• ENGINEERING

    Power of 8 provides professional advisory and technical engineering direction and support for the various disciplines in civil, mechanical, piping, structural steel, electrical, control and instrumentation, specialized services such as boiler, turbine, HVAC and commissioning engineering.

    We have the capability to deliver concept or feasibility studies to scope projects and to provide terms of reference for a project based on clients’ requirements and specifications.

  • PROJECT MANAGEMENT

    At Power of 8 we offer professional services in project management. Our project management practices ensure effective decision making through streamlined processes and structures. This also allows for flexibility in relation to contracting models and an adaptable profile to respond to unique project environments.

    We have the resources, expertise and experience to tailor our services to meet our clients’ project budget, scope of work and project schedules.

    The range of project management services that we have and the expertise to execute include drafting, implementation and management of execution plans, contracting strategies, environmental and social management plans, legal registers, health and safety plans, project schedules, financial management, communications management, quality management and risk management.

    From these terms of reference, we are able to draft, implement and manage process requirements, process models, control philosophy, system integration philosophy, facility functional design specification, engineering design specification and track engineering risks.

  • MAINTENANCE

    1. Plant Maintenance Systems

    Any business that has a manufacturing operation need, and some level of maintenance to keep their facility operating efficiently. This system is normally part of the logistics system and includes material management.

    The objective of plant maintenance is to achieve minimum breakdowns and to keep the plant in optimal working condition at the lowest possible cost.

    The plant maintenance System functions covers five areas of maintenance:

    • Inspection;

    Inspection identifies current condition of the equipment.

    • Preventative

    Maintenance executed to keep equipment in optimal functioning condition and within manufacturing specifications.

    • Condition based

    Using vibration monitoring, oil analysis and ultrasonic tests to identify deviations before major damage can occur.

    • Repair

    Corrective maintenance executed on failed equipment to restore the equipment to its full functionality/specification.

    • Reliability maintenance

    Focuses on a process to identify high maintenance frequencies and how to improve the equipment or maintenance processes, to improve your equipment failure rate.

    Our experienced team will help to identify possible system process and equipment failures, and/ or maintenance needs and make recommendations for improvements for identified issues. An immediate consequence of this is cost reduction because of less repair costs and a higher turnover because of higher plant availability.

    2. Plant Maintenance Optimization

    Plant maintenance often fails as a result of no system in place, poor quality master data, inefficient/incorrect strategies, and a number of other issues. The results is that very often the maintenance planning and execution is poor, inefficient and of little or no value. By correcting these inefficiencies, maintenance breakdown costs can be reduced and plant availability increased dramatically.

    No System in place:
    A system can be sourced and installed through a 3rd party vendor, through a partnership to ensure that the correct maintenance strategies are identified and implemented.

    Poor quality master data:
    A 5-step quality process can be implemented in co-operation with the company to ensure that the P&I D corresponds with the actual equipment in the plant.

    The Equipment can be classified according to a pre-determined list of scientifically identified questions. Each functional location will be assigned a strategy, which clearly identifies all maintenance tasks and frequencies of each task. These tasks are based on failure modes and effects (FMEA). The final list is then signed of by Engineering to ensure that the correct data has been identified and assigned.

    Maintenance strategies:
    A 3-step quality process is implemented based on the assigned strategies, which identifies maintenance task, frequency and failure modes and effects. A quality task list is put in place that identifies the necessary steps and flow of work and where necessary detailed instruction and measurements
    as required.

    The work is executed as identified by the frequency on a regular basis or as required.

    3. Planning and Scheduling

    Work management and on-time execution is two of the major pillars of plant maintenance. Should this process fail, operations will suffer and possible income loss is the consequence of this. As part of our service delivery, we also do maintenance effectiveness assessments to identify possible flaws in the maintenance planning as well as the execution of work.

    We specialize in planning and scheduling, and part of our services is the training of planners and certifying them as competent in the process.

    4. Condition Based Monitoring

    The ultimate objective of Condition based maintenance is to ensure the availability of equipment for safe and reliable operation during its useful life at optimum maintenance cost.

    Condition Based Monitoring allows for planned maintenance rather than breakdowns.

    • Production can be modified to extend unit life.
    • Cause of failure can be analysed.
    • Manpower / Spares can be arranged well in advance.
    • Modifications can be planned.
    • This can be incorporated into the maintenance planning system for scheduling.

    Data analysis and reporting:
    Data analysis is a very important part of condition-based maintenance.

    As an example:
    Slurry is pumped using a pipeline.

    Where regular bursts or leakage occurs, a wall thickness test through ultrasonic testing can be done on a regular bases to determine the deterioration rate of the pipeline. Establishing a trend can predict where the most wear is taking place and based on the pipeline classification which identifies the allowable corrosion on the pipe, the pipe can be replaced before the pipe starts leaking or a burst occur.

  • VARIABLE SPEED DRIVES (VSD)

    We do sales of new products, spares sales, commissioning, predictive and
    Preventative maintenance, 24hour technical support, shutdown and planned service and installation of:

    • Variable Speed Drives (VSD) – ABB, Siemens, Rockwell Automation, Danfoss, Schneider.
    • PLC, SCADA, DCS Systems,
    • Switchgear (LV and MV)
    • Heating Ventilation and Air-Conditioning (HVAC) Systems
    • Panel Building and wiring
    • Certificate of Compliance

    Automation & System Integration

    We supply the following equipment and provided value added services to clients.

    Variable Speed Drives
    • Application design and sizing (LV & MV)
    • Commissioning
    • Preventative and predictive maintenance
    • After sales repairs and after hours call- outs
    • Crane drives specialist
    • Control System Design
    • Control system audit and risk assessment
    • PLC system design, including panel design
    • Preparation of functional specification
    • PLC programming, configuration and commissioning
    • SCADA configuration
    • Telemetry system design
    • PLC – PLC and PLC – SCADA communication networks
    • Profibus, Profi NET, DeviceNET implementation, configuration and Programming

    Asset Management

    • Condition Monitoring (Thermography, Infra-red, Vibration Monitoring, X-ray)
    • Non-destructive Testing
    • Spares Optimization
    • Reliability Basis Optimization (RCM)
  • CALIBRATION

    Process manufacturing plants require hundreds of sophisticated devices that perform countless critical operations ceaselessly, accurately and reliably. Those devices in turn require regular inspection, testing, calibration and repair.

    We offer efficient Field instrumentation calibration services and our calibration system maintains appropriate reference standards, working standards, check standards and calibration processes in our well established Calibration Workshop with state of the art equipment, fully accredited by SANAS (South African National Accreditation System) for:

    • Pressure Measurement (FLUKE 6270A PRESSURE CALIBRATOR)
    • Temperature Measurement
    • Weight Measurement
    • Level

    A new generation of “smarter” field calibration tools increases worker productivity by consolidating multiple tools into one and performing functions beyond basic test and measurement, such as assisting with analysis and documentation. Multi-function documenting process calibrators are handheld, electronic test tools that consolidate multiple calibration steps and functions into a single device, sourcing simulating and measuring pressure, temperature, and a wide variety of electrical and electronic signals.

    Benefits of this include:

    • Fewer tools that technicians need carry into the field.
    • Similar calibration processes and data output across multiple devices.
    • Automated procedures replace many manual calibration steps.
    • Faster calibration time per device
    • Ability to calculate the error of a single tool rather than adding the errors of several tools.

    REPAIRS
    Instrument Repairs are carried out by qualified, experienced staff in our well workshop and in-situ should service requires.

    HIRE
    Hire electrical, pressure and temperature calibration and test equipment at competitive rates. All equipment is supplied fully tested and, where appropriate with a valid SANAS calibration certificate.

    A wide range of portable calibration equipment is available and our technicians are available 24 hours per day 7 days a week.

  • OPERATIONS AND TRAINING

    1. LEGISLATIVE RESPONSIBILITIES

    Overall knowledge of the various systems;

    • Plant and electrical layout for PSR and HV
    • At least five years experience as LCO
    • All relevant training as training assessor and moderator.
    • Presenting all legislative material, including OHSA, RISK, AUTHORISED SUPERVISOR and ARC PROTECTION as per schedule.
    • Keeping record of attendance.
    • Testing and marking of exam papers.
    • Feedback of results to LII Manager.

    2. UNIT CONTROLLER RESPONSIBILITIES

    • Light up and shutdown unit.
    • Manage plant emergencies.
    • Report plant abnormalities to USS and Shift Manager
    • Keep concise chronological log of events during shift.
    • Provide clear instructions to SPO.
    • Submit defects for malfunctioning plant to the relevant maintenance dept.
    • Follow up with maintenance dept.’s regarding defects in progress with focus on defects that have a negative effect on production.
    • Assist with training of SPO’s
    • Hand over and take over shift in a clear and concise manner
    • Adhere to all safety, operating and FFFR instructions and regulations

    3. TRAINING COACHES

    On Job Trainer: a person appointed to conduct individual facilitation in order to transfer skills and knowledge through practical on job training to operating learners.

    Operational equipment: equipment in operation used in the process of generating electricity.

    Practical training: transfer of skills and knowledge within the physical plant environment by means of operating the plant, plant simulations, demonstrations and observations.

    Refresher Training: training as a result of occurrences, emergencies, legislative requirements, and modifications to plant processes, equipment or operating philosophies.

    4. DUTIES OF SIMULATOR FACILITATOR

    • To assist SPO’s in completing the SPO Development Program and Function groups to enable them to become learner Unit Controllers.
    • Assist current unit controllers who are having problems on the units, to identify problem areas and refer them for Simulator Training.
    • To be up to date with Plant modifications and make sure unit controllers are being made aware of it.
    • Make sure unit controllers are making use of all procedures, specially start up and Shut down of the units.
    • Make sure all unit controllers are competent in the FFFR regulation.
    • Before learner controllers start with their practical training, they must be competent in all the theory unit standards.
    • Make sure the learners can utilise multi skilling and can prioritise.
    • Once the theory is completed and found competent in all the US, they will start with their practical training, providing that they have achieved NQF level 4.
    • The Portfolio of evidence must also be kept up to standard at all times.
    • A very good relationship between the learners and myself is very important, as they must feel free to communicate any problems experienced during their training.
    • Depending on the amount of students, the practical training can take up to a year to complete.
    • Their shift Managers must also be kept informed of their progress and problem areas addressed.

    5. SIMULATOR FACILITATOR JOB RESPONSIBILITIES

    Provide Operating Training Functions

    • Determine operating staff training needs, and liaison with all the stakeholders.
    • Plan and schedule courses to meet training needs.
    • Arrange course bookings taking into account availability of students, availability of material and facilities.
    • Recording training records of complete courses and planning attendance of future courses.
    • Check that all trainees follow the laid down curriculum career path, and learner ships.
    • Provide coaching and mentoring to all operating personnel.
    • Conducting refresher training to all the Unit Controllers and Unit Shift Supervisors.
    • Check course material and training records to maintain quality.
    • Revise and update the contents of training material according to the latest technological developments and/or modifications and then communicate with all the relevant parties.
    • Give inputs in all simulator-training activities.
    • Analyse investigation reports, identify any training deficiency and co-ordinate any on-job-training activity that may arise from these incidents.
    • Involve in all the Simulator upgrade projects.

    6. PRESENTATION OF COURSES

    6.1 Presenting the following Simulator courses:

    • Control Load Variations (U/S 13596)
    • Unit Shutdown (U/S 13597)
    • Process Control Loops (U/S 116084)
    • Thermal Efficiency (U/S 114470)
    • Unit Chemistry (U/S 14055)
    • Monitor and Sustain Plant Operability Conditions (U/S 255894)
    • Unit Start Up (U/S 255895)
    • Stabilise Out of Normal and Emergency Conditions (U/S 13599)
    • Fossil Fuel Firing Regulations (FFFR) U/S 255874)

    6.2 Capturing of learner’s records
    6.3 Compiling weekly & month-end reports and reporting to all the stakeholders.

    7. ASSESSMENTS AND MODERATION

    • Conduct assessments and moderations of examination scripts and portfolio of evidences.
    • Verify that assessments have been conducted in line with relevant assessment criteria.
    • Compile assessment reports.
    • Compile moderation reports.

We also supply and do the refurbishment of pumps, gearboxes, motors, valves and hammers.