Mining

Through our experience in the mining field we understand and act on the additional safety, reliability and maintainability requirements for mining related projects. Whether you are reviewing your standards, designing a new facility or even if you are already operating and are planning improvement projects – we can help.

Contact us now to discuss your specific needs or scroll down for examples of recently completed projects.

Mill Maintenance Monorail

Dynamic Engineering Consultants can assist with your mill maintenance monorail project in accordance with AS1418. We will take care of all the civil, structural and mechanical aspects of your monorail installation project. Because of this, the final product will be tailored specifically for your application. From a cost point of view, a recent project also revealed that our project was only a fraction of the cost of our closest competitor in this area.

Dynamic Engineering Consultants can assist with:

Initial Consultation phase to determine requirements
Civil and Structural Design
3D Modelling and Drafting
Fabrication Quality Assurance

A typical design would include a discussion with the maintenance team in which their requirements are recorded and noted. After this initial consultation we can produce 3D models for discussion / approval. From there we complete the detailed structural design and drawings. The extent of the drawing range from GA drawings down to shop drawing level. This is all performed in-house.

Below are some examples of completed designed monorail systems.

mill monorail system
3D model of mill maintenance monorail system
Actual mill monorail (discharge end)
Actual mill monorail – as installed (discharge end)
Typical monorail GA drawing

For simpler (straight) monorails no 3d modelling may be required, and we can skip directly to the detail design calculations.

Contact us to discuss your specific needs. To see how we can assist you with your maintenance needs, visit our Maintenance page.

Load Rating of Equipment and Structures

Sometimes there is a need to retrospectively certify existing structures or equipment. This is done by determining their load rating and Dynamic Engineering Consultants can assist you to do this. In broad terms, the procedure to do this is broken up in the following steps:

  1. Measure up existing structure or model from drawings
  2. Determine grade of materials of construction
  3. Model in 3D or use SPACE GASS structural analysis
  4. Apply loads and load cases in accordance with the relevant Australian Standard. Latest versions of the Australians can be purchased here.
  5. Iteratively calculate the load that would lead to compliance with the standards
  6. Record load rating in a calculation report
  7. Perform actual load testing if required
  8. Provide nameplate/marking of structure.

Examples of structures on which Dynamic Engineering have applied this process are: monorail structures, maintenance stands, job cranes, platforms, winches etc.

Below a fabricated welding rotating jig is shown. The next picture shows the 3D model, ready to be analysed with Finite Element Analysis by applying loads and constraints to find the highest stresses and deflections.

Load roller frame
Welding Rotation Jig
Rotating Welding Jig MOdel
Welding Rotation Jig 7.5T

Do you have similar equipment which needs to be certified? Please contact us to discuss how we can assist you. If you like to know more about our certification services, please click here.

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

 

Washbay vehicle ramp

Actual ramp during testing

Contact us to discuss your specific minesite requirements.

Hopper Structural Design Certification

A hopper collects ore, which typically falls from an overhead conveyor 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 with Finite Element Analysis. We 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.

Below the 3D model is shown:

Final hopper design

Final hopper design

Finite Element Analysis was used to find the stresses:

FEA analysis of hopper

FEA analysis of hopper

Our client was able to make significant monetary and time savings by using our expertise as opposed to using one of the larger engineering consulting companies. All our work complies with the relevant Australian Standards.

Most organisations need a trusted partner who will help them navigate through today’s ever changing business environment. Dynamic Engineering Consultants has built up a reputation for providing cost effective world-class engineering support in very quick turnaround times. This makes us the ideal partner for small to medium sized clients that need more flexibility from engineering contractors. Contact us to discuss your requirements.

Radiation Source Cradle Design and Supply

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

Aluminium cradle

Due to the weight of the source the cradle was designed to that it can be carried by two people. To keep the weight to a minimum, the cradle’s design called for aluminium for its construction. To make it multi functional (to move different sizes of radiation gauges) it was fitted with spacers, which could be moved into place very easily. It was also furnished with a stainless steel nameplate that contained information regarding the load rating and use.

Below is the CAD model of the cradle showing the smaller gauge in place. Rod spacers are used to ensure the gauge is safely secured. These rods are designed for easy fitting and removal.

Radiation Cradle

Concept radiation source cradle

The design was finalised with Finite Element Analysis where the stresses and deflection were determined to ensure that it was below the permissible values according to Australian Standards.

The picture below shows the stresses in the cradle:

Stresses in cradle

Below the deflection is shown:

Deflection plot

After our client has approved the design, the cradle was fabricated and shipped to site, ready for use.

Radiation Source Cradle

Fabricated radiation source cradle

Do you require custom made cradles? Please contact us to see how we can assist you.

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. We are able to assist our clients with project schedule development, mechanical and civil estimates as well as client representation when dealing with EPCM contractors.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:

project management

Dust Extractor Foundation being poured

Dirty air duct supports awaiting ducting

Dust extractor installation (Dust extractor by Luhr filter)

project management

Photo of the completed project site

During expansion Dynamic Engineering can help you with complying with WorkSafe requirements.

Nothing matters more to us than making sure that you are completely satisfied with the results we deliver. Your goals are our goals too. We focus on exceeding expectations and making sure that you have been provided with the service and support that you expect. Please contact us to discuss your next project.

Kibble systems (Back up ball charging)

After being mined, mills use small steel balls to grind ore smaller for further processing. To load and unload these steel balls, kibble systems are used. This provides a safe and easier way to charge mill chutes or inlets. Dynamic Engineering can design kibble systems to suit your unique mining operation.

An example of such a back up ball charging system is given below:

After consultation with our client, the system is designed to ensure it is suitable for the application and in accordance with Australian Standards. The kibble is analysed with finite element analysis to check the stresses and deflections so that the design can be strengthened for a long work life.

An example of a stress plot can be seen below:

kibble systems

Finite element model and stress analysis

Below are some photos of the fabricated kibble being used on site. First the kibble is being charged with mill balls. Its size and design makes filling the kibble an easy task.

Kibble being charged

Then it is moved into position and the balls are discharged into the system:

Kibble discharge system in use

We take into account mine site structural constraints to find the best solution for moving the kibble in place and utilise existing equipment where possible. Contact us to discuss your specific mine site requirements.

Civil / Structural Design and Certification

Dynamic Engineering also provides civil or structural design certification services to Australian Standards. Structural work comprises footings and foundations – including drive-in sumps and retaining walls. In addition, we can also assist you with project management of new installations or expansion projects.

We specialise in modelling, analysing and certifying your structural designs. Typical applications include lifting lugs and frames, load bearing structures and foundations.

Below are some examples of our recent work.

Here is an example of a container lifter foundation:

structural design

Container lifter foundation

New exhaust stack foundation being poured in Port Hedland:

structural design

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:

structural design

Space gass model of conveyor structure

Below is a photo of the conveyors on site.

Structural check completed for these conveyors

Structural check completed for these conveyors

Our clear, well-proven methodologies help identify new and innovative ways of delivering improvements.

Have you got a similar requirement? Contact us to discuss your needs.

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. All designs conform to the relevant Australian Standards.

Some examples of specialised access systems are given below:

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

Bus platform in use

access systems

Platform

access systems

SAG Mill Access Ramp

SAG ramp

Crusher access platform

access systems

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. Dynamic Engineering can help with these process improvements.

Sometimes plants have not been optimised and a relatively small production bottleneck can make a big difference to the overall productivity of a process plant. We can help to design, develop and install new processes or equipment, improve existing ones and reduce or eliminate downtime. We support plant operation at every level; establish essential designs, monitor performance and achieve approvals. After all, production is the name of the game.

Dynamic Engineering can provide a custom solution to your problem by performing detailed slurry or water pump calculations. In addition, we can help improving throughput by resizing slurry pumps and piping systems and designing pump foundations / skids. This is done whilst still keeping impeller tip speeds low enough to achieve satisfactory wear rates. Below are some examples of excessive linear wear due to incorrect sizing.

process improvements

Incorrectly sized pump resulting in excessive liner wear

Liner wear

Liner wear

Our clear, well-proven methodologies can help identify new and innovative ways of delivering improvements. All our work done is according to the relevant Australian Standards.

Contact us to discuss how Dynamic Engineering can assist with your process improvements.