Welcome CONTENTS. Tailoring effective engineered solutions to meet the individual needs of our clients 2 MACHINERY GROUP 2017 MACHINERY GROUP

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2 2 MACHINERY GROUP 207 MACHINERY GROUP CONTENTS : Dump Station Virtual Reality Remote Operation 5: Impact Test Facility Upgrade for Britax 6: Independent verification, optimization and review of wave and tidal energy devices 8: Specialist Engineering for Bucket-Wheel Machines 0: Re-assuring Wharf Vibration Safety Concerns 2: 2nd Generation Shovel Payload Monitoring System 4: Expanding Services to the Defence Industry 4: BMT WBM's John Pidgeon Scoops IMechE Awards 5: Future Leader Program Welcome Tailoring effective engineered solutions to meet the individual needs of our clients Welcome to our BMT WBM Machinery Magazine for 207. IMechE BMT WBM Machinery Group prides itself on our ability to solve complex technical problems. Our niche skills and specialist services make our company unique within the engineering consulting industry. Solutions provided to clients are conducted with the greatest attention to detail as we attempt to deliver definitive solutions of the highest quality. The following case studies provide a snap shot of current projects conducted by our staff. I hope you find this issue of interest. Please do not hesitate to us if your machinery needs demand customised solutions. Rob Angus, Operations Director, Machinery rob.angus@bmtwbm.com.au

3 4 MACHINERY GROUP 207 MACHINERY GROUP Dump Station Virtual Reality Remote Operation Impact Test Facility Upgrade for Britax In collaboration with Hay Point Coal Terminal, BMT WBM Automation has developed a novel means of assisting in the remote operation of a coal dump station. The system takes measurements from various sensors in the terminal and presents all aspects of the process in an intuitive, interactive virtual reality environment which is easy to interrogate. In the cluttered but long environment of a coal dump station, many cameras are needed to show the area in its entirety, meaning that a holistic view of operations is very difficult to obtain. The VR environment overcomes this limitation by removing unneeded visual aspects, such as obstructing walls, and provides a singlescreen overview from any perspective. One key aspect of this approach is that the flow of the coal is concurrently modelled using a Discrete Element Method (DEM) physics simulation. The ability to perform this kind of high fidelity material simulation in real-time was developed in-house for use on the dragline simulator project. The simulation takes account of the available measurements from overhead LiDAR scanners and integrates them into the DEM model, allowing the remote operators to have insights into the unloading process that were previously unobservable. Alistair Roe alistair.roe@bmtwbm.com.au BMT WBM has been commissioned by leading child car restraint manufacturer Britax to upgrade its impact sled test facility in Melbourne. This upgrade will enable Britax to continue testing its products to comply with the updated Australian Standard AS754:203, the Child Restraint Evaluation Program (CREP), and other international legislation. At the heart of the test facility is a rail-mounted impact sled carrying the child restraint and test dummy, which collides with a seismic block under observation by high-speed cameras. A full re-design of the existing impact sled was required to meet the additional requirements of AS754:203. Associated upgrades of the existing hydraulic and ancillary systems and integration with the existing facility structure were also required. Our Melbourne office personnel were able to use their expertise in machine design, finite element analysis (FEA), hydraulics, and detailed design engineering and drafting services to meet the challenges posed by a unique project. Work is ongoing with expected completion in 207. Hamish Woodcock hamish.woodcock@bmtwbm.com.au

4 6 MACHINERY GROUP 207 MACHINERY GROUP Independent Verification, Optimization and Review of Wave and Tidal Energy Devices Wave energy is generated by converting the energy of ocean waves (swells) into other forms such as electricity. Currently there are numerous technologies being developed and trialed. Tidal energy is generated from tidal movements. Tides contain both potential energy, related to the vertical fluctuations in sea level, and kinetic energy, related to the horizontal motion of the water. Consequently electricity can be produced through technologies using energy from the rise and fall of the tides or energy from tidal currents. BMT has extensive engineering design experience with both wave and tidal energy devices in Australia and internationally. Our experience includes: Engineering technical review (mechanical, structural, foundations, electrical) and Levelised Cost of Energy (LCOE) review at various stages of all major wave energy device developments in Australia over the past 6 years on behalf of the Australian Renewable Energy Agency (ARENA). Advanced analysis including Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) for a tidal current energy device. Bombora Wave Power mwavetm Device (image reproduced with permission) For instance, BMT has undertaken advanced analysis engineering for a tidal current device. This included CFD and FEA modelling to determine the stresses on the machine structure resulting from the applied loads due to power generation and the tidal current flows. As a result of the initial FEA analysis BMT were able to highlight several areas of high risk, and over a series of iterations the design was optimized to meet the client s performance requirements. Technical oversight of the mechanical and structural design for a wave energy device. Test and measurement services to trouble-shoot renewable energy projects. Technical support with regard to tidal current turbine performance and design calculations. Development of wave energy device performance software. Project risk assessment review at the concept stage of a wave energy device. Chris Shearer chris.shearer@bmtwbm.com.au Carnegie Clean Energy CET06 Array (image reproduced with permission)

5 8 MACHINERY GROUP 207 MACHINERY GROUP Specialist Engineering for Bucket-Wheel Machines Hazelwood Mine D Hazelwood Mine D25 Since 969, BMT WBM Machinery Group have provided engineering services associated with large bulk materials handling machinery such as stackers, reclaimers, shiploaders, conveyors and bucket-wheel machines. This case study will focus on recent engineering services provided to Hazelwood Mine s bucket-wheel excavator fleet. Hazelwood Mine in Victoria s Latrobe Valley operates a fleet of five crawler mounted bucketwheel excavators for coal and overburden mining. BMT WBM has continued our long-standing relationship with Hazelwood Mine, and has recently assisted in various projects and engineering services support including:. Stability of balanced machine: (a) During abnormal maintenance activities, (b) As a result of modifications to the machine, (c) Machine park up and decommissioning, 2. Specialist mechanical engineering services including: (a) Operating limits and load cells, (b) Hoist ram replacement, (c) Ball path wear, (d) Machine weighing advice, (e) Shaft material specification, testing, and metallurgical advice, 3. Specialist structural engineering services including: (a) Cracking of turntable structure, (b) Fire damaged steelwork, 4. Outage planning including: (a) Site engineering procedures, (b) Offloading and jacking procedures, (c) Detailed design checks, Our recent work at Hazelwood Mine is representative of our engineering capabilities for balanced bulk materials handling machinery. Recently we have also provided engineering services for Loy Yang Mine including bucketwheel design checks, machine stability checks, outage planning, site engineering secondment, walkway access modifications, and slew lock installation. We have also recently provided expertise for balanced machines at Mount Thorley Warkworth, Clermont, and Esperance Ports. Chris Shearer chris.shearer@bmtwbm.com.au

6 0 MACHINERY GROUP 207 MACHINERY GROUP 207 Re-assuring Wharf Vibration Safety Concerns To investigate the issue, BMT WBM personnel conducted a series of technical investigations to determine not only the root cause of the vibration but also the degree of impact that the vibration would have on the structural integrity of the wharf. Technical investigations included; On site vibration measurements; Identification of potential causes of vibration; Detailed structural assessment to verify the capacity of the wharf to support the loads & vibration imposed by the unloading equipment. The structural review showed that the wharf structure could safely withstand the additional loading and the likely cause of the vibration was identified with recommendations to minimise it. BMT engineering personnel visited the 200MW Tanjung Bin Power Station operated by Malakoff Power to investigate a vibration issue on the Coal Unloading Wharf. The Tanjung Bin Power Station coal unloading wharf originally supported two rail mounted continuous ship unloaders (CSU). As part of a proposed expansion to 300MW, a rail mounted grab unloader (GUL) was also installed on the wharf. Concerns were raised by site personnel who would observe significant transverse movement of the wharf at times during operation of the GUL. The concern was that the additional loading from the GUL exceeded the structural capacity of the wharf. Steve Saflekos steve.saflekos@bmtwbm.com.au

7 2 MACHINERY GROUP 207 MACHINERY GROUP nd Generation Shovel Payload Monitoring System BMT WBM has announced its latest development of the PULSETerraMetrixRS (PTMRS) system for managing the machine health, production and payload measurement on large rope shovels. Productivity improvements of 8-5% have been proven after deployment of the PTMRS system. A unique industry offering, the PTMRS system provides a real time dipper payload estimate during the swing cycle prior to dumping. Immediate and accurate dipper-by-dipper load indication to the shovel operator is required in order for the final dipper load to be trimmed to match the target load for the truck. Automatic dipper carry back measurement and compensation supports real time differential payload calculation an important feature for operations where the material can often stick to the dipper, for instance in the Canadian Oilsands. Charles Constancon, Director of BMT WBM Canada explains: Unlike other payload monitoring systems which are based on electrical parameter or structural model estimation techniques to approximate the payload, the PULSETerraMetrixRS system deploys a smart loadcell sensing device, directly measuring the inertial and dynamic loads applied to the dipper and the payload. As a result, high fidelity payload measurement is maintained, even under severe dynamic loading conditions. Configured to communicate with any third party truck dispatch system, the PULSETerraMetrixRS can be applied to both P&H and CAT rope shovels. The system is fully supported by comprehensive data base analytics and automatically generated SQL Server reporting. Recent advances include the definition of a robust diggability algorithm and efficiency reports mapping digging conditions on the mine plan. This provides feedback on the effectiveness of blast patterns in differing conditions within the mine, so that patterns can be optimized and blasting adjusted to suit those conditions, resulting in further cost savings. The second generation PULSETerraMetrixRS system deploys high accuracy shear pin loadcell technology in the equalizer of the P&H machines (for configurations with and without a bail) or in the reeving blocks of the CAT machines. This increased load resolution and ease of installation represents a significant advance in the already demonstrated PTMRS approach of direct load and inertial measurement. Charles Constancon continues: This second generation development maintains our strong focus on payload accuracy and integrity. With over ten years of sustained commitment, we are very proud to release this new version of the system which clearly demonstrates our innovative approach to product improvement. Additionally, on hydraulic excavator machines, we expect similar performance for our PTMEX product line using smart inertially compensated loadcell sensor technology. The PULSE TerraMetrix system was at CIM Mine Expo 206 in Vancouver. Charles Constancon was there along with other staff answering questions about PTM and explaining the advantages of shovel based payload monitoring. The group was also showing off their :7 scale rope shovel. The model is used for R&D of the PTM system. Further information is available at or Charles Constancon Charles.constancon@bmtwbm.com

8 4 MACHINERY GROUP 207 MACHINERY GROUP Expanding Services to the Defence Industry BMT WBM has a long history providing services into the Defence sector. BMT WBM has grown its wings over the last year by participating in several defence industry groups (SADIG, RPDE, AIDN, HunterNet) and events. This has given the group a higher profile and increased opportunities in defence. RPDE Membership On 4th November last year, BMT WBM was accepted as a member of Rapid Prototyping, Development and Evaluation Program (RPDE), org.au/ which will provide the John Pidgeon, a Graduate Engineer from BMT WBM has won the 206 Australian Speak Out for Engineering competition. Introduced by the IMechE, the competition is designed to help develop verbal and visual communication when explaining technical mechanical engineering related subjects. John delivered a presentation detailing the development of a computer model to simulate the dragline excavator during operation. Rob Angus, Operations Director, Machinery Group at BMT WBM comments: It s fantastic to see one of our very own graduate engineers being recognised not only for his technical capability, but for his ability to communicate in an engaging and effective way. benefit for BMT WBM to engage in the various tasks, Quicklooks, Quick Answers and opportunities. RPDE will become part of the Defence Innovation Hub supported by the Centre for Defence Industry Capability. During the RPDE Biannual Meeting of Participants on 22nd November, Rob Widders accepted the membership certificate from Ms Kate Lewis, First Assistant Secretary Defence Industry Policy and RPDE Board Chair with 8 other organisations adding to the 242 members. This is a great opportunity for BMT WBM to utilise and expand its capabilities in the defence space. BMT WBM s John Pidgeon Scoops IMechE Award In his winning presentation, John presented a holistic training solution for improving dragline efficiency, which he believes requires two components. John explains: Mine operators want to get as much out of their equipment as possible, without overly stressing critical components which in turn, could lead to increased downtime and premature failure. Therefore, it was important to develop a comprehensive training simulator that not only trained operators in the effective use of the machine, but also provided real time feedback on the stressing of key components. The simulator interfaces directly with our PULSE TerraMetrix system, which provides real time stress and productivity monitoring to operators on real SADIG Membership BMT WBM has become a member of SADIG (Sydney Aerospace and Defence Industry Group), sadig.org.au/ which has provided the company the opportunity to receive information and updates on defence activities, projects and events. The group meets regularly and provides an opportunity to participate in presentations and network with industry and defence in the greater Sydney area. machines. This allows trainees to gain familiarity with the system and effectually interpret its responses to help balance productivity and machine health. John Pidgeon john.pidgeon@bmtwbm.com.au Future Leader Program Richard Douchkov (left) congratulates Ian Stevenson Ian Stevenson (Newcastle mechatronic engineer) recently participated in a Future Leaders program run by Hunternet. This program is held each year where selected employees with high potential from local companies participate in a program where they develop innovative and practical solutions to address the theme of the year. This year, it involved developing an innovative approach to increasing the patronage of the Newcastle public transport system worthy of meeting the Smart City profile that is being portrayed. The presentation and Gala dinner was held 4//206. The dinner was attended by local business leaders (including Newcastle Team Leader Richard Douchkov) and politicians. Team Obelisk, the group that Ian participated in, was the overall winner. Well done Ian and congratulations on your efforts. This reflects extremely favourably on the reputation of BMT WBM and helps cement BMT WBM within the local business community.

9 BMT WBM has a proven record in addressing today s engineering and environmental issues. We aim to continue to enhance our services, capabilities and areas of application to meet the community s future development and environmental protection needs. 3 BMT WBM Brisbane Level Creek Street Brisbane Queensland 4000 PO Box 203 Spring Hill QLD 4004 Tel Fax bmtwbm@bmtwbm.com.au BMT WBM Denver Suite S. Akron Street Centennial Denver Colorado CO 802 United States Tel (+) Fax (+) denver@bmtwbm.com BMT WBM Melbourne Level 5 99 King Street Melbourne Victoria 3000 PO Box 604 Collins Street West VIC 8007 Tel Fax melbourne@bmtwbm.com.au BMT WBM Newcastle 26 Belford Street Broadmeadow New South Wales 2292 PO Box 266 Broadmeadow New South Wales 2292 Tel Fax newcastle@bmtwbm.com.au BMT WBM Northern Rivers Suite 6 20 Byron Street Bangalow New South Wales 2479 Tel Fax northern.rivers@bmtwbm.com.au BMT WBM Perth Level 4 20 Parkland Road Osborne Park WA 607 PO Box 027 Innaloo WA 608 Tel Fax perth@bmtwbm.com.au BMT WBM Sydney Suite G2 3-5 Smail Street Ultimo Sydney New South Wales 2007 Tel Fax sydney@bmtwbm.com.au BMT WBM United Kingdom st Floor International House St Katharine s Way London EW AY Tel +44 (0) london@bmtwbm.co.uk BMT WBM Vancouver 40-6 Alexander Street Vancouver British Columbia V6A E Canada Tel (+) Fax (+) vancouver@bmtwbm.com bmtwbm.com.au