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Mechanical Design Certification Service

Australian Standards require that equipment or structures be designed according to a specific standard. We at Dynamic Engineering makes this process as easy as possible for our clients by providing a design certification service. There are several different ways in accomplishing this, through physical testing of equipment and computer simulations, such as Finite Element Analysis.

Physical testing of equipment

In some instances, computer simulation cannot be used to certify a design. Then it is necessary to build a prototype and physical test the equipment, often to destruction. This approach is sometimes specified in the standard – for example for ROPS, FOPS and FUPS devices

FOPS testing

Testing of prototype FOPS

 

Finite Element Analysis

Computer assisted stress analysis streamlines the certification of equipment. A 3d-computer model takes the guesswork out of new designs. Changes can be made quickly and inexpensively and the result can be checked straightaway. With Finite Element Analysis (FEA) different loads can be applied, including gravity, remote force and torque. The resultant stresses and deflection can be checked against design specifications.

engine stand

3D model of an engine stand

 

Design certification is becoming more and more popular and in the case of some mining clients is now a requirement for all new equipment. Design certification can be achieved for both new and used equipment, provided certain information is known:

1) For new equipment the following is required:

  • A drawing that fix the design (dimensions, materials and welding)
  • Engineering calculations (require loads and load combinations)

2) For existing equipment

  • A drawing that fix the design (dimensions, materials and welding). The equipment would therefore need to be measured up (in some cases dismantled)
  • Engineering calculations (require loads and load combinations)
  • Actual load test to confirm the design calculations and construction.

We can help with all of the above. By developing a 3D model of your equipment and applying the loads, we can produce a stress plot that can be used to prove the design or even to increase the reliability of the design. It is fast, cost effective and saves a lot of time and money associated with breakdowns – not to mention the safety risks associated with failures.

Stress analysis of a tool table

Stress analysis of a tool table

 

In some cases we are asked to give our opinion if certain maintenance activities would be safe. One such assignment was to check if a corroded tailing pipe could be lifted while in operation. Our analysis showed this to be a high risk activity and we advised our client against this – showing areas of concern as well as the behaviour of the model under certain load cases. With our model we were able to predict load versus deflection curves, as well as the required crane tonnage.

Load cases showing stresses and deflections associated with lifting the tailing pipe

Pipe lifting analysis

 

Although our analysis indicated that the lift should not take place, our client still received the benefit of avoiding a large clean-up bill and other associated incidents. Sometimes it really pays to check out the engineering aspects of a job before it is attempted.

Short description of FEA

The first step in computer modelling is drawing the equipment or tool in three dimensions. The CAD software then meshes the model by subdividing it into smaller elements. The loads and constraints are added and the resultant stresses and deflections are calculated for each of these numerous elements. Lastly stress and deflection equations are solved for each of these elements and the results are combined to find the overall solution. Below are some stress analysis examples showing the resultant stresses:

Stress analysis of a belt lifter

Stress analysis of a belt lifter

 

jacking tool

3D model of jacking tool

 

reel drum frame

3D model of reel drum frame

 

track guide lifter

3D model of track guide lifter

 

Finite element analysis can be applied to several different applications, such as Machine design, Maintenance tools and Civil/Structural design

 

Modular Minesite Washbay Vehicle Ramp Design

Dynamic Engineering Consultants recently completed a 5T capacity Modular Minesite Washbay Vehicle Ramp Design for one of our clients. The client requirements were:

1) Constructed from large welded assemblies that can be transported easily and that would minimise construction time on site – modular.

2) Galvanised surface treatment.

3) Open sections to make it easy to monitor corrosion and damage.

4) Capable of handling certain site vehicles.

5) Fully compliant with the relevant Australian Standards.

6) 5T capacity.

7) Incorporated vehicle wheel guides (safety).

The final design for this ramp is shown below. It complied with all of the above requirements and is currently installed at a few minesites around WA. It was constructed in four large sections that was bolted together on site with splice plates and was also attached to the concrete with mechanical anchors. The all-important feedback that was received from our clients are very positive. The ramp was easy to transport, easy to install, had a quality construction and was easy to use. It is an example of a simple design that just works.

3D model 5T capacity vehicle ramp

3D model 5T capacity vehicle ramp

 

 

 

 

 

 

 

 

 

 

 

 

Photos of the Modular Minesite Washbay Vehicle Ramp Design during construction and testing

Actual ramp during construction

Actual ramp during construction

 

 

 

 

 

 

 

 

 

 

 

 

Actual ramp during testing

Actual ramp during testing

Hopper Structural Design Certification

A hopper collects ore, which typically falls from an overhead conveyer or is dumped by a belt feeder into the bin. This causes dynamic loads and stresses, which need to be taken into account when designing the hopper. Dynamic Engineering analysed our client’s proposed design and found that it would require strengthening in order to reliably withstand the imposed forces. With relatively cheap modifications, a more robust design was implemented – saving our client on future repair and maintenance costs.

Final hopper design

Final hopper design

 

 

 

 

 

 

 

 

 

 

 

FEA analysis of hopper

FEA analysis of hopper

Radiation Source Cradle Design and Supply

A radiation source cradle was designed to assist plant metallurgists to easily and safely move radiation sources around inside a process plant.

Due to the weight of the source the cradle was designed to that it can be carried by two people. The cradle weight was kept low by using aluminium for its construction and was fitted with spacers that made it multi functional. It was also furnished with a stainless steel nameplate that contained information regarding the load rating and use.

Radiation Cradle

Radiation  Source Cradle

 

 

 

 

 

 

 

 

 

 

 

Radiation Source Cradle

Radiation Source Cradle

Project Management and Expansion Projects

Dynamic Engineering Consultants has wide experience with project management and can assist you with your small to medium projects. This includes management up to approx $AU 3mil total project cost. Whether it is a new project or you are looking to expand an existing one, Dynamic Engineering can help you. As part of this services we can assist with the following:

1) Scope of works development

2) Layout drawings

3) Project schedule development

4) Detail foundation design and drafting

5) Detail structural design and drafting

6) Detail mechanical design and drafting

Below are some examples of the projects we have done recently:

Dust Extractor Foundation being poured

Dirty air duct supports awaiting ducting

 

Dust extractor installation (Dust extractor by Luhr filter)

 

Photo of the completed project site

Kibble (Back up ball charging) systems

Mills use small steel balls to grind ore smaller for further processing.  A kibble system provides a safe way to charge mill chutes or inlets. Dynamic Engineering can design kibble systems (back up ball charging systems) to suit. Example of such a ball charging system is given below:

Kibble design

Kibble model and stress analysis

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Kibble being charged with mill balls:

Kibble being charged

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Kibble discharge system:

Kibble discharge system in use

Civil / Structural Design and Certification

Dynamic Engineering also provides a civil or structural design service. Below are some examples of our recent work.

Structural work comprises footings and foundations – including drive-in sumps and retaining walls. Here is an example of a container lifter foundation:

Container lifter foundation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

New exhaust stack foundation being poured in Port Hedland:

Dust extractor foundation being poured

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

We have also done building cladding projects:

This is a photo of the building BEFORE we installed the cladding system:

Building prior to installation of cladding

 

This is the cladding system design we developed:

New cladding system

 

This is a photo of the cladding system being installed:

Cladding being installed

 

Conveyor structural checks:

Below is an example where we performed a structural check on a conveyor manufacturer’s design using Space gass:

Space gass model of conveyor structure

Space gass model of conveyor structure

 

 

 

 

 

 

 

 

 

 

 

 

 

Structural check completed for these conveyors on behalf of Oreflow

Structural check completed for these conveyors on behalf of Oreflow

 

Have you got a similar requirement? Give us a call today. Refer to our “contact-us” section for ways to contact us and discuss your requirements.

Access Systems and Ramps Design

Dynamic Engineering Consultants design specialised access systems and ramps. Our services include concept design, fabrication drawings, lasercut files, engineering certification and we can also assist with quality control and quality plans. Some examples of specialised access systems are given below:

50T bus platform (28m long, fully bolted)

 

Bus platform in use

 

Platform

SAG mill Access Ramp

SAG ramp

Crusher access platform

 

The forklift ramps shown below are used for loading and unloading of food trucks. These ramps were fabricated by others some time ago and were never rated for a safe working load / engineered and thus needed to be certified for a specific capacity. An analysis of the Forklift and Access Ramp Design was done by Dynamic Engineering Consultants. It indicated that the ramps were indeed not fit for purpose as it did not comply with the relevant standards in relation to the required load rating. Dynamic Engineering recommended modifications to the ramps to ensure compliance and issued a design report based on the proposed modifications (certified the proposed design).

The revised and upgraded ramps are shown in the second picture below. The new design incorporated design improvements where required (upgraded pin connections and sleeves), and also included some safety recommendations (“keep-clear” areas added). Through our involvement in this project we were able to provide value to our client by: 1) Improve the existing design in terms of safety 2) Provide the required paperwork required by the mines safety inspector.

Forklift Ramps Prior to Design Check

 

 

 

 

 

 

 

 

 

 

Forklift Ramps After Design Check Completed

 

Process Improvements and Fault-finding

At Dynamic Engineering we understand that our clients are always pushing to improve productivity, whilst at the same time reducing maintenance related delays. After all, production is the name of the game. Dynamic Engineering can help with process improvements.

We also understand that sometimes plants have not been optimised and that a relatively small production bottleneck can make a big difference to the overall productivity of a process plant. We can help by improving throughput by resizing slurry pumps and piping systems – whilst still keeping impeller tip speeds low enough to achieve satisfactory wear rates.

We can perform detailed slurry or water pump calculations, design pump foundations / skids and provide a custom solution to your problem.

 

Incorrectly sized pump resulting in excessive liner wear

Incorrectly sized pump resulting in excessive liner wear

Liner wear

Liner wear