BMG has recently introduced the Next Generation Hansen I4 Industrial Gear Units (IGUs) which have been developed for safe and efficient use in tough mining and conveying applications.

These compact, invertible Hansen I4 units are engineered to deliver high torque capacity, dimensional accuracy and operational reliability in both underground and surface applications, while ensuring minimal maintenance requirements and extended service life.

Important advantages of the Next Generation Hansen I4 programme – which combines cost optimisation with retained design integrity – include reduced lead times and OEM-backed technical support throughout Africa.

“By standardising the core materials required in key Hansen I4 models, we are able to improve supply efficiency, while maintaining the original torque ratings, gear geometry and bearing performance required for heavy-duty mining and conveying applications,” explains Barry Stoltz, BMG’s Gears Regional Manager, Electro-Mechanical division.“The result is a robust and reliable unit that conforms with Hansen’s global design standards and technical specifications, but with improved availability for operations throughout the African continent.

“BMG has streamlined production and supply processes, reducing delivery lead times to a maximum of four weeks. This shorter turnaround time supports plant uptime strategies for our customers, where conveyor availability is directly linked to output and revenue.”

The revised I4 platform incorporates a standardised bill of materials across the core RDD, RDE and RDF configurations, with gear ratios between 16:1 and 35:1. This rationalisation enables bulk procurement of critical components, including bearings, seals, spacers, nilos rings, bolts and nuts. As a result, accessibility and cost-efficiency are improved, with no compromise on performance, even in arduous conditions. Local sourcing further strengthens supply continuity for the African market.

The Hansen I4 is built around precision-manufactured helical gearing and designed to AGMA-rated standards to balance high torque density with controlled noise levels. High torque geometry is applied to low-speed gears, while high-speed stages are configured to reduce noise emission. Detailed service factor and operating life calculations underpin the shaft and bearing design, ensuring suitability for continuous-duty conveyor and mining drives.

Installation flexibility is a core feature of the Hansen I4 range. The gearbox can be inverted through 180 degrees to accommodate left- or right-hand drive arrangements, reducing inventory requirements and simplifying plant layout. A robust horizontally split housing facilitates easy inspection and maintenance, while horizontal or vertical shaft configurations provide adaptability for different mechanical interfaces. Hansen’s Oil-Lock sealing arrangement ensures long-term oil retention and reduced contamination risk in abrasive environments.

As the official OEM for Hansen gearboxes in Southern Africa, BMG is authorised to repair Hansen IGUs in accordance with the manufacturer’s documented procedures, maintaining original tolerances and operating specifications. Every unit undergoes detailed incoming inspection, full disassembly and dimensional verification of housings, shafts and gears before reassembly to factory-defined clearances. Bearings and seals are replaced as standard, fasteners are torqued to specified values and gear contact patterns are verified to meet correct mesh alignment requirements.

No gearbox is released before a controlled running test confirms mechanical, thermal and lubrication performance, including checks on temperature, noise and oil tightness.

BMG’s Next Generation Hansen I4 range meets the requirements of customers seeking a standardised, high-torque cost-efficient IGU, with reduced lead times and local OEM-backed technical support.

Website: www.bmgworld.net

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Namibia is prioritizing local content development to ensure its oil and gas boom translates into jobs, skills and long-term economic value

Namibia’s emerging offshore oil and gas sector is rapidly shifting from a story of geological discovery to one of industrial execution, institutional readiness and domestic economic transformation. As the country advances toward first oil production by 2030, the central question is no longer what lies beneath its offshore basins, but how effectively Namibia can convert its resources into sustained local value, jobs and industrial capacity across the energy value chain.

Under efforts to ensure the ongoing oil and gas boom translates into economic opportunities for local Namibians, the country has already started taking steps toward implementing policy to ensure projects translate into jobs, investment and contracts. As the voice of the African energy sector, the African Energy Chamber (AEC) supports Namibia’s intensified focus on local content development, emphasizing that strong policy frameworks must be matched by equally robust institutions capable of implementation.

As Namibia refines its upstream regulatory environment, the Chamber underscores the importance of coordinated policy execution, skills development and institutional strengthening to ensure local companies can actively participate in – and benefit from – the country’s energy expansion. Building resilient local institutions will be critical to translating policy ambition into measurable economic outcomes.

“Through strong local content frameworks, Namibia’s oil and gas industry could become a strategic economic driver. The country has an opportunity to build institutions that empower its people, develop competitive local industries and ensure that value is retained within the country. This is how you turn a resource discovery into a national economic engine,” states NJ Ayuk, Executive Chairman, AEC.

Namibia has already taken key steps towards improving its local content frameworks. The country’s cabinet approved the National Upstream Local Content Policy in late-2024, aimed at strengthening economic sovereignty and empowering Namibians within the country’s oil and gas industry. The policy is designed to balance the interests of local stakeholders with the needs of international oil companies, offering a framework to shift the sector away from a purely extractive model toward one that embeds domestic participation across procurement, services and technical operations.

Platforms such as the Namibia International Energy Conference (NIEC) – which took place last week in Windhoek – have also brought local content to the forefront. A series of panel discussions tackled the topic of local content development, with industry leaders and local services providers gathering to assess how local content policies are being translated from regulatory intent into practical outcomes on the ground. The event converged on a shared reality: Namibia’s upstream transformation is no longer about discovery potential, but rather focuses on execution, readiness and local participation at scale.

NIEC featured several discussions on local content, with stakeholders highlighting key steps being taken by Namibia to strengthen participation. The policy environment – strengthened by ongoing petroleum legislative reforms and a more centralized regulatory structure – was broadly framed by participants as a necessary foundation rather than an endpoint. The emphasis is now shifting toward implementation capacity: whether Namibian firms can meet offshore standards, scale quickly and integrate into complex global supply chains.

Gideon Tshomokuti, Founder and Managing Director of Benguela Petroleum Supplies, highlighted that for Namibia’s oil and gas discoveries to truly transform the nation, the country must move beyond mere representation toward a model where skills transfer and local ownership become the foundation of our energy independence. Jamilla Jacobs, Managing Partner, Greenwood Supply Services Namibia, echoed these remarks, stating that local content must become a cornerstone of the country’s national industrial strategy.

Workshops – including RichAfrica Consultancy’s Legacy Leaders Program – certification programs and supplier days were highlighted as critical mechanisms for bridging the gap between international oil company requirements and domestic SME readiness. However, participants also pointed out that coordination across institutions remains essential to avoid fragmentation and duplication.

Ultimately, the consensus was clear: Namibia’s offshore opportunity will be defined far less by the size of its discoveries than by the speed and discipline with which it builds domestic capability around them. In a tightening global race for capital and energy investment, it was agreed that Namibia’s competitiveness will rest on a simple outcome, which is turning hydrocarbons into a durable engine of inclusive industrial growth.

Distributed by APO Group on behalf of African Energy Chamber.

SOURCE
African Energy Chamber

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As South Africa’s renewable energy market expands and matures, more companies are turning to private energy infrastructure to manage costs, reduce reliance on the grid and secure long-term power supply. Commercial solar installations, hybrid systems and off-grid solutions are increasingly becoming part of core business strategy in sectors ranging from mining and manufacturing to agriculture and logistics.

But while the technology behind renewable energy has matured significantly, the decision of who builds that infrastructure has become just as important as the decision to invest in it.

For companies planning energy projects that may operate for 20 years or more, selecting the right engineering, procurement and construction (EPC) partner is emerging as one of the most consequential decisions in the entire process.

Poor engineering choices, inexperienced contractors or weak operational support can undermine system performance, introduce safety risks and erode the financial case for renewable investment.

As the market grows and new entrants emerge, business leaders are increasingly asking the same question: how do you distinguish a credible EPC partner from a risky one?

Why EPC Selection Matters Now

South Africa’s commercial and industrial renewable energy market has grown rapidly in recent years, driven by electricity supply instability, rising tariffs and regulatory changes that have opened the door to private generation.

As a result, companies that once relied exclusively on a single national supplier are now entering long-term infrastructure partnerships with private energy providers.

That shift fundamentally changes the decision-making process.

“In the past businesses effectively had one electricity supplier,” explains Claude Peters, Managing Director at RenEnergy. “Now that companies have the opportunity to choose a partner for their energy infrastructure, the decision shouldn’t be driven by cost alone. There are many other factors that matter first.”

Unlike short-term operational purchases, energy infrastructure projects operate on multi-decade timelines. A poorly designed or poorly maintained system may continue to operate for years  but at significantly lower performance levels.

“You can install two solar systems of exactly the same size next to each other,” Peters says. “But if one is engineered better, it could produce five to ten percent more energy every year. Over twenty years, that difference becomes enormous.”

In other words, renewable infrastructure is not just about installing panels. It is about engineering an energy system that performs reliably over decades.

The Growing Risks in a Rapidly Expanding Market

Rapid industry growth inevitably attracts new operators. While many are experienced engineering firms expanding into renewables, others enter the market with limited large-scale project experience.

This creates a new set of risks for businesses investing in major energy infrastructure.

“Inexperienced operators can present themselves as capable EPC providers very quickly,” Peters notes. “But installing a few rooftop panels is very different from designing and building a complex commercial energy system.”

The consequences of poor project design can be significant.

Substandard engineering can introduce electrical safety risks, compromise building infrastructure or result in systems that fail to deliver expected energy output. In extreme cases, companies may discover that the contractor responsible for installation is no longer operating when problems arise.

“If something goes wrong a year later and the EPC is no longer in business, who do you call?” Peters asks. “This is a long-term asset. You need to know the partner behind it will still be there.”

Another risk is underperformance. A solar installation may be sold on the basis of projected energy production  for example, generating one million kilowatt-hours per year  but poor design or inadequate maintenance could result in significantly lower output.

“It might have been cheaper upfront,” Peters says, “but if the system only produces 60% of what was promised, it becomes a very expensive decision.”

Five Criteria Businesses Should Evaluate When Choosing an EPC

For executives evaluating renewable energy projects, selecting an EPC partner requires a structured due diligence process. While the technical details may differ across industries and project types, several key evaluation criteria consistently emerge.

1. Engineering Capability

At the core of any renewable energy project is engineering design. A credible EPC partner should demonstrate strong internal engineering expertise capable of modelling energy generation, system integration and load management across the entire lifecycle of the electricity system.

“In renewable energy engineering you are looking at the full journey of electricity,” Peters explains. “From generation to grid interaction to consumption. That requires a broad engineering perspective.”

Companies should assess whether engineering work is conducted in-house, the experience level of the engineering team and whether designs are tailored to each project’s environment and energy requirements.

2. Procurement Standards and Technology Selection

Component selection including panels, inverters, mounting systems and batteries has a direct impact on system reliability and lifespan. A credible partner selects ‘bankable’ technology components that insurers and lenders trust for the long haul.

Businesses should evaluate how EPC providers source equipment, whether they work with established technology suppliers and whether procurement processes include competitive supplier evaluation.

Environmental conditions also matter. Equipment that performs well in one setting may be unsuitable in others, such as high-dust mining environments or extreme temperatures.

“Certain technologies perform better in specific conditions,” Peters notes. “The right solution should be selected for the environment.”

3. Installation Quality and Construction Control

Even well-designed projects can fail if installation standards are poor.

Construction quality includes electrical integration, structural mounting systems and civil engineering considerations particularly in regions exposed to strong winds or extreme weather.

Peters recalls a recent example in the Langkloof region where severe storms damaged surrounding structures while a nearby solar installation remained intact.

“The mechanical design and installation quality make a significant difference in how systems withstand real-world conditions,” he says.

For this reason, forward-thinking companies prioritise EPC partners that maintain direct oversight of construction, ensuring accountability is not lost in a chain of sub-contractors.

4. Long-Term Operations and Maintenance

Renewable energy systems are often marketed as low-maintenance, but that does not mean they are maintenance-free.

Cleaning, system monitoring, component replacement and performance optimisation all play a role in maintaining long-term energy yield.

“Solar systems still need to be looked after,” Peters says. “Even something as simple as panel cleaning can affect performance.”

Equally important is the responsiveness of the service provider when problems arise.

“Infrastructure failures rarely happen during office hours,” he notes. “If a facility loses energy production on a Friday night, the response time matters.”

Mr Sim Khuluse, Technical and Policy Manger of the South African Photovoltaic Industry Association (SAPVIA), reinforces this lifecycle view: “Quality in solar projects cannot be confined to installation alone. It must be embedded across the full lifecycle from engineering and procurement through to operations and maintenance, ensuring long-term performance and reliability. It is for this reason that SAPVIA will be launching a Working Group focusing on Operations and Maintenance”

5. Financial Stability and Track Record

Because renewable energy projects operate over long timelines, the financial stability and operational history of the EPC partner should also be considered.

A strong balance sheet established project portfolio and verifiable client references can provide reassurance that the company has the capacity to support infrastructure over its lifetime.

Companies evaluating EPC providers should request reference projects and speak directly with existing clients  not only about successful projects, but also about how problems were handled when they occurred.

“You cannot judge a partner only when things go well,” Peters says. “You must understand how they respond when things go wrong.”

From an industry perspective, SAPVIA has increasingly emphasised the importance of standardisation and due diligence in EPC selection. “Best-practice frameworks exist to guide engineering design, procurement quality and construction management,” Khuluse notes. “These are critical not only for project success, but for building investor confidence in the sector.”

Lessons From Industry Experience

As the renewable energy sector matures, industry standards and regulatory frameworks are gradually strengthening. Compliance requirements, engineering sign-offs and installation standards now play a greater role in project evaluation.

SAPVIA, while not a regulator, plays a key role in shaping these standards through industry guidelines, working groups and quality frameworks. Initiatives such as Operations and Maintenance best-practice guidelines and the PV GreenCard programme aim to improve installation quality, safety and compliance across the sector.

“Industry bodies provide an important alignment function,” says Khuluse. “They help ensure that projects meet recognised standards for safety, performance and regulatory compliance, even in a rapidly evolving market.”

Financial institutions are also introducing their own due diligence processes for EPC providers involved in financed projects, reflecting the financial risks associated with underperforming infrastructure.

Yet many experienced industry participants argue that regulation alone cannot guarantee quality,

ultimately, responsible project development requires informed decision-making by businesses themselves.

“When companies invest in a renewable energy system, they are integrating new infrastructure into the most critical parts of their operations the electrical backbone of the facility,” Peters says. “That is not something where corners can be cut.”

Renewable Infrastructure as a Long-Term Partnership

For many organisations, renewable energy investments are among the largest infrastructure decisions they will make this decade.

Panels, inverters and batteries may be the most visible components, but the long-term success of these projects depends on the engineering and operational ecosystem behind them.

That is why industry experts increasingly encourage businesses to approach EPC selection not as a procurement exercise, but as the beginning of a long-term partnership.

“The real test of a partner is not when everything is working perfectly,” Peters says. “It is when something goes wrong and they are still there to solve the problem.”

In a rapidly expanding renewable energy market, that distinction may ultimately determine whether an energy investment delivers its promised returns or becomes a costly lesson in infrastructure due diligence.

The post Beyond the Panels: Why EPC Selection is the Most Critical Decision in South Africa’s Energy Transition appeared first on African Petrochemicals & Energy.

From Manual Monitoring Challenges to Smart Groundwater Management

Monitoring groundwater levels across large industrial sites is critical—but for Salzgitter Flachstahl GmbH, it became increasingly difficult to manage.

With an extensive works area and surrounding landfill sites requiring constant observation, groundwater levels were traditionally measured manually. This process was not only time-consuming and labour-intensive, but also limited in scalability. As the number of required measuring points grew, the existing approach could no longer keep up—creating a clear need for a more efficient, reliable, and future-ready solution.

A Smarter, Scalable Solution

To address this challenge, Salzgitter Digital Solution GmbH was tasked with developing a fully automated and digital monitoring system using LoRaWAN technology. LoRaWAN (Long Range Wide Area Network) is a wireless communication protocol designed for long-distance, low-power data transmission, making it ideal for industrial monitoring.

In collaboration with KELLER Pressure, a solution was implemented using high-precision level probes and the ADT1 LoRa transmission unit, which wirelessly sends measurement data over the LoRaWAN network. This setup enabled continuous, wireless groundwater monitoring across multiple sites.

The system delivered:

• Accurate, validated measurement data through high-quality sensors
• Seamless integration into the existing LoRaWAN network
• Real-time visibility of groundwater levels across all monitoring points

Beyond basic measurements, the solution also captures critical diagnostic data, including battery voltage (amount of electrical energy remaining), temperature (internal system heat), humidity (moisture in the air around the system), and signal quality (strength and clarity of data transmission). This information provides early warnings for maintenance and helps ensure long-term reliability.

Built for Reliability and Efficiency

The ADT1 LoRa unit was designed with practicality in mind. Using standard AA batteries with a lifespan of up to five years, the system minimises maintenance requirements while ensuring continuous operation.

Data security was another key consideration. With encrypted LoRa (Long Range) communication, which transmits data wirelessly over long distances, and an integrated data logger (a device that records and stores data), the system ensures that no critical data is lost—even during transmission interruptions.

Proven Performance

Since its implementation, the automated groundwater monitoring system has been running reliably for over three years. What was once a labour-intensive and limiting process has been transformed into a smart, scalable, and efficient solution—supporting better decision-making and long-term environmental compliance.

KELLER’s equipment manufacturing team develops solutions tailored to its production department’s requirements and meets its high standards of quality and precision. This has allowed KELLER to continuously improve its products, process stability and efficiency over the last 50 years.  

Contact INSTROTECH, local representative, for more information on KELLER’s GROUNDWATER LEVEL MEASUREMENT USING LoRa MODULE on 010 595 1831 or sales@instrotech.co.za

The post GROUNDWATER LEVEL MEASUREMENT USING LoRa MODULEA KELLER Case History  appeared first on African Petrochemicals & Energy.

Maintaining safe and comfortable working conditions in the cabs of construction, earthmoving and mobile mining equipment is critical to both operator wellbeing and overall productivity. In demanding environments characterised by extreme temperatures, dust and airborne contaminants, effective climate control and air filtration systems are no longer optional – they are essential.

Booyco Engineering, a specialist in heating, ventilation and air conditioning (HVAC) systems for mobile equipment, continues to emphasise the importance of properly designed and maintained cab environments to support safe and efficient operations across industries.

Managing Director, Brenton Spies explains that operators often spend long hours inside machine cabs, exposed to fluctuating temperatures and harsh environmental conditions. “Without adequate temperature control, heat stress or excessive cold can impair concentration, increase fatigue and ultimately raise the risk of incidents on site,” he says.

“Comfort in the cab directly affects operator performance,” he continues. “When temperatures are properly regulated, operators are able to remain focused and alert which contributes to safer and more productive operations.”

Equally important is the role of advanced air filtration. In industries such as mining and construction, airborne dust and particulates pose a significant health risk if not effectively managed. Poor air quality can lead to respiratory issues over time and reduce the overall working life of operators as well as long term medical issues.

Booyco Engineering’s HVAC systems are designed to address these challenges by maintaining optimal temperature ranges while ensuring that clean filtered air is continuously supplied into the cab. By creating a pressurised environment these systems help prevent dust ingress protecting both the operator and sensitive onboard equipment.

Spies says that in addition to improving safety, well-maintained climate control systems can enhance equipment longevity. “Excessive heat and dust can negatively impact electronic components and control systems within the cab, leading to increased maintenance requirements and potential downtime.”

As industries place greater emphasis on health, safety and environmental standards, the expectations around operator working conditions continue to rise. Regulations and best practice guidelines are increasingly recognising the importance of air quality and temperature control in mobile equipment environments.

Booyco Engineering works closely with OEMs and end users to ensure that HVAC systems are fit for purpose, robust and capable of performing reliably in some of the harshest operating conditions. This includes solutions tailored for both surface and underground applications, where environmental challenges can differ significantly.

“Providing a controlled, clean and comfortable cab environment is not just about compliance – it is about protecting people and enabling them to perform at their best,” Spies notes.

“By prioritising operator comfort through effective temperature control and air filtration, companies can reduce health risks, improve productivity and support safer operations across construction, earthmoving and mining sectors,” he concludes.

www.booyco.co.za

The post Booyco Engineering Drives Safer, More Productive Operations Through Cab Comfort And Air Quality appeared first on African Petrochemicals & Energy.

The 34 km underground tunnel enables water transfer between the Polihali and Katse reservoirs, forming a critical link in the system.

Multinational, buildings and infrastructure engineering consultancy Zutari is contributing to one of the most technically complex components of the Lesotho Highlands Water Project (LHWP) Phase II through its role in the Metsi a Senqu-Khubelu Consultants (MSKC) Joint Venture for the design and construction supervision of the Polihali Transfer Tunnel.

The project is being undertaken in the Kingdom of Lesotho by the Lesotho Highlands Development Authority (LHDA), the implementing and management authority of the LHWP, on behalf of the governments of Lesotho and South Africa.

Stretching approximately 34 km beneath Lesotho’s mountainous highlands, the Polihali Transfer Tunnel forms a critical link between the Polihali and Katse reservoirs, strengthening the water transfer system that supports regional water and hydropower security.

The tunnel incorporates a sophisticated design comprising a five-metre-diameter segmentally lined hard-rock TBM bored tunnel, intake works and gate shaft upstream of the new 165 m high Polihali Dam, as well as outlet works and lake-tap into the Katse Reservoir. Additional access tunnels and associated infrastructure support the construction and future operation of the system.

Engineering beneath the Highlands

Unlike visible infrastructure such as bridges or dams, the Polihali Transfer Tunnel represents an engineering achievement largely hidden from view. Yet the underground system is among the most significant elements of the entire LHWP Phase II programme.

Freddie Laas, Project Manager for the MSKC Joint Venture overseeing the tunnel’s implementation, says the project requires a high level of coordination, planning and technical precision. “The Polihali Transfer Tunnel is one of the most technically demanding components of the Lesotho Highlands Water Project Phase II. Delivering infrastructure at this scale requires careful coordination across engineering disciplines, contractors and project stakeholders to ensure that safety, quality and environmental stewardship remain central throughout the construction process.”

Laas adds that projects of this complexity extend beyond engineering alone. “Large-scale infrastructure programmes involve many moving parts, from geological conditions and environmental considerations to social and economic responsibilities. Successfully managing these elements is what ultimately ensures that the project delivers long-term value for both Lesotho and the broader region.”

Strengthening regional water security

The LHWP is a multi-phase bi-national initiative between the Kingdom of Lesotho and the Republic of South Africa designed to harness the water resources of Lesotho’s highlands through a network of dams, tunnels and associated infrastructure.

While the project supports water supply to South Africa’s economic hub, it also generates substantial economic benefits for Lesotho through royalties, infrastructure development and long-term employment opportunities.

Projects of this scale also create opportunities for collaboration between international engineering specialists and local professionals, contributing to skills development and long-term technical capacity within the region.

Zutari has been involved in infrastructure development in Lesotho for decades, supporting projects across water, transport and environmental sectors. The company’s participation in the Polihali Transfer Tunnel forms part of its broader contribution to the LHWP programme and to infrastructure development across the region.

Engineering partnerships that deliver impact

Tlhabeli Ralebitso, Chief Executive Officer for Africa at Zutari, says projects such as the Polihali Transfer Tunnel highlight the importance of collaboration in delivering infrastructure of national and regional significance.

“The LHWP is one of Africa’s most important examples of infrastructure delivered through partnership. Complex engineering programmes such as the Polihali Transfer Tunnel require the combined expertise of governments, engineering firms and local professionals working toward a shared goal. Through these collaborations, infrastructure can deliver lasting benefits, strengthening water security, supporting economic growth and building technical capacity across the region.”

Although largely invisible once completed, the Polihali Transfer Tunnel will play a vital role in the long-term operation of the LHWP, ensuring the efficient transfer of water through the system while supporting the continued development of water infrastructure across Southern Africa.

As construction progresses on Phase II of the project, the tunnel stands as a powerful example of the engineering innovation and strategic collaboration required to deliver infrastructure on a truly regional scale.

More info, https://www.zutari.com

The post Engineering the Polihali Transfer Tunnel in Lesotho Highlands Water Project Phase II appeared first on African Petrochemicals & Energy.

This webinar offers an engaging technical discussion to challenge perspectives and highlight opportunities in the evolving energy sector.

Let’s discuss the future of energy with an emphasis on future coal technology!

• Clean coal technologies
 

What are they, how do they work, and can they present a viable path forward?

• Energy transition challenges

What about affordability, grid stability, and technological maturity?

• Dual energy landscape

Is there a 21st-century energy landscape that balances fossil fuel with rapid renewable energy growth and transformation?

• The role of Artificial Intelligence

Lets talk about digital twins, industry 4.0 and how these will shape the future of AI within the industry.

• Simulation
 

How do we built digital twins with simulation tools?

      Speakers

• Mr. Brian Colling / Mr. Corniel Zwaan ( EnFloTech) – Facilitator / Program Director
• Mr. Abrie Preller / Mr. Matthew Muller (EnFloTech) – Coal Desander, a post milling beneficiation process
• Mr. Darren Bibby (Aircure) – Optimising Emissions Control with Cyclonic Separation Technology
• Mr. Ignus le Roux / Mr. JG Serfontein (Aerotherm) –The important role of digital twins in coal combustion systems (Siemens Simcenter STAR-CCM+)
• Mrs. Melissa Coetzee (EnFloTech) – Coal milling plant digital twins 

Secure your virtual seat and join the conversation—we look forward to an exciting tech chat with you. Don’t miss out!

More info, please click here

The post EnFloTech Presents Fossil Fuel in the 21st Century appeared first on African Petrochemicals & Energy.

Encouragingly, collaboration between public and private sector stakeholders in South Africa’s civil engineering industry is strengthening – underpinned by a firmer stance on accountability across the construction value chain. According to Lindie Fourie, Operations Manager at the Bargaining Council for the Civil Engineering Industry (BCCEI), recent remarks by the Department of Public Works and Infrastructure that a number of contractors have already been blacklisted in 2026 for non-compliance and unethical practices send a clear signal that enforcement is gaining traction.

“The increased visibility of enforcement actions is an important step in restoring confidence in the sector,” Fourie says. “It demonstrates a commitment to accountability and helps to protect those contractors who are operating responsibly and within the framework of the law.”

Against this backdrop, South Africa’s civil engineering sector is showing early signs of recovery, although ongoing economic pressures continue to constrain the pace and sustainability of growth. While anticipated increases in infrastructure investment and improving project pipelines are providing some optimism, contractors are still navigating tight margins, rising input costs and persistent uncertainty.

Activity in the sector has been supported by renewed focus on infrastructure development, particularly in roads, energy and water projects. However, the benefits are not yet evenly distributed across the industry. Many contractors, especially small and medium-sized players, remain under strain due to delayed project rollouts, payment bottlenecks and limited access to consistent work.

Cost pressures continue to weigh heavily on operations. Escalating fuel prices, material cost volatility and labour-related expenses are eroding margins, leaving little room for inefficiencies. In this environment, disciplined project management, accurate pricing and stringent cost control have become critical for business sustainability.

Amid these challenges, the BCCEI continues to play a central role in promoting stability, fairness and compliance across the sector. Fourie emphasises that a structured regulatory environment is essential to building a sustainable and competitive industry.

“Labour compliance is not just a regulatory requirement – it is a cornerstone of a stable and competitive civil engineering sector,” she says. “When all contractors operate on a level playing field and meet their obligations in terms of wages and conditions of employment, it creates an environment where businesses can compete fairly and projects can be delivered more effectively.”

She adds that the industry must also condemn the abominable practice of some contractors that attempt to exploit the most vulnerable purely to secure a tender and undercut their law-abiding fellow contractors who tender on BCCEI rates.

She notes that economic pressure often places strain on both large contractors and smaller subcontractors, making compliance more challenging but even more critical. “In difficult economic conditions, there can be a temptation to cut corners. However, non-compliance undermines the entire industry and ultimately impacts project delivery, worker welfare and investor confidence.”

Fourie adds that enforcement alone is not sufficient to achieve long-term stability. “Alongside enforcement, there must be active support for contractors to understand and meet their obligations,” she says.

To this end, the BCCEI continues to support contractor development and compliance awareness, working closely with both established firms and emerging contractors. This includes providing guidance on collective agreements, labour obligations and administrative processes, helping especially smaller businesses to build sustainable, legally compliant operations while remaining competitive in a challenging economic environment.

Despite these positive indicators, challenges remain. The sector continues to face skills shortages, administrative complexity and the lingering effects of historical underinvestment. For meaningful, long-term growth, consistent infrastructure spend, streamlined approvals and reliable payment practices will be essential.

While the sector remains under pressure, there is growing confidence that stronger enforcement and improved collaboration are laying the groundwork for a more stable and sustainable industry.

Fourie emphasises that consistency will be key. “Sustained infrastructure investment, combined with firm but fair enforcement of compliance, will be critical to unlocking the sector’s full potential. When the right structures are in place and consistently applied, the civil engineering industry can deliver meaningful economic growth, support job creation and contribute significantly to South Africa’s development,” she concludes.

More info, please visit www.bccei.co.za

The post Stronger Enforcement And Collaboration Signal Shift In South Africa’s Civil Engineering Sector appeared first on African Petrochemicals & Energy.

CASE STUDIES: Fluke Renewable Energy                                                               

Photovoltaic (PV) systems are subject to various hardware issues that can significantly impact their performance. Diagnosing these issues accurately is crucial for maintaining system efficiency and longevity. I-V curve tracing is a powerful tool that helps technicians identify specific hardware failures in PV systems. This article provides a detailed guide on troubleshooting common hardware issues using I-V curve tracers.

Common Hardware Issues in PV Systems

PV systems can experience several module-related problems that affect their performance. Here are some of the most common issues:

1. Shorted Bypass Diodes
2. Microcracks in PV Cells
3. Connector Failures
4. Potential Induced Degradation (PID)
5. Hotspots
6. Shorted Bypass Diodes

Description: Bypass diodes are integrated into PV modules to protect cells from overheating and damage due to partial shading or issues within the module. A shorted bypass diode can cause significant performance issues, leading to a reduced voltage output.

Symptoms:

• Low Open-Circuit Voltage (Voc): The I-V curve will show a significantly lower Voc.
  • Stepped I-V Curve: The curve may display steps or abrupt changes in slope.

Troubleshooting Steps:

1. I-V curve tracing: Use the I-V curve tracer to identify deviations in the Voc and detect steps in the I-V curve.
2. Visual Inspection: Inspect the module for visible signs of damage or overheating.
3. Multimeter Test: Test the bypass diodes with a multimeter. A shorted diode will show continuity in both directions.
4. Replacement: Replace the affected module or bypass diode as necessary.

Case Study: In a commercial PV installation, technicians noticed a drop in system performance. I-V curve tracing revealed a low Voc in one string. Testing the bypass diodes confirmed a shorted diode. Replacing the affected module restored the system’s performance.

7. Microcracks in PV Cells

Description: Microcracks are small cracks in PV cells that can occur during manufacturing, transportation, and installation and due to weather events like high wind or hail. These cracks can grow over time, leading to reduced performance and potential failure.

Symptoms:

• Stepped or Irregular I-V Curve: The I-V curve may show steps or irregularities, indicating current mismatch.
• Reduced Current Output (Isc): The overall current output may be lower than expected.

Troubleshooting Steps:

1. I-V Curve Tracing: Identify deviations and steps in the I-V curve.
2. Electroluminescence Testing (EL): EL testing applies a reverse-bias current to a string of modules and uses a specialised camera to detect microcracks. This is the most accurate way to detect microcracks, but EL equipment is currently expensive, and the test is labour-intensive.
3. Infrared (IR) Imaging: Use an IR camera to detect hot spots, which may be indicative of microcracks.
4. Replacement: Replace modules with significant microcracks.

Case Study: A utility-scale PV farm experienced a gradual decline in performance. I-V curve tracing and IR imaging identified microcracks in several modules. Replacing these modules improved the system’s overall output.

8. Connector Failures

Description: Connectors are critical components in PV systems. Failures can result from corrosion, poor installation, or physical damage, leading to increased resistance and reduced performance.

Symptoms:

• Low Voltage Ratio: The I-V curve will show a lower-than-expected voltage ratio (Vmp/Voc).
• Irregular I-V Curve: The curve may display irregularities or a lower-than-expected current output.

Troubleshooting Steps:

1. I-V Curve Tracing: Identify irregularities in the I-V curve.
   1. Visual Inspection: Inspect connections for signs of corrosion, damage, or poor installation.
   1. Electrical Testing: Use a multimeter to test for continuity and resistance in connectors.
   1. Thermal Imaging: Use a thermal camera to detect connectors that are operating at a higher temperature when compared to other connectors under the same environmental conditions.
   1. Replacement or Repair: Repair or replace faulty connectors.

Case Study: A solar carport installation had inconsistent performance. I-V curve tracing showed irregular I-V curves. Inspection revealed corroded connectors. Replacing the connectors restored consistent performance.

9. Potential Induced Degradation (PID)

Description: PID is a phenomenon that occurs when voltage differences between the PV system and the ground lead to leakage currents, causing module degradation.

Symptoms:

• Low Voc and Isc: The I-V curve will show both low Voc and Isc.
• Degraded I-V Curve: The curve may appear flattened and degraded over time.

Troubleshooting Steps:

1. I-V Curve Tracing: Identify degraded I-V curves with low Voc and Isc.
2. IR Imaging: Use an IR camera to detect areas of degradation.
3. Electrical Testing: Test for leakage currents and potential differences.
4. Mitigation: Install PID mitigation equipment or replace affected modules.

Troubleshooting Guide for Common Hardware Issues

Case Study: A PV farm in a high-humidity area experienced significant PID. I-V curve tracing and IR imaging confirmed the issue. Installing PID mitigation equipment and replacing severely affected modules restored performance.

10. Hotspots

Description: Hotspots occur when a part of a PV module becomes significantly hotter than its surroundings, often due to shading, soiling, or cell damage, leading to reduced performance and possible damage.

Symptoms:

1. Stepped or Irregular I-V Curve: The I-V curve may show steps or irregularities.
2. Visible Hotspots: Detected using IR imaging.

Troubleshooting Steps:

1. I-V Curve Tracing: Identify steps or irregularities in the I-V curve.
2. IR Imaging: Use an IR camera to detect hotspots on the modules.
3. Visual Inspection: Inspect for shading, soiling, or physical damage.
4. Cleaning and Repair: Clean soiled modules and repair or replace damaged modules.

Case Study: A residential PV system had reduced output. I-V curve tracing and IR imaging identified hotspots caused by bird droppings and a cracked cell. Cleaning the array and replacing the affected module resolved the issue.

Conclusion

I-V curve tracing is an invaluable tool for diagnosing module failures in PV systems. By identifying specific issues such as shorted bypass diodes, microcracks, connector failures, PID, and hotspots, technicians can take targeted actions to restore and optimise system performance. Regular use of I-V curve tracers, combined with thorough inspections and appropriate repairs, ensures that PV systems operate efficiently and reliably.

Frequently Asked Questions (FAQs) About Diagnosing Hardware Failures in PV Systems Using I-V Curve Tracers

Q1: What are the common hardware issues in PV arrays?

Common hardware issues include shorted bypass diodes, microcracks in PV cells, connector failures, potential induced degradation (PID), and hotspots.

Q2: How can I detect shorted bypass diodes?

Use I-V curve tracing to identify low Voc and steps in the I-V curve. Confirm with a multimeter test for continuity in the bypass diodes.

Q3: What tools can help identify microcracks in PV cells?

I-V curve tracers, visual inspections, electroluminescence testing, and infrared (IR) imaging can help detect microcracks.

Q4: How do connector failures affect PV systems?

These failures increase resistance and reduce performance, often visible as irregularities in the I-V curve, low voltage ratios, and high-temperature connections in thermal images.

Q5: What is Potential Induced Degradation (PID), and how can it be mitigated?

PID is caused by voltage differences, leading to leakage currents and module degradation. Mitigation includes installing PID mitigation equipment and replacing affected modules.

Contact COMTEST on + 010 595 1821, sales@comtest.co.za or www.comtest.co.za for more information on FLUKE “DIAGNOSING HARDWARE FAILURES IN PV SYSTEMS USING I-V CURVE TRACERS”, technical or seminar information, demonstrations, or locating your nearest Authorised Comtest Channel Partner.

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In an era where operational efficiency and machine health are critical, oil quality sensors are proving to be indispensable tools for preventative maintenance and lubrication management. By harnessing these cutting-edge technologies, businesses can proactively detect potential issues and take prompt action to avoid machinery failures and costly downtime.

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Website: www.yatekafrica.co.za

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