembled where needed for immediate service – required precision technology that was demonstrably superior to old methods such as using a hand-made jig laboriously fabricated for the purpose, with no way of determining if the process was accurate.

The EziTite ® Bearing Setter employed its high-pressure hydraulic oil feed (at 700 bar) to compactly, powerfully, and precisely to complete the process in a controlled and carefully governed process.

“Use of the EziTite Bearing Setter was simple, with the assembly screwed into place and energized with a pressure pump. The internal pressure generated acted upon the internal annular piston to press against bearing’s inner race, driving the sleeve,” said Bucknell. Once the bearing sleeve operation was complete, the pressure was released, and the EziTite Bearing Setter removed.

Technofast’s EziTite hydraulic bearing setters are available in standard sizes, or they can be produced for custom applications in as little as two weeks, further reducing potential downtime, says Bucknell.

The principle of the EziTite Bearing Setter’s operation is similar in operation to the standard Technofast EziTite Hydraulic Nuts used globally – except the nuts don’t have the mechanical locking ring used on bearing installation tasks, says Bucknell. On these, a standard locking nut and washer are set to maintain correct operating preload.

Technofast’s ranges of EziTite, EziJac ® and CamNut products are proven globally in mission-critical applications where speed, precision and avoidance of downtime are paramount. They are easy to fit and remove with little physical effort, optimising safety, and minimising downtime.

About Technofast

Technofast Industries is a worldwide leader and specialist in Bolt Tensioning, providing innovative and effective technical solutions along with uncompromising customer service.