Custom Continuous Tram Scaler for Mining Applications
A Saskatchewan potash mine contacted Rockford Engineering with the need to develop a machine to improve the scaling operations ahead–of and behind their miners.
Scaling is the required removal of loose material from the walls and roof of the drift to eliminate the hazard of it falling on personnel or equipment.
Problem
Previous scaling solutions using scoop tram buckets were problematic: they had limitations on articulation, overturned machines due to their narrow wheelbase, and caused safety concerns with scale falling near the operator canopy. Through consultation with the customer, it was believed a scoop chassis still offered the most versatility and was perhaps the best choice for a scaler platform.
Solution
Rockford proceeded to identify and mitigate all inherent risks associated with using a scoop tram for light-wall scaling with a custom scaling attachment in lieu of a bucket. An in-depth application review began considering stability, working envelope, falling scale, and ease of integration into the OEM control system. The attachment design was to incorporate five degrees of freedom: lift, tilt, lateral swing, rotate, and pivot. Extensive analysis of different loading scenarios and considerations for machine centre of gravity was key in validating usage of the scoop platform.
The result of the analysis and design process was an attachment equipped with:
- a replaceable pick for scaling,
- an articulating thumb joint for prying scale from the wall,
- a 270-degree slewing drive for accurate orientation of the pick against the walls and ceiling, and,
- lateral swing functionality for left or right wall accessibility.
The factory tilt and lift functionality of the scoop chassis served to satisfy the remaining degrees of freedom required for the design.
Tilt sensors for lateral stability were utilized for the operator to identify and react when the machine exceeded an acceptable level of lateral elevation.
Required modifications to the operating system of the scoop tram were also realized. A speed restriction was implemented to limit travel to 5 kph when the scoop is equipped with the scaling attachment. This reduces the potential of tipping by limiting the force at which the scoop can impact the wall. A boom lift height restriction was also employed during scaling operation to prevent excessive elevation of the boom. This provides added stability to the machine when scaling by keeping the equipment center of gravity low to the ground.
Hydraulic boom float functionality was implemented in the swing circuit to allow for the scaling attachment itself to absorb any perpendicular force to the wall during tram scaling. This drastically limited the tipping force from being imparted onto the scoop. The relief setpoint of the float is set well below the tipping threshold of the machine in its worst-case operating scenario. 
The Rockford scaler attachment is all controlled from a single operator joystick in the cab of the machine.
All procurement, fabrication, paint, and assembly of the attachment were managed directly by Rockford and factory acceptance testing was witnessed by the client and performed in Rockford’s assembly plant.
Work with Rockford
Rockford Engineers are well versed in industrial machine design with experience in both theoretical and practical designs. This mix of skill sets makes Rockford the perfect choice for all your machine design needs.
Our in-depth understanding of industrial machine design can be an asset in both greenfield and brownfield initiatives. Whether designing a new system for your specific application or analyzing an existing system for improvement and optimization, Rockford can help.
We cater to all industries in both mobile and plant environments – contact us today!
Natural Gas Process and Piping Design
A local client had a requirement to build a number of remote natural gas compression sites in a short period of time. They contacted Rockford Engineering to take existing designs, modularize them, and make them expandable to meet local compression demands. The client’s desire was for the design to focus on as much in-shop fabrication and assembly as possible in order to minimize installation time in the field.
Our Solution
We worked closely alongside our client to design the compressor station while ensuring compliance with all applicable codes and regulations. Using a combination of Cadworx for the piping models, and Autodesk Inventor for all other mechanical items, Rockford delivered a successful project.
A set of fabrication and instrumentation drawings were completed to ensure every assembly was plumbed in the same manner before arriving on-site. Using the 3D piping model, Rockford created spool drawings with special consideration for the tie-in connections in the field – these were then issued to the pipe fabrication shops. 
All piping skids were designed to be modular and accommodate any number of additional interconnected skids, which could be easily dropped onto existing pile caps and welded in place. In addition, the existing facility condition was surveyed to ensure a seamless fit with the items being expanded.
Rockford designed the piping to meet the requirements of either ASME B31.3 or CSA Z662 (whichever was applicable), ensuring that all pipe was completely inspected, x-rayed, and hydrostatically tested. Because the design allowed for the majority of this work to happen in-shop, our client realized substantial cost savings on this project.
The skids were also designed to have modular platforms, grating, handrails, and guardrails compliant with the requirements laid out by the National Building Code of Canada and Occupational Health and Safety. Platforms were designed to interconnect between the compressor buildings to allow the operators and maintenance personnel to walk along safely and access all valves and instrumentation air with ease.
Rockford prepared the layout for the cable tray runs and designed appropriate support stands. Expansion joints were specified to account for thermal expansion, and the cable tray was fully detailed with part numbers, cut lengths and assembly hardware. Similar to the skids and piping, the cable tray supports were designed to be fully fabricated in-shop and shipped to site for installation on piles – a design which included a threaded rod levelling connection at the base for ease of installation.
Previously, instrumentation was run in the field with the aid of only a Process and Instrumentation Diagram (P&ID); causing issues for our client such as plumbing being installed incorrectly, and necessary parts being missed altogether during procurement. These issues were further compounded by installations taking place in remote locations, so acquiring new fittings or parts short notice was problematic. To alleviate this, all valves, actuators, regulators, fittings, tubing, etc. were modelled by Rockford and represented in a 3D layout using Autodesk Inventor. This was further supported by a complete set of instrumentation assembly and installation drawings, which also conformed to ASME B31.3 or CSA Z662 as applicable.
Work with Rockford
Rockford Engineering has specific expertise in mechanical piping design, along with all required equipment supports, electrical tray supports, platforms, walkways, and guarding. Our engineers’ combination of knowledge of the pertinent codes and regulations, along with industry-standard manufacturing and installation processes, makes us a perfect candidate for projects of this nature.
Whether designing a new system for your specific application or modifying an existing system, Rockford can help.
We cater to all industries in both mobile and plant environments – contact us today!
Improving a Spiral Pipe Double Joining Facility
In 2015, a local large-diameter steel pipe producer contracted Rockford Engineering to assist them with the design and implementation of a new Double-Joining facility. Double-Joining is a process where spiral pipe offcuts are re-cut, bevelled, welded together, and inspected to form a saleable full-length product. Their current system did not have the capability to process the larger diameter and heavier wall product that would be produced.
The client elected to re-purpose an existing building on their current site that would house a combination of used equipment (purchased by the client), re-purposed equipment from their existing process, and new designs. Rockford’s scope of work was as follows:
- Evaluate and survey the existing buildings to determine available space, yard machine travel paths, crane way envelopes, and overall product flow.
- Evaluate and catalogue purchased equipment using existing drawings and felid sketching. Equipment such as conveyors, lifts/letdowns, skids, and indexers were obtained by the client from a decommissioned facility elsewhere.
- Analyze existing client process equipment to determine what could be used in the new layout. This included sorting through archive drawings and field sketching certain areas during periodic maintenance shutdowns.
- Design and prepare drawings for all new process and handling equipment that would be required to complement the purchased and existing equipment.
Our Solution
Purchased equipment was offloaded and staged at the client’s yard. Rockford field sketched and cross-referenced the existing drawings to ensure no discrepancies existed. All equipment was 3D modelled in Autodesk Inventor and was reviewed for both fit and function to determine what would or would not work in the new layout. An in-depth understanding of pipe handling and how different types of process equipment needed to fit together to work properly was key in determining what was practical and usable.
Rockford’s focus during the sketching of the client’s existing process equipment was on takeover points, operational envelope, and capacity limitations. A fundamental understanding of how pipe is bevelled, welded, handled, and inspected was crucial in evaluating the viable relocation of the client’s existing equipment. A costs benefit analysis was performed to determine if it was commercially profitable to relocate and repurpose the equipment, or to make new. Our experience in the tube and pipe industry allowed us to prepare high-level cost estimates regarding design, fabrication, and installation in order for the client to make informed and timely decisions.
Rockford was also tasked with performing a detailed cycle time analysis for the facility. Both new and existing hydraulic power units were to be considered and a completely new circuit design was required for the new layout. This included P&ID’s, line sizing, valve selection, and pipe transfer time estimates.
All equipment was pulled together in one master 3D model and presented to the client for feedback. A number of tweaks and iterations took place to ensure all client’s internal departments were satisfied with the product flow, area access, and safety (engineering, operations, maintenance).
All fabrication and installation were awarded to a local shop that Rockford often works closely with. We were able to work easily with them to ensure all designs were completed to spec. and that all equipment was installed as intended.
Work with Rockford
Rockford Engineering has specific expertise regarding mechanical and automation design in the pipe handling industry. Our engineers’ combination of both practical in-the-field experience and technical training makes us a perfect candidate for projects such as this.
Our in-depth understanding of how pipe is made and processed can be an asset in both greenfield and brownfield initiatives. Whether designing a new system for your specific application or analyzing an existing system for improvement and optimization, Rockford can help.
We cater to all industries in both mobile and plant environments – contact us today!
Pipe Handling & Inspection Automation
The team at Rockford Engineering brings knowledge and enthusiasm to every project, but local projects ramp up the enthusiasm which helps to deliver world-class solutions to our local industries. In 2013, we were given the opportunity to design and fabricate an automated pipe-handling facility in the heart of oil country Saskatchewan, Estevan. After the successful startup up and implementation, a second system was provided to CJ’s Grad Prairie facility in 2017.
Clayton Jahn, the owner of CJ-CSM Inspection Ltd. was worried about the implications of human error in regards to their pipe handling including safety concerns for workers and leaks once the product went into the field. He decided to reach out to Rockford Engineering Works Ltd. to see if it was possible to create an automated system that would increase efficiency, be more reliable, and offer employees a safer work environment. The result was an automated pipe handling and inspection facility.
From the initial napkin sketch, through fabrication, testing, and installation, Rockford worked together with CJ-CSM to help create a safer, more efficient facility, with all of the facility’s sorting and cataloguing of pipe being performed by one operator safely behind a touch screen monitor.
Key Features of the Facility
- The facility is operated through a programmable logic control system (PLC)
- From a touch screen station, the automated inspections allow the facility to sort and catalogue all pipe into appropriate batches
- Five building exits allow for sorting and storage of pipe for future processing
- All equipment was designed to be modular for quick installation and easy replacement of wear items such as v-rolls and transfer blades.
- The system was pre-wired and completely shop-tested with the actual product prior to shipping.
- Installation and start-up of the system was fully supported on-site by Rockford engineers and technical resources.
See All the Project Images
Rockford continued to stay in touch with the client not only to ensure the system operated properly but to receive feedback for further improvements. We take pride in working with our clients and believe this is an important part of our process.
“By working with a local engineering firm here in Saskatchewan, we benefitted from the drive and teamwork to do something totally different and many times better.”
– Clayton Jahn (SIMSA, Chain Reaction: A Series of Case Studies on Saskatchewan’s Industrial and Mining Supply Chain)
See the Project
Read the SIMSA Interview
Work with Rockford
Rockford Engineering has specific expertise regarding mechanical and automation design in the pipe handling industry. Our engineers’ combination of both practical in-the-field experience and technical training makes us a perfect candidate for projects such as this.
Our in-depth understanding of how pipe is made and processed can be an asset in both greenfield and brownfield initiatives. Whether designing a new system for your specific application or analyzing an existing system for improvement and optimization, Rockford can help.
We cater to all industries in both mobile and plant environments – contact us today!
Compactor Redesign for Mining Applications
Rockford Engineering works closely with clients in the mining industry. One such client approached us with an issue regarding their hydraulic compactors which compress the mineral fines into sheets for further processing. Rockford designed and tested a solution at their Regina location, then delivered the units to the client’s site. The goal was to introduce an automated system focusing on increasing reliability, improving maintainability, and achieving a tighter, more accurate control of the operating pressure.
The Problem
Each compactor has (2) two rolls -one fixed and one floating. The floating roll has (2) two hydraulic cylinders that exert a force to compress the product as it passes between the rolls. Two different systems currently provide hydraulic pressure to the system, however, there are known reliability issues and relatively poor control of the operating pressure.
Existing System 1:
A pneumatically driven hydraulic pump is used to generate cylinder pressure –this allows compressed air to produce high-pressure hydraulic fluid. The hydraulic pressure is adjusted by setting a conventional knob-style pneumatic pressure regulator. There are also hydraulic relief valves and accumulators that protect the system in case of over-pressure spikes created from lumps of debris passing between the rolls.
Existing System 2:
An electric fixed displacement pump, submerged in a reservoir, is used to generate cylinder pressure. There are (2) two solenoid valves in the system – one functions as an orifice to bleed downstream pressure and the other functions as a dump valve which allows the system pressure to be rapidly lowered. A combination of both is used to control the system pressure. There is also a kick-down relief valve located near the cylinders to protect the system in the case of a significant overpressure condition.
The client approached Rockford Engineering to develop a practical solution that would accomplish the following:
- Allow the pressure set-point to be maintained within a predictable and repeatable tolerance and be adjusted by the PLC control system.
- Address the maintenance issue of increased wear on the electric motor and starter components caused by frequent motor starts.
- Generate minimal heat, as the ambient conditions can be quite hot and reliable heat rejection is difficult in a potash mill environment.
- Allow the system to reduce the pressure when no product is present, referred to as “park pressure”.
- Develop a hydraulic system that is suitable in a mill environment in regards to cleanliness, maintainability, and ruggedness.
The Solution
For this solution, we considered the benefits of each existing system and coupled that with the latest technology in order to provide a practical solution. The high points of the new system design are as follows:
- Utilize the same pneumatic-over-hydraulic pumps due to their ability to maintain a constant pressure without generating heat.
- Incorporate an additional proportional pressure reducing / relieving valve with an integral pressure transducer to allow the downstream pressure to the compactor cylinders to be set from the PLC. The closed-loop PID operation allows for extremely accurate performance.
- Two additional accumulators will be added and set at a higher pre-charge pressure which will minimize pressure fluctuations during cylinder movement.
- A pressure filter would be located downstream of the hydraulic pump to protect the system against contaminants. The filter has a pressure switch so that a plugged filter condition will be visible in the PLC control system.
- A particulate and coalescing filter on the compressed air supply to protect the pneumatic-over-hydraulic pump will be added. These both have pressure switches to detect a plugged filter condition in the PLC control system.
- Incorporate a kick-down relief valve on the pump side to protect the circuit from over-pressure conditions. There is also a lockable ball valve to allow for maintenance operations and manual pull valves to bleed the pressure down.
- Add oil level and temperature monitors to detect low oil level or high-temperature conditions in the PLC control system.
Rockford worked closely with the client thought the design process, obtaining the concept and design approvals at key stages of the project life cycle. Final design & detailed production drawings were completed including general arrangements, detailed schematics, and weldments.
Eight units were completed and tested at Rockford’s facility in Regina.
Representatives from the client company were present during the factory acceptance testing and provided excellent feedback on the testing parameters, their expectations, and provided sign off prior to shipment.
The first unit has been put into production and the client is very pleased with the performance. It has allowed for a significant increase in stability and steady control of the operating pressure. The new system maintains the pressure within a tolerance approximately 20 times tighter than the previous system.
Work with Rockford
Rockford Engineering has specific expertise regarding custom hydraulic system design. Our engineers’ combination of both practical in-the-field experience and high-level hydraulics training makes us a perfect candidate for projects such as this.
Our in-depth understanding of complex hydraulic systems can be an asset in both greenfield and brownfield initiatives. Whether designing a new system for your specific application or analyzing an existing system for improvement and optimization, Rockford can help.
We cater to all industries in both mobile and plant environments – contact us today!
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