In 2013, Northam Platinum commissioned Barloworld Power to supply and commission two Cat C175 generators at Booysendal in Mpumalanga.

The 2 500 kVA units, incorporating Cat C175-16 diesel engines, are being used for standby power. A small 45 kVA Olympian unit was also supplied as part of the order. Barloworld Power is the dealer for Cat power systems in Southern Africa. The power project, completed by Barloworld Power and audited by Caterpillar in May 2013, is being maintained by Barloworld Power in a customer service agreement.

Booysendal is located on the eastern limb of South Africa’s Bushveld Igneous Complex, near Mashishing (formerly Lydenburg). The property covers an extensive Upper Group 2 and Merensky Reef mineral resource (103 million ounces of 3PGE+Au). The mine started operations last year and is planned to produce some 2 250 million tonnes of ore a year at steady state by mid-2015. It expects to generate around 160 000 ounces of metals in concentrate, together with associated precious and base metal by-products.

Other mines in Southern Africa for which Barloworld Power has supplied electric power (EP) solutions include Caledonia Mining’s Blanket gold mine and New Dawn’s Turk gold mine in Zimbabwe, Gem Diamonds’ Letseng mine and Storm Mountain Diamonds’ Kao mine in Lesotho, as well as South African coal mines Tshikondeni in Musina (Exxaro) and Mooiplaats in Ermelo (Coal of Africa).

Power-generation solutions

Barloworld’s power-generation solutions range from retail off-the-shelf generators to large rental and power plant construction, as well as co-generation projects. Barloworld Power is able to supply and commission Cat diesel gensets ranging from 13 kVA to 4 000 kVA capacity, Cat gas generator sets from 50 kW to 4 300 kW, and Cat heavy fuel oil (HFO) gensets in the 2 765 kVA to 13 970 kVA range.

In-house engineering expertise is put to work on the selection and design of systems that provide customers with the lowest total cost of electricity, reduce risk and power downtime, extend genset life and minimise operating cost. Customised solutions are fabricated in Barloworld Power’s Customised Solutions Centre (CSC) in Boksburg, and delivered to site as assembled units ready for installation and commissioning.

Combined heat and power (CHP) technology can be incorporated to offer even higher energy efficiency. The wasted heat generated by the engine can be utilised further for other heating or cooling requirements by incorporating heat exchangers or chillers into the overall solution.

Structuring individual power needs

When it comes to structuring individual electric power needs, Barloworld Power provides the options of short- and long-term rental, very large rental solutions, outright purchase, new turnkey installation, upgrading and expansion of prime and standby EP solutions, as well as battery, uninterrupted power supply (UPS) and flywheel UPS. Financing is available at competitive interest rates. Barloworld also represents allied equipment such as Allight mobile lighting towers specific to mine and large construction sites, as well as Sykes dewatering pumps.

Aftersales support is an integral part of EP solutions provided by Barloworld Power. In addition to project management and design, fabrication, installation and commissioning, the CSC structures remote monitoring and comprehensive aftersales support options.

An extensive footprint across South Africa, Namibia, Botswana, Angola, Zambia, Mozambique, Malawi and the Katanga province in the Democratic Republic of Congo ensures consistent service availability on the ground. Quick availability of professional support is particularly essential to remote mine sites.

Customer service agreements

Customer service agreements (CSAs) can range from simple maintenance contracts for single units to integrated solutions for complex installations and large fleets, and are fully customised to customer requirements. A scheduled oil sampling (SOS) programme, operated in conjunction with Caterpillar, is designed to identify failures before they happen, prevent catastrophic failures, encourage planned interventions, extend component life and save costs.

The Barloworld Reman Centre in Boksburg offers a comprehensive stock of remanufactured components backed by the same warranty as new components. Fast and efficient parts delivery is facilitated by comprehensive parts stores at all Barloworld Power facilities and excellent logistic capability, supported by Caterpillar’s Johannesburg parts centre.

Caterpillar produces more than 500 000 engines a year. The number is growing as urbanisation and industrialisation push up global demand for electric power. In response to significant future opportunities, Barloworld Global Power was formed in 2010 to leverage the strengths and synergies of all its Cat dealership territories, namely Southern Africa, Iberia (Spain and Portugal) and a large portion of Russia.

Innovative power solutions

This enables the group to respond to growing demand, particularly in the developing territories in Africa and Russia, for innovative power solutions in all economic sectors. Focus is placed on providing specialist skills to serve the large minerals exploration and mining industry in both Southern Africa and Russia, which frequently needs stable electric power supply beyond what is available from the national grid.

Barloworld Global Power has assembled a high-level team to augment the skills and facilities already in place in its dealership territories, recognising that both a global and a local approach is necessary to satisfy customer needs. In addition to electric power, Barloworld Global Power aims to be a recognised global market leader in marine, oil and gas, industrial and rail power.

Barloworld’s strategic partnership with Energyst allows it to provide complete temporary power plant installations anywhere in the world. Following Caterpillar’s acquisition of MWM in 2011, Barloworld is able to offer the MWM range of gas engines through its network in Southern Africa and Russia.

Specialist skills

The availability of specialist skills is central to the success of Barloworld Global Power. One of the advantages of the organisation is its ability to redeploy skills between Southern Africa, Iberia and Russia, or elsewhere depending on customer requirements.

In-house technical training capabilities ensure that Barloworld Global Power maintains a robust skills base. The global business has the resources to attract skills from across the world. Skills are developed through comprehensive training programmes offered by Caterpillar, which add value to all employees from sales staff to technicians, and in Barloworld’s purpose-built technical training facilities in Johannesburg, Luanda, Madrid, Lisbon and Novisibirsk, Russia.

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