Mechanical and Process Engineering
ERWAT WATERVAL
ENGINEERING PERSPECTIVE
Engineering processes employ mechanical and chemical operations to transform matter for social benefit. At the core of sustainability, good process design reduces the formation of entropy, which is achieved through:
- Minimisation of losses and optimisation of heat and power transfer
- Resource recovery and emission control in solid, liquid and gas states
- Design considerations directed towards operations and maintenance and customising installations to the available means
PROFESSIONAL SERVICES
Virtual Consulting Engineers employs specialist process and mechanical engineers to work on a range of systems from concept to commissioning, operation and maintenance. We are proficient with the interpretation and local application of international design codes, including:
- American Petroleum Institute/Energy Institute’s specifications and codes, such as API 1540 Design, Construction, Operation and Maintenance of Aviation Fuelling Facilities
- Joint Inspection Group’s Standards for Aviation Fuel Quality Control and Operating Procedures at Airports and Upstream Fuel Facilities
- American Society of Mechanical Engineers, including ASME B31.1 Power piping and ASME B31.3 Process piping
- Pressure Equipment Regulations
Our computer aided design packages include libraries of symbols and sub-systems that were developed over years, in accordance with:
- Process Flow Diagrams (ISO 10628: General Rules for Flow Diagrams for Process Plants)
- Piping & Instrumentation Diagrams (ISA 5.1 Instrumentation Symbols and Identification)
PROJECTS
Waterkloof Air Force Base: Aircraft Refuelling System (2010)
Department of Public Works / South African Air Force
Repair, Upgrade and Maintenance of the rail siding with rising fuel main to the base, a main fuel facility with road tanker loading bay, defuelling quarantine tanks and a booster pump installation, as well as the back-up pump station to supply jet-fuel to the hydrant system and Presidential VIP Unit. Mechanical fire fighting systems and cathodic protection completed the scope of work.
Makhado Air Force Base: Aircraft Refuelling System (2011)
Department of Public Works / South African Air Force
Condition assessment, compliance audits, hydraulic flow and pressure analysis led to the Repair, Upgrade and Maintenance project that included the rail siding fuel supply system (1,250ℓ/min), two main booster pump stations (2,500ℓ/min) with storage tanks, fighter aircraft revetments, gantry with refuelling points for training aircraft and refuelling pit installations.
St Helena Airport Fuel Facility (2015)
Government of St Helena / Basil Read
Conceptualisation and detail design, as per API1540, Design, Construction, etc., of the new St Helena Airport Fuel Facility, that comprised dual function receipt and refuelling pumps with automated flow control, fuel coalescer filter separators, four horizontal epoxy coated storage tanks with capacity of 50m3 each and a complete product recovery system.
Waterval Blower Replacement and Mechanical Ventilation (2019)
Ekurhuleni Water Care Company
Compressors from 1993 were replaced after careful functional and spatial analysis. Five new 400kW aeration compressors (10,896rpm) were designed, manufactured and subjected to ISO 5389: Turbo compressors performance test code. The installation included new electrical supply with Variable Speed Drive starters. Radiators and extractor fans ensure air cooling of the blower house.
Simon’s Town Maritime Training Centre: HVAC system (2020)
Department of Public Works / South African Navy
Condition assessment of the two old centralised heating ventilation and air conditioning systems revealed operational inadequacies. Replacement of the central chiller makes use of modern control systems to regulate air flow and temperature to individual rooms. Fresh air supply and spent air exhaust ducting were retained where feasible.
Replacement of Boilers and Steam Installations (2020)
Development Bank of Southern Africa / North West Health
Replacement of old boilers at Hospitals with new coal fired boilers at Mahikeng (8.0ton/h), Gelukspan and Wolmaransstad (3.2ton/h), Schweizer-Reneke (1.8ton/h) and refurbishment of boilers at Klerksdorp and Tshepong. Work included installation of feed water softening plants, repair of steam distribution pipes, calorifier installations and condensate return piping.