2019 RI Brochure With Case Studies

Optimizing Engineering Assets over the Complete Lifecycle
Resonant Industrial (Pty) Ltd is an engineering company that provides Engineering

Design and Asset Management services to the Industry, in order to assist companies
to make the most of their physical assets. Our services include the following:
MECHANICAL ENGINEERING DESIGN

▪ Design of pressure vessels to ASME VIII Div 1 & 2 and equivalent codes.
▪ Design of storage tanks to API 620, API 650 and equivalent codes.
▪ Plant modelling using CadWorx® software.
▪ Isometric pipeline drawings.
▪ Finite element analysis using Patran / Nastran® software.
▪ Pipe stress analysis using Caesar II® software to ASME B31.3 and equivalent.
▪ Fluid flow analyses (CFD) using FloEFD® software.
▪ Pipeline network flow analysis using Flownex® software.
▪ Heat transfer and thermal analysis.
▪ 3D modelling.
▪ Detailed manufacturing drawings.
▪ Design and analysis of general mechanical equipment and structures.
▪ All designs signed off by experienced Professional Engineers (ECSA registered).
ASSET MANAGEMENT SERVICES (Systems and Integrity)

▪ Development of Asset Management Policy and Strategy to ISO 55000.
▪ RCM (Reliability Centred Maintenance) studies.
▪ FMECA (Failure Mode, Effect and Criticality Analyses).
▪ Development of maintenance plans and schedules.
▪ Activity based costing of maintenance resources.
▪ Reliability, Availability and Maintainability (RAM) simulations using Reliasoft
Blocksim® software.
▪ Analysis of historical maintenance data using Reliasoft Weibull++® software.
▪ Asset management and maintenance audits.
▪ Maintenance logistics and inventory analysis.
▪ Asset condition assessments.
▪ FFS (Fit-for-Service) analyses of in-service equipment, according to API 579-1.
▪ Failure investigations.
▪ Re-design / modification of existing assets.
ENGINEERING DESIGN: PRESSURE VESSELS

Resonant Industrial is well experienced in the design of pressure vessels according
to the requirements of the ASME VIII Div 1 & 2, EN 13445, BS PD 5500 and
equivalent codes.
Design reports and drawings are signed off by ECSA registered professional
engineers with many years’ design experience of pressure vessels.
REPORT NO: 123-45-6 APPLICABLE DESIGN CODES: PLANT NAME: PROPULSION FACILITY
REVISION: 0 ASME 8 Div 1 (2015) EQUIPMENT NO: TK-XYZ
DATE: 2016/10/01 ASME 2 PART D (2015) PREPARED BY: J Conradie
CLIENT: RET SANS 347 (2012) REVIEWED BY: A Groenewald
REINFORCEMENT CHECK - NOZZLE TO CYLINDRICAL SHELL
PART CONSIDERED: NOZZLE X (DN150, LWN CL300# FLANGE)
PARAMETER SYMBOL VALUE UNIT CODE COMMENT

REFERENCE
INPUT VALUES
Design temperature Td 155 °C UG-20
Nozzle outside diameter Do 206,4 mm
Nozzle wall thickness specified tn 27 mm Uncorroded, nominal size
Minimum nozzle thickness required trn 1,35 mm From nozzle sizing calcs
Nozzle inwards protrusion length h 0 mm Corroded, check UG-40 for limits
Outer weld leg lenth lo 0 mm Fig UG-37.1
Inner weld leg lenth li 0 mm Fig UG-37.1
Minimum required shell thickness tr 6,2 mm From shell sizing calcs
Specified shell wall thickness tshell 10 mm UG-37 In uncorroded condition
Corrosion allowance CA 2 mm UG-25
Nozzle material SA240 GR 304L
Nozzle material allowable strength Snozzle 114,5 MPa From ASME 2 Part D (2015)
Shell material SA240 GR 304L
Shell material allowable strength Sshell 114,5 MPa From ASME 2 Part D (2015)
Reinforcement pad material Not used
Reinf. material allowable strength Sreinf. Not used MPa
Joint efficiency E1 1 UG-37
Correction factor F 1 UG-37 Normally 1.0, else refer Fig. UG-37
Stress ratio 1 fr1 1 UG-37
Reinforment element diameter Dp 0 Fig UG-37.1 Zero if not used; UG-40 for limits
Reinforment element thickness te 0 Fig UG-37.1 Set to zero if not used
Outer element weld length le 0 Fig UG-37.1 Set to zero if not required
ENGINEERING DESIGN: STORAGE TANKS

We are experienced in the design of high volume storage tanks according to the
requirements of the API 620 and API 650 codes.
Design and analysis of specialised GRP tanks have also been performed.
Design reports and drawings are signed off by ECSA registered professional
engineers with many years’ design experience of storage tanks.
ENGINEERING DESIGN: PLANT LAYOUT AND DESIGN
We use Cadworx® software to develop extensive 3D models of process plants.

These models form the base of the geometric layout and space claims required by
the equipment as well as access requirements. It also creates a database where
the required equipment and components are digitally stored, from where BOM’s,
isometric drawings, piping lists, valve lists etc. can be extracted.
ENGINEERING DESIGN: PIPELINE DESIGN
We develop pipeline isometric drawings for construction and also use Caesar II®
software to analyse pipeline flexibility and stresses according to ASME B31.3,
EN13480 and equivalent codes, to ensure that correct sizing of piping is used and
pipelines are supported correctly. Sizing and detail design of pipe supports are also
done.
ENGINEERING DESIGN: FINITE ELEMENT ANALYSIS
We perform finite element analyses on structures using Patran / Nastran ®

software. We have years of experience in a wide range of analyses including stress
and deformation, vibration, buckling, fatigue, thermal and dynamic analysis.
ENGINEERING DESIGN: FLUID FLOW ANALYSIS (CFD)
We make use FloEFD® software to perform fluid flow analyses on complex flow
applications. We have experience in a wide range of analyses including steady state
flow, transient flow, gas flow, liquid flow, thermal analysis and gas extraction
evaluation.
ENGINEERING DESIGN: PIPE NETWORK FLOW ANALYSIS
We utilise Flownex® software to perform fluid flow analyses on piping systems.

Analyses are performed to solve for parameters such as pump sizes, volumetric
flow rates, flow velocities, pressure, temperature, heat transfer, density, pipe sizes,
valves, fittings etc. for complex pipe network systems.
ENGINEERING DESIGN: GENERAL DESIGN AND 3D MODELING

We also perform general mechanical engineering design including 3D modelling,
design calculations and creation of manufacturing drawings.
ASSET MANAGEMENT: STRATEGY, POLICY AND MAINTENANCE PLANS

We can assist in developing company Asset Management Strategy and Policy
according to ISO 55000 requirements. Furthermore, RCM and FMECA studies are
performed to determine and prioritise the maintenance requirements of
engineering assets, from which detailed maintenance schedules are developed.
ASSET MANAGEMENT: MAINTENANCE AND RELIABILITY ANALYSIS
We make use of Reliasoft Blocksim® software to simulate and predict future asset
reliability and availability and Reliasoft Weibull++ ® to analyse historic
maintenance data. Activity based costing of maintenance resources can be
performed, in order to perform cost-benefit analyses on the feasibility of
maintenance activities.
ASSET MANAGEMENT: MAINTENANCE AUDITING AND LOGISTICS

Once good maintenance plans have been developed, it is important that the
maintenance activities are correctly executed, year in and year out. The
maintenance plan should also be assessed and revised on a periodic basis to
ensure it remains relevant. Resonant Industrial can perform Asset Management
System and Maintenance Execution audits, as well as develop a list of required
spare parts and critical spares to be kept in stock, in order to support the
operational aspects of the Maintenance function.
General / Min
Complete Stores Unique Repair Current
Productive asset common Quantity Reclamation Stock Storage
Rotable / Rotable fitment position Structured Name Control Control Rationale numbering Cycle Stock on Priority
construction type name for in service Method Quantity Location
Part (Y/N) requiremets (Weeks) hand
this item required
R AC motor Motor;Hitachi,Type TAFW;3 300 N Critical part needed S/N used 6 Refurbish 4 1 1 High 1Plant Motor
Ball mill Mill motor kW;6.6 kV on plant. Store
R Gearbox Gearbox;David Brown, Size 925 N Critical part needed S/N used 6 Refurbish 4 1 1 High 1Plant Mill
Mill gearbox CRS, Ratio 5.1:1 on plant. house
R Starter Liquid starter;Hitachi Type: MSP N Critical part needed S/N used 6 Refurbish 4 1 1 High 1Plant Motor
3083;Form SWY;3 300 kW; 2.5 on plant. Store
Liquid Starter kV;789 A
R Bearing Slide bearing;1700 mm;SG42 N Critical part needed S/N used 6 Refurbish 6 3 3 High 1 Plant IMS
Gr420;Lined GM120 white on plant. Store
Mill bearing - Drive End metal;w=876mm
Mill bearing - Non drive end metal;w=860mm
R Gearbox Gearbox,David Brown, Size N Critical part needed S/N used 6 Refurbish 4 1 1 High 1Plant Motor
Barring Gearbox DDU20, Ratio 200:1 on plant. Store
R AC motor Motor;BMM;37 kW;985 rpm N Critical part needed S/N used 6 Refurbish 4 1 1 High 1Plant Motor
Barring Motor on plant. Store
R Pump Oil pump;David N Critical part needed S/N used 6 Refurbish 2 3 3 High 1Plant Mech
Brown;Roloid;Gear pump;Size on plant. Workshop
Gearbox oil pump 1 C40H Max
R AC motor GEC;5.5 kW; 960 rpm N Critical part needed S/N used 6 Refurbish 4 2 2 High 1Plant Motor
Gearbox pump motor 1 on plant. Store
R Pump Oil pump;David
Brown;Roloid;Gear pump;Size
R AC motor GEC;5.5 kW; 960 rpm
Gearbox pump motor 2
R Cooler Oil cooler;Bauman;GK 190-1658-3 N Critical part needed S/N used 6 Refurbish 2 2 2 High 1Plant Mech
Oil cooler on plant. Workshop
R Pump Gear pump;Polyhodron;P/N 120- N Critical part needed S/N used 6 Refurbish 2 2 2 High 1Plant Mech
Mill Bearing DE HP Pump 1 05 on plant. Workshop
R AC motor Motor;Actom;5.5 kW;1460 rpm N Critical part needed S/N used 6 Refurbish 4 4 4 High 1Plant Motor
Mill Bearing DE HP Motor 1 on plant. Store
R Pump Gear pump;Polyhodron;P/N 120-
05
Mill Bearing DE HP Pump 2
R AC motor Motor;Actom;5.5 kW;1460 rpm
Mill Bearing DE HP Motor 2
R Pump Radial piston N Critical part needed S/N used 6 Refurbish 2 2 2 High 1Plant Mech
Mill Bearing DE LP Pump 1 pump;Polyhodron;Type 2RC on plant. Workshop
Mill Bearing DE LP Motor 1 on plant. Store
ASSET INTEGRITY MANAGEMENT

We also perform services related to the integrity of engineering assets. This
includes the assessment of asset condition, Fit for Service (FFS) analysis according
to the API 579-1 code, fatigue life analysis, failure investigations and the
modification / re-design of in-service assets.
CONTACT US:
For more information, please get in touch:
Resonant Industrial (Pty) Ltd

+27 (0)12 665 1109
+27 (0)82 554 4242
abraham@resonant.co.za
johanc@resonant.co.za
Physical address:
Uitzicht Park #10
Bellingham Street
Centurion
South Africa
Case Studies
DESIGN OF DUCTINGS FOR GENERAL ELECTRIC COMPRESSORS AT AL KHALEEJ SUGAR

A design was done for the ducting system (1.2 m diameter, stainless steel piping) for a new GE
compressor at the Al Khaleej sugar refinery in Dubai. A number of different piping configurations were
designed and analysed, and the most suitable design configuration was selected. Pipe stress analyses
were performed, and detail design drawings for the ducting system were created. Support beams and
structures were also designed for the piping system.
The design was accepted by the client and successfully implemented.
DESIGN OF FUEL PLANTS FOR A SPACE PROPULSION PROGRAMME

A design was done for two petrochemical plants that will form part of a space propulsion production
facility.
Resonant Industrial was responsible for the development of 3D models of the plant layout, services,
equipment, piping, and support gantries.
Mechanical design of the pressure equipment (pressure vessels, distillation columns, piping) and
storage tanks were done in accordance with the relevant design codes.
General assembly drawings, isometric pipeline drawings and detailed manufacturing drawings were
made for all the pipelines and equipment.
DESIGN OF A WF6 PLANT

Resonant was rewarded a contract for the design of a state of the art, fit for purpose design for a
Tungsten Hexafluoride (WF6) Production Plant. Resonant Industrial was responsible for the general
layout of the plant, the piping design as well as all the pressure equipment designs (reactors, a
desublimer vessel, vacuum columns, hoppers & other pressure vessels).
The piping components were drafted using CADWorx and isometric drawings were generated. Critical
lines were analysed using pipe stress analysis software, Caesar.
Detail code calculations were done according to the ASME Boiler Pressure Vessel Code (BPVC) in order
to verify the designs. Finite Element Analysis (FEA) as well as Computational Fluid Dynamics (CFD)
analyses were also performed on the main reactor vessel.
DESIGN OF BOOSTER FAN DUCTING AND SUPPORT STRUCTURES FOR LYDENBURG SMELTER
Booster fans of furnaces A, B & C had to be replaced at Lydenburg Smelter. The ducting connected to
the booster fans had to be rerouted for the new fans. Drawings were drafted of new proposed routings
for the ducting. Pipe stress analyses were performed according to the ASME B31.3 code in order to
evaluate proposed routing for each furnace. Special care had to be taken to ensure that all components
are accessible for maintenance. The proposed designs were found to be adequate for its design intent.
Structural pipe support designs were also done for the ducting of each of the furnaces. The structures
were evaluated using Prokon according to the SANS 10162 code.
The client accepted the designs and it was constructed and commissioned at Lydenburg.
DESIGN OF A WATER COOLING PIPELINE FOR TRANSALLOYS

A design was done for a cooling water system for a CLU converter gas cleaning system at Transalloys.
A flow analysis was performed in order to size the pumps and piping required to cool the water cooled
duct (WCD). The routing of the water cooling lines were done using CADWorx. The design of the water
cooling lines were analysed in Caesar using the ASME B31.3 code. All the piping supports as well as
gantries were also designed. Prokon was used to verify the designs of the gantries according to the
SANS 10162 code. Isometric drawings of the pipelines were generated using CADWorx. Several other
process lines were also drafted in CADWorx. Pipe support drawings were also drafted for the smaller
process lines.
DESIGN OF PRESSURE VESSELS AND TANKS

A variety of pressure vessels and tanks have been designed by Resonant Industrial. These designs
included vessels manufactured from carbon steel, different stainless steels, nonferrous materials such
as titanium, and GRP (fibreglass). Design codes used included ASME VIII, Division 1 & 2, BS PD 5500, EN
13445 and EN 13121 (GRP). Designs are performed, checked and signed off by Professional Engineers.
DESIGN OF A WAX FRACTIONATION PLANT FOR REFINEX

A design was done for a 2m diameter 19 m high vacuum column with reboiler, condenser and side
stripper. The loads that the main column will see during operation and during installation were
investigated. Detail code calculations were done according to the ASME Boiler Pressure Vessel Code
(BPVC). A finite element analysis (FEA) was also performed on the design of the column in order
evaluate the stresses of several loading combinations according to the ASME BPVC.VIII.2 code.
The design was accepted by the client and the plant was constructed and successfully commissioned.
DESIGN REVIEW OF GLYCOL SUPPLY PIPELINES FOR OYU TOLGOI MINE

A design review was done for glycol supply main lines at Oyu Tolgoi mine in Mongolia. The design of
the pipelines were evaluated according to the ASME B31.3 design code using pipe stress analysis
software, CAESAR. The results of the analyses showed that the design of the pipe line is compliant with
the ASME B31.3 code. The piping supports were also evaluated according to structural design codes.
The design calculations showed that the design of piping as well as its supports is adequate for the
intended design conditions.
PIPELINE DESIGN FOR VARIOUS REFURBISHED ESKOM POWER STATIONS

Numerous pipe stress analyses were performed on refurbished high pressure pipelines for Eskom
Komati and Camden Power Stations. The pipelines were modelled using Caesar software, and the
appropriate loads and support conditions were applied to the models. The stress results were
interpreted according to the EN13480 piping design code.
Rod hangers and pipe guides were also specified where required, in order to keep the stress and
deformation values to within acceptable levels. The pipeline designs were accepted and successfully
implemented at the power stations..
FIBRE-GLASS PIPELINE DESIGN FOR BOKPOORT SOLAR POWER STATION

Hydraulic water hammer and pipe stress analyses were performed on a 1200 mm diameter GRP (fibre-
glass) header pipeline, for a solar power plant at Bokpoort. The analyses were performed in order to
evaluate the structural integrity of the pipe under the expected operating and design conditions. The
analyses were performed using AFT Impulse and Caesar II software. It was determined that a maximum
pressure pulse of about 130 kPa could be expected due to events such as pump start-up, trips, and
valve openings and closures. The pipeline thicknesses and supports were designed such that the
stresses generated in the pipeline are acceptable for the considered loads. The pipeline was
successfully constructed and operates reliably.
DYNAMIC AND STATIC STRESS ANALYSES ON GRP AND STAINLESS STEEL PIPELINES
Pipe stress analyses were performed on a number of pipes, some stainless steel and some GRP pipes,
that connects to an SO2 absorber tower (also made from GRP) at a paper manufacturing plant. The pipe
stresses were evaluated according to the applicable Design Codes (EN13480 for the stainless steel pipes
and BS7159 for GRP piping). The nozzle and support reaction loads were also obtained through the
analysis, for use as an input in the design of the support structures and tank nozzles. The loads
considered to act upon the pipelines included the, design pressure, pipe weight, product weight, tower
temperature, piping temperature, wind load, water hammer load and measured vibration effects.
Reaction loads on pump and vessel nozzles were also evaluated and compared to allowable values. The
pipelines and vessel were constructed and successfully put in operation.
PROJECT MANAGEMENT FOR THE CONSTRUCTION OF AN ASME VIII SUMP TANK

Project management was done for Forgeweld, for the manufacturing of a number of sump tanks that
needed to be made according to some ASME VIII Div 1 requirements. The tank was made for Transnet
Container Terminal in Durban.
This included setting up manufacturing schedules, managing the logistics and procurement of steel and
fittings for the tanks according to the Bill of Materials, and ensuring that all QA processes were passed
and a comprehensive data book was compiled for the tanks.
The tanks were successfully manufactured and passed QA, and were installed and commissioned by
Transnet.
DYNAMIC STRUCTURAL ANALYSES ON TURBINE-GENERATOR FOUNDATIONS
Dynamic analyses were performed on the turbo-generator foundation system at Komati Power Station,
Units 6 and 7, using FEM (finite element methodology) analyses. The analyses considered the original
design configuration of the power generating systems, as well as for the proposed refurbishment for
which a new generator with a different mass was installed. Modal and frequency response analyses
were performed. The results of both these analyses indicated that the design was adequate: For the
applied dynamic loads caused by the rotation of the turbine-generator set, the maximum calculated
deformation of the structure was about 13 microns for the original design, and about 14 microns for
the refurbished design. These values were below the maximum allowable value of 31 microns. It was
therefore recommended that the proposed refurbishments (new generator) could be installed, and the
refurbishment was successfully done as such.
SRSS - B4
1.0E-05
9.0E-06
8.0E-06
7.0E-06
Displacement (m)
6.0E-06
Longitudinal
5.0E-06 Transversal
Vertical
4.0E-06
3.0E-06
2.0E-06
1.0E-06
0.0E+00
45 46 47 48 49 50 51 52 53 54 55
Frequency (Hz)
FATIGUE ANALYSES ON CONTAINER LOADING CRANES

Following the discovery of some fatigue cracks at welded joints, structural and fatigue analyses were
performed on certain Container Gantry Cranes of the Transnet Durban Container Terminal. The
structural analyses indicated that the highest stresses occurred in the bridge-girder and boom regions
of the crane, and it was recommended that these regions be maintained very well. Fatigue analyses
were also performed and an area on the bridge-girder was identified where the estimated remaining
life for certain parts were only between 200 000 to 500 000 cycles (2 to 5 years), depending on the past
usage and corrosion damage on the specific crane region. Design modifications were made to these
problematic regions of the crane. An improved estimated remaining life of around 2 million cycles (20
years) were calculated for the suggested design changes. The design modifications were implemented
and the cranes operated safely for a further 10 years before being finally decommissioned.
STRUCTURAL ANALYSIS ON UNDERGROUND ROCK-BREAKER

A structural analysis was performed on the design of an underground rock-breaker. Finite element
analyses (FEA) was performed on the 4 components of the breaker, to assess its integrity under
expected working and maximum loading conditions.
A number of relevant load cases were applied to each model, based upon expected working and
maximum loads that the structure would experience during its useful life.
The analysis results indicated what design changes needed to be made to the structure, as well as what
type of bolts would be acceptable for attachment of the baseplate to the machine. The modified design
was constructed and operates reliably in its working environment.
STRUCTURAL ANALYSIS ON CONVERTED MINING TRUCK CHASSIS
A structural analysis was performed on the chassis of a modified mining truck, for an Anglo American
mine. The mining truck was converted to carry 2 large generator sets on its back, as well as a cable reel
and stairs platform at its front.
Stability analyses were also performed for the truck for its new load configuration. Structural analyses
on the frame and stairs were also performed, to ensure that all structural components of the truck are
strong enough to safely carry the new loads over the intended life of the truck.
STRUCTURAL ANALYSIS ON ESKOM HENDRINA AIR HEATER UNITS

A structural analysis was performed on an air pre-heater system that is used on the Eskom Hendrina
Power Station. Thermal loads, own weight, pressure loads and combined loads were applied to a finite
element model of the structure. The stress results were evaluated according to BS PD:5500 and BS7608
code recommendations. It was determined that the stress levels were below the required allowable
values, with some peak stresses occurring in localised regions, typically in the corners of the connections
of the square ducts to the rest of the structure. It was recommended that these areas are checked for
possible cracks periodically as part of the preventative maintenance schedule.
SEISMIC ANALYSES ON GRP (FIBRE-GLASS) TANKS FOR THE PHILIPPINES

A seismic analysis was performed on a 2.5 x 5.5 m GRP tank. The tank was designed to operate in a
region with high seismic potential (SHZ = 4). The foundation was also built in relatively sandy ground,
which increases the seismic effect. These conditions results in a very high seismic load that is applied
on the structure. A finite element model of the fibreglass tank was analysed. The appropriate
dimensions and directional properties of the GRP material were applied to the model. The loads on the
tank were established using the SANS 10160-4 and 10160-1 codes. A load combination consisting of
equivalent seismic loads, own weight and internal fluid pressure was applied to the tank model. The
stress results were evaluated against the criteria of the BS4994 code, which is specifically applicable for
the fibreglass material. The required reinforcements in the tank were recommended and incorporated
into the design. The design was accepted and the tank was built and installed on site.
VIBRATION ANALYSES ON A COMPRESSOR SKID
Modal and frequency response analyses were performed on a compressor skid that experienced high
vibration levels in service. A number of problematic natural frequencies and mode shapes were
discovered with the analysis. In particular there were high vibration levels cause by a 3” connection
pipe. This pipe was made more flexible by including 4 x 90° long radius bends in the routing. This change,
together with some other changes and improved fixing to the concrete structures, caused the vibration
levels to reduce significantly.
VENTILATION ANALYSIS AT AMPLATS POLOKWANE SMELTER

CFD analyses regarding fugitive gas capturing and building ventilation at Anglo Platinum’s Polokwane
Metallurgical Complex were performed. Analyses were performed for 3 wind conditions (calms,
prevailing and winter wind). It was determined that the prevailing wind resulted in the worst fugitive
extraction efficiencies in the matte aisle, and results were obtained for the following regions:
 Dry casting pits – A combination of a cover and higher extraction rates should be applied to
improve the capturing efficiency.
 Dry casting ladle – This ladle is basically too far removed from any suction hoods for the fugitive
gases to be captured efficiently.
 Machine casting – For this region it was clear that a higher extraction rate makes no difference to
the extraction efficiency of the hood. When inserting covers, however, the capturing efficiency
improves by a quantum leap. For this case a better cover is recommended.
 Matte launders and ladle – For these regions the extraction efficiencies were relatively good.
Additional covers did improve the capturing somewhat, but in general the same extraction
efficiencies can be obtained if the suction rates are increased.
HEAT TRANSFER ANALYSIS ON AN AVIONIC ELECTRONIC COMPONENT BOX

Thermal analyses were performed on an electronic component box, used in a military aircraft
environment, to determine its cooling requirements.
Two scenarios were considered. For the first scenario, the required rate of cooling air (at a temperature
of 55°C) was determined to keep the internal components below 85 °C, given that the electronic
components has an aggregate heat output of 100 W. It was determined that a flow rate of about 4.5
l/s would be required to fulfil in this requirement.
The second scenario considered the case where an aluminium heat sink at 55 °C is attached to the box.
It had to be determined what the maximum aggregate heat generation rate of the components can be
while the maximum internal temperature is still below 85 °C. It was determined that this maximum
allowable aggregate heat output can be 272 W for this scenario.
It was thus recommended that, where possible, the box be mounted to a heat sink on the vehicle or
aircraft frame, as this could eliminate the need for any air forced air cooling.
HEATING AND WATER WITDRAWAL ANALYSES OF GEYSERS

Analyses were performed to assess the thermal performance of a number of 150 litre capacity geyser
designs. In total, ten different configurations were analysed, of which eight were horizontal and two
were vertical.
The flow patterns, temperature distributions and outlet temperatures of the different configurations
were determined, over a time period of 180 seconds (3 minutes). It was assumed that the initial water
temperature is at 60 °C, and the cold water flows in at 15 °C and 40 litres per minute.
From the analysis results, the geyser designs with the best and worst performances could be
determined.
In general it was determined that a vertical geyser with the heating element installed low, would give
better performance and a horizontal geyser with heating element located high would give the worst
performance.
FLOW AND HEAT TRANSFER ANALYSIS ON A GRATE PELLETIZER PLANT

A design change on a pelletizing plant of a smelter was analysed using a CFD model, based upon the
actual dimensions of the system. A Flownex (pipe network) model was used in parallel to solve the
heat transfer between the off gas and the moving pellet bed. The results of the two models were
calibrated against each other and measured values. The new design is simplified and smaller – hence
there is less risk for heat losses, leakages and failures. The air flow results in enhanced heating of the
pellets. Less air needs to be extracted through to the baghouse; 80 kg/s extraction through the new
design performs the same as 100 kg/s through the old design. Furthermore the new design requires 6
dampers whereas the old design had 9 dampers. There are less dust particles extracted to the
baghouse with the new design than with the current design. The results indicated that for the new
design, only 5% of the dust as is extracted currently will pass through to the baghouse. Also, no water
cooled jackets would be required. The hot gas exiting into the ducting can immediately be cooled by
the new cold air bleeding damper on the new ducting branch.
PIPE FLOW AND WATER HAMMER ANALYSES FOR MEDUPI LP WATER SERVICES
Flow and water-hammer analyses were performed for LP (Low Pressure) Services at the Medupi Power
Station. AFT models were analysed of the Open Water Circuit, Unitized Water Circuit, Common Plant
Water Circuit and Water Make-Up Circuit.
All the relevant piping, fittings, valves, pumps, tanks, sumps, spray nozzles etc. were included in the
models. Flow analyses were done to determine flow rates to all recipients, orifice sizes for water flow
control purposes, maximum operating pressures in the lines, pump efficiencies, and water hammer
forces that could be experienced within the piping system due to activities such as pump start-up, valve
closure, pump trips, etc. The LP water systems were constructed as per the analysed design, and
functions effectively.
THERMAL AND FLOW ANALYSIS ON LARGE ELECTRIC MOTOR

Flow and thermal analyses were performed on an electric motor that operates at Eskom’s Kriel Power
Station, which overheated frequently. For this motor design, the manufacturer decided to include
booster turbine fans, in order to increase the airflow and hence get better heat transfer. The analysis
was done to determine the maximum temperatures of internal components under maximum load
conditions of the motor. The motor components are cooled through forced convective cooling, by air
that is recirculated through internal fans through the motor internals and a tube heat exchanger. It
was found that due to a design error (large gap between turbofan blades and stator), the effect of the
fan was actually negative – since flow from the high pressure region just downstream of the fan “short
circuited” back to the low pressure region just upstream of the fan, due to the path of least resistance
that the air will follow. It was determined that the flow through the system with the turbo fans
removed was 6.4 kg/s, as compared to 4.5 kg/s for the design with the turbofans. Hence a 42% flow
increase was predicted by simply reducing the inefficient and incorrectly designed turbofans.
Inefficient turbofan
Turbulent backflow
generated by turbo fan
DESIGN OF A CUSTOM TRAILER DRAWBAR

A towbar design was required for the towing of a 13 ton trailer (transformers) behind a continuous
miner (CM). The effect of the forces due to acceleration, braking and turning on the towbar was
investigated. A towbar extension was also added to design and investigated for its structural integrity.
The design was evaluated using finite element analyses as well as first principle calculations.
Based on the calculations performed and the finite element analysis results, the design of the towbar
was found to be adequate for its intended design purpose.
Manufacturing drawings were drafted and were accepted by the client. The drawbar was
manufactured and delivered to the client, and operates reliably.
DESIGN REVIEW OF A CUSTOM TRAILER

A design review was done on a custom trailer used for transporting a 2000l tank at Anglo Coal Central
Workshop. The design of the towbar section was evaluated according to the Australian Design Rule 62
(ADR 62) vehicle standard. The rest of the trailer structure was evaluated according to the structural
code SANS 10162. A finite element analysis was performed on the trailer and oil tank. Displacement
and stress results due to the loading conditions were evaluated and interpreted according to the ADR
62 & SANS 10162 codes.
The stability of the trailer was also checked using a quasi-static approximation. It was determined that
the stability of the trailer was sufficient.
The design report was accepted by the client, and the trailer was built and is operating reliably.
DESIGN OF ROLL-OVER PROTECTIVE STRUCTURES (ROPS) FOR SAFARI TRUCKS & LDVs
Roll-over protection frames were designed for Safari Conversions (Pty) Ltd. The passenger safety
was assessed in accordance with SANS 1563:2005.
Resonant Industrial performed the 3D modelling services and generated manufacturing drawings
of the ROPS frames for various LDVs (“bakkies”) as well as for a Hino truck.
The design and drawings were accepted by the client, and the rollover frames were manufactured
and installed.
DESIGN REVIEW OF A LOWBED TRAILING ARM FOR ISITHELO

A fifth wheel assembly design that was previously used on a CAT 769 truck was modified to fit onto a
Komatsu 465 truck. Analyses were performed to investigate the stresses caused by the loads that will
be exerted onto the modified Komatsu 465 chassis. Finite element analyses were performed on the
chassis as well as the trailer arm in order to obtain the expected stresses due to towing, acceleration
and braking.
The results showed that some modifications were required on the towing arm structure. It was found
that the chassis of the truck are not significantly affected. All stresses observed in the chassis in the
analysis model were below the required allowable values.
The design report was accepted by the client. The structure was built and is operating reliably.
FAILURE INVESTIGATION OF THE TLS MECHANISM ON A CONTAINER CRANE

Following a failure during a container lift of the Trim, List and Skew (TLS) mechanism on one of the
refurbished cranes of Transnet Port Terminal’s Durban harbour, the structural integrity of the
attachment welds as well as of the steel plates of the mechanism, were evaluated. The structural
analysis was done using a finite element model.
It was determined that the design of neither the welds or plates were compliant to the requirements
of the F.E.M 1.001 crane design code. This was used as evidence in a court case.
FFS (Fitness-for-Service) ANALYSIS ON A LARGE DUCT OF ESKOM KUSILE

A “Level 2” fitness for service assessment was done according to the API 579-1 / ASME FFS-1 2007
Fitness-For-Service code, on a large ducting (6m diameter) for Eskom Kusile Power Station.
There was a concern about some cracks that were found in the welding, and an FFS analysis was done
to evaluate what the acceptable crack-like-flaw size could be for the operational stresses that are likely
to be experienced during a 40 year lifetime of the ducting.
It was found that the crack lengths were still acceptable, and the ducting would be safe to use.
FAILURE INVESTIGATION ON LARGE OFF-GAS DUCT

An investigation on a large off-gas duct failure was performed. It was determined that elastic buckling
failure due to internal suction at high metal temperature was the most likely cause of failure of the
duct.
It was furthermore determined that the buckling failure occurred due to a combination of overheating,
as well as the fact that the stiffening rings on the duct were inadequate. Hence more stiffening rings
were added to the design, which increased the resistance to buckling failure with a factor of 4. The
design changes were made and the ducts performed reliably after that.
FFS (Fitness-for-Service) ANALYSIS ON STAINLESS STEEL TANKS

An API 579-1 Fitness-for-Service analysis was performed on a stainless steel Nickel Spent Tank of Anglo
Platinum. Cracks were found in the bottom of the tank. It was determined that the tank bottom plate
could be repaired by cleaning, grinding and welding of the cracks. Should cracks start to open again
and leakage would occur, the leakage will be detectable for the crack lengths allowed. Should these
leaks be detected, a repair session should be scheduled for the tank bottom plate.
Without any additional stiffening, the allowable length of a vertical crack of the tank cylindrical shell
would be 25 mm. If however a 25 mm thick stiffening ring is installed 100mm above the bottom plate,
the allowable crack length would increase to 70 mm. The 25 mm stiffening ring was thus added to the
tank.
DEVELOPMENT OF PCM’S (PROCESS CONTROL MANUALS) FOR ESKOM MAINTENANCE

Resonant Industrial was involved to provide SME (subject matter expert) services for the development
of Process Control Manuals for Eskom’s Maintenance, Operations, Outages and Engineering
departments. This required technical inputs into the development of the process flow diagrams,
identifying risks and controls, determining responsibilities etc.
DEVELOPMENT OF A MAINTENANCE PLAN FOR A MINING TRUCK BASED ON THE RCM METHOD
The RCM (Reliability Centred Maintenance) methodology was used to determine the functional failures
and failure modes of the haul truck, from which comprehensive maintenance tasks and frequencies
were developed for the 20 most critical sub-systems of the truck.
DEVELOPMENT OF MAINTENANCE PLAN FOR AN ORE CRUSHER BASED ON THE RCM METHOD
The RCM (Reliability Centred Maintenance) methodology was used to determine the functional failures
and failure modes for a platinum ore crusher, from which comprehensive maintenance tasks and
frequencies were developed for the crusher. This was used to develop a maintenance schedule in the
ERP system of the mine.
DEVELOPMENT OF MAINTENANCE PLAN FOR A BAG FILTER PLANT IN RUSSIA

A maintenance plan (based on RCM methodology), as well as a maintenance execution guide, based on
the principles of the ISO 55000 standard for Asset Management, was developed for a bag filter plant at
a smelter in Russia.
A s s igne d inte rv a l o f
T a s k ID T a s k N a me E quipme nt N a me T a s k T ype La s t Upda t e d B y La s t Upda t e d F a ilure M o de
tas k
1 Test lo uver actuatio n cycle Dilutio n air damper M aintenance 1mo nth A braham Gro enewald 2018/04/18 7:08 A M A ctuato r mo to r failure
2 Check that emissio n levels are acceptable, if no t inspect the Filter B ags M aintenance 1day A braham Gro enewald 2018/04/19 8:20 A M B ags damaged due to o ld age (o lder than 5 years)
filter bags and the spring tensio ning
3 Inspect filter bags and replace if necessary Filter B ags M aintenance 1mo nth A braham Gro enewald 2018/04/19 8:20 A M B ags damaged due to o ld age (o lder than 5 years)
4 Check spring tensio ning Filter B ags M aintenance 1mo nth A braham Gro enewald 2018/04/19 8:21AM Inco rrect tensio ning o f springs o n the to p
5 Strictly fo llo w installatio n pro cedure Filter B ags M anagement A braham Gro enewald 2018/04/19 8:21AM Tears due to inco rrect installatio n
actio n
6 Check that clamps are pro perly installed during installatio n Filter B ags M anagement A braham Gro enewald 2018/04/18 6:20 A M Inco rrect tensio ning o f clamp at bo tto m, o r missing
actio n clamp.
7 Check that bo tto m clamps are in place Filter B ags M aintenance 1mo nth A braham Gro enewald 2018/04/19 8:22 A M Inco rrect tensio ning o f clamp at bo tto m, o r missing
clamp.
8 Ensure that o peratio nal pro cedures are fo llo wed Filter B ags M anagement A braham Gro enewald 2018/04/18 6:26 A M If to o many (mo re than 4) co mpartments are o ffline, then
actio n dust wo n't fall o ff the bags
9 Operatio ns need to minimize disruptio ns fro m the furnace Filter B ags M anagement A braham Gro enewald 2018/04/18 8:26 A M Due to disruptio n o f the furnace pro cess, the amo unt o f
pro cess. actio n dust extracted can be exceeded
10 Whenever a disruptio n o ccured, check that emissio n levels Filter B ags M aintenance On o ccurrence o f failure A braham Gro enewald 2018/04/18 8:27 A M Due to disruptio n o f the furnace pro cess, the amo unt o f
are still acceptable dust extracted can be exceeded
11 Ensure that co mmissio ning pro cedures are fo llo wed strictly Filter B ags M anagement A braham Gro enewald 2018/04/18 6:31AM If new bags are no t co mmissio ned pro perly, they can get
actio n blo cked
12 Check that lo uvres are clo sed during no rmal o peratio n Dilutio n air damper M aintenance 1mo nth A braham Gro enewald 2018/04/23 9:12 A M Dilutio n damper fails in o pen po sitio n
13 A dd alarm signal that will indicate if damper was o n manual Dilutio n air damper M anagement A braham Gro enewald 2018/04/23 9:13 A M M anual o verride - no t returned to auto matic co ntro l
o verride fo r a to o lo ng perio d actio n system
14 Inspect the temperature pro bes Electric mo to r o f main M aintenance 6 mo nths A braham Gro enewald 2018/04/18 10:49 A M Winding temperature to o high
gas fan
15 Check ventilatio n system befo re summer and winter Electric mo to r o f main M aintenance 6 mo nths A braham Gro enewald 2018/04/18 10:59 A M A mbient temperature to o high
gas fan
16 Grease mo to r bearings Electric mo to r o f main M aintenance 1mo nth A braham Gro enewald 2018/04/19 7:32 A M Lack o f grease in bearings causes high temperatures
gas fan
17 Ensure that design specificatio n fo r mo to r and fan is co rrect Electric mo to r o f main M anagement A braham Gro enewald 2018/04/18 11:02 A M M ismatch between fan and mo to r capacities
gas fan actio n
18 Ensure that pro per quality bearings are pro cured Electric mo to r o f main M anagement A braham Gro enewald 2018/04/18 11:08 A M Insufficient quality o f bearings
gas fan actio n
19 Ensure that the co rrect quality o f grease is purchased Electric mo to r o f main M anagement A braham Gro enewald 2018/04/18 11:09 A M Quality o f grease is insufficient
gas fan actio n
20 M easure vibratio n levels Electric mo to r o f main M aintenance 2 weeks A braham Gro enewald 2018/04/24 11:10 A M Damaged bearings
gas fan
21 Check that po sitio ns o f reverse air dampers are co rrectly set M ain gas fan M aintenance 6 mo nths A braham Gro enewald 2018/04/24 10:47 A M Damper clo sed in circuit
Management & Planning Domain

1. Maintenance Policy 2. Maintenance Strategy 3. Maintenance Objectives 4. Maintenance Plan
Maintenance Execution Domain

5. Maintenance Organisation
6. Maintenance
Administration
8. Task Feedback
7. Task Execution
Asset Condition Domain

11. Failure Data
10. Asset Failures 9. Asset Condition
Measurement Domain 12. Asset Performance

14. Maintenance Audit 13. Asset Cost Results
Results
RAM STUDIES FOR ESKOM NITROGEN AND HYDROGEN PLANTS

RAM (Reliability, Availability and Maintainability) studies were performed for Nitrogen and Hydrogen
Plants, at Eskom Medupi and Majuba respectively. Reliasoft Blocksim was used to analyse system
reliability and availability, using a Reliability Block Diagram (RBD) model. The overall reliability of these
systems must be 99.8 % over a 30 year lifetime. The maintenance requirements, required redundancy
levels and spare part stock levels and replacement policies (local and overseas content) were evaluated
and specified for the lifecycle of the systems.
ASSET MANAGEMENT IMPROVEMENT PROJECT FOR HARMONY GOLD

A comprehensive asset management improvement project was done for Harmony Gold. This included
evaluating the maintenance strategy according to ISO55000 requirements, verifying and updating the
asset register of a number of critical assets, determining the critical spare parts required for these
assets, as well as determining the maintenance plans for the assets, using the RCM (Reliability Centred
Maintenance) methodology.
General / Min
Complete Stores Unique Repair Current
Productive asset common Quantity Reclamation Stock Storage
Rotable / Rotable fitment position Structured Name Control Control Rationale numbering Cycle Stock on Priority
construction type name for in service Method Quantity Location
Part (Y/N) requiremets (Weeks) hand
this item required
R AC motor Motor;Hitachi,Type TAFW;3 300 N Critical part needed S/N used 6 Refurbish 4 1 1 High 1Plant Motor
Ball mill Mill motor kW;6.6 kV on plant. Store
R Gearbox Gearbox;David Brown, Size 925 N Critical part needed S/N used 6 Refurbish 4 1 1 High 1Plant Mill
Mill gearbox CRS, Ratio 5.1:1 on plant. house
R Starter Liquid starter;Hitachi Type: MSP N Critical part needed S/N used 6 Refurbish 4 1 1 High 1Plant Motor
3083;Form SWY;3 300 kW; 2.5 on plant. Store
Liquid Starter kV;789 A
Mill bearing - Drive End metal;w=876mm
Mill bearing - Non drive end metal;w=860mm
R Gearbox Gearbox,David Brown, Size N Critical part needed S/N used 6 Refurbish 4 1 1 High 1Plant Motor
Barring Gearbox DDU20, Ratio 200:1 on plant. Store
R AC motor Motor;BMM;37 kW;985 rpm N Critical part needed S/N used 6 Refurbish 4 1 1 High 1Plant Motor
Barring Motor on plant. Store
R Pump Oil pump;David N Critical part needed S/N used 6 Refurbish 2 3 3 High 1Plant Mech
Brown;Roloid;Gear pump;Size on plant. Workshop
R AC motor GEC;5.5 kW; 960 rpm N Critical part needed S/N used 6 Refurbish 4 2 2 High 1Plant Motor
Gearbox pump motor 1 on plant. Store
R Pump Oil pump;David
Brown;Roloid;Gear pump;Size
R AC motor GEC;5.5 kW; 960 rpm
Gearbox pump motor 2
R Cooler Oil cooler;Bauman;GK 190-1658-3 N Critical part needed S/N used 6 Refurbish 2 2 2 High 1Plant Mech
Oil cooler on plant. Workshop
R Pump Gear pump;Polyhodron;P/N 120- N Critical part needed S/N used 6 Refurbish 2 2 2 High 1Plant Mech
Mill Bearing DE HP Pump 1 05 on plant. Workshop
Mill Bearing DE HP Motor 1 on plant. Store
R Pump Gear pump;Polyhodron;P/N 120-
05
Mill Bearing DE HP Pump 2
R AC motor Motor;Actom;5.5 kW;1460 rpm
Mill Bearing DE HP Motor 2
R Pump Radial piston N Critical part needed S/N used 6 Refurbish 2 2 2 High 1Plant Mech
Mill Bearing DE LP Pump 1 pump;Polyhodron;Type 2RC on plant. Workshop
Mill Bearing DE LP Motor 1 on plant. Store
VISUAL ASSESSMENT OF PELCHEM FLO AND HF PLANTS

A practical visual assessment was done on the HF and FLO Plants of Pelchem (NECSA). Recommended
corrective maintenance actions were communicated to management, based on the visual
assessments.
CONTACT US:
For more information, please get in touch:
Resonant Industrial (Pty) Ltd

+27 (0)12 665 1109
+27 (0)82 554 4242
abraham@resonant.co.za
johanc@resonant.co.za
Physical address:
Uitzicht Park #10
Bellingham Street
Centurion

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Optimizing Engineering Assets over the Complete Lifecycle

Resonant Industrial (Pty) Ltd is an engineering company that provides Engineering

MECHANICAL ENGINEERING DESIGN

ASSET MANAGEMENT SERVICES (Systems and Integrity)

ENGINEERING DESIGN: PRESSURE VESSELS

REINFORCEMENT CHECK - NOZZLE TO CYLINDRICAL SHELL

PART CONSIDERED: NOZZLE X (DN150, LWN CL300# FLANGE)

PARAMETER SYMBOL VALUE UNIT CODE COMMENT

ENGINEERING DESIGN: STORAGE TANKS

ENGINEERING DESIGN: PLANT LAYOUT AND DESIGN

We use Cadworx® software to develop extensive 3D models of process plants.

ENGINEERING DESIGN: PIPELINE DESIGN

ENGINEERING DESIGN: FINITE ELEMENT ANALYSIS

We perform finite element analyses on structures using Patran / Nastran ®

ENGINEERING DESIGN: FLUID FLOW ANALYSIS (CFD)

ENGINEERING DESIGN: PIPE NETWORK FLOW ANALYSIS

We utilise Flownex® software to perform fluid flow analyses on piping systems.

ENGINEERING DESIGN: GENERAL DESIGN AND 3D MODELING

ASSET MANAGEMENT: STRATEGY, POLICY AND MAINTENANCE PLANS

ASSET MANAGEMENT: MAINTENANCE AND RELIABILITY ANALYSIS

ASSET MANAGEMENT: MAINTENANCE AUDITING AND LOGISTICS

ASSET INTEGRITY MANAGEMENT

Resonant Industrial (Pty) Ltd

DESIGN OF DUCTINGS FOR GENERAL ELECTRIC COMPRESSORS AT AL KHALEEJ SUGAR

DESIGN OF FUEL PLANTS FOR A SPACE PROPULSION PROGRAMME

DESIGN OF A WF6 PLANT

DESIGN OF A WATER COOLING PIPELINE FOR TRANSALLOYS

DESIGN OF PRESSURE VESSELS AND TANKS

DESIGN OF A WAX FRACTIONATION PLANT FOR REFINEX

DESIGN REVIEW OF GLYCOL SUPPLY PIPELINES FOR OYU TOLGOI MINE

PIPELINE DESIGN FOR VARIOUS REFURBISHED ESKOM POWER STATIONS

FIBRE-GLASS PIPELINE DESIGN FOR BOKPOORT SOLAR POWER STATION

PROJECT MANAGEMENT FOR THE CONSTRUCTION OF AN ASME VIII SUMP TANK

DYNAMIC STRUCTURAL ANALYSES ON TURBINE-GENERATOR FOUNDATIONS

FATIGUE ANALYSES ON CONTAINER LOADING CRANES

STRUCTURAL ANALYSIS ON UNDERGROUND ROCK-BREAKER

STRUCTURAL ANALYSIS ON CONVERTED MINING TRUCK CHASSIS

STRUCTURAL ANALYSIS ON ESKOM HENDRINA AIR HEATER UNITS

SEISMIC ANALYSES ON GRP (FIBRE-GLASS) TANKS FOR THE PHILIPPINES

VIBRATION ANALYSES ON A COMPRESSOR SKID

VENTILATION ANALYSIS AT AMPLATS POLOKWANE SMELTER

HEAT TRANSFER ANALYSIS ON AN AVIONIC ELECTRONIC COMPONENT BOX

HEATING AND WATER WITDRAWAL ANALYSES OF GEYSERS

FLOW AND HEAT TRANSFER ANALYSIS ON A GRATE PELLETIZER PLANT

THERMAL AND FLOW ANALYSIS ON LARGE ELECTRIC MOTOR

DESIGN OF A CUSTOM TRAILER DRAWBAR

DESIGN REVIEW OF A CUSTOM TRAILER

DESIGN REVIEW OF A LOWBED TRAILING ARM FOR ISITHELO

FAILURE INVESTIGATION OF THE TLS MECHANISM ON A CONTAINER CRANE

FFS (Fitness-for-Service) ANALYSIS ON A LARGE DUCT OF ESKOM KUSILE

FAILURE INVESTIGATION ON LARGE OFF-GAS DUCT

FFS (Fitness-for-Service) ANALYSIS ON STAINLESS STEEL TANKS

DEVELOPMENT OF PCM’S (PROCESS CONTROL MANUALS) FOR ESKOM MAINTENANCE

DEVELOPMENT OF MAINTENANCE PLAN FOR A BAG FILTER PLANT IN RUSSIA

Management & Planning Domain

Maintenance Execution Domain

Asset Condition Domain

10. Asset Failures 9. Asset Condition

Measurement Domain 12. Asset Performance

RAM STUDIES FOR ESKOM NITROGEN AND HYDROGEN PLANTS

ASSET MANAGEMENT IMPROVEMENT PROJECT FOR HARMONY GOLD

VISUAL ASSESSMENT OF PELCHEM FLO AND HF PLANTS

Resonant Industrial (Pty) Ltd

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