Mining Case Study

Case Study 1- Counter Current (CCD) Thickener Gearbox Repair

Camco Engineering was contacted late on a Friday afternoon by a large Western Australian Nickel producer to assess the repair to one of the seven CCD Wash Thickeners onsite. Camco responded quickly with personnel dispatched at 6.00 am the following morning on a chartered flight to the facility.
Assessing the drive unit Camco staff found that the rake arm drive cage adapter bolts together with the main bearing bolts had sheared off. This catastrophic failure was caused through extreme slumping conditions on the rake arms. Access to the unit was complicated as wash thickeners have a column in the centre to support the gearbox and walkway bridge. Gearbox access required an inventive method of removing sections of the walkway bridge while supporting the bridge on the centre column. Craneage of the capacity required to remove the walkway bridge from its position is not available in the region and inadequate site access to the CCD Wash Thickeners dictates alternative lifting methods be employed.

Camco personnel determined it was practical and safe to remove components of the thickener bridge truss whilst supporting the bridge from the truss top chord members. Camco installed substantial scaffolding to support the 60t feed well with additional supports designed and fabricated to bear the weight of the 20t rake arms. Specialised lifting beams and needles were designed and fabricated to enable the simultaneous use of up to eight chain blocks.
On dismantling the drive unit it was found that all of the gear-bearing bolts had sheared. A new cage adapter and bearing was required, these were provided by Camco Engineering in conjunction with the Original Equipment Manufacturer (OEM).

Although the bearing was not serviceable, it was determined that the 2200mm ring gear was salvageable by drilling and tapping the bearing cage adaptor using specilised equipment designed to drill the (380bhn) gear.

Working in conjunction with the customer and the equipment manufacturer, Camco Engineering succeeded in executing a difficult and technically challenging task in a safe manner to ensure production was back to full capacity in the shortest possible time frame.

Mining Case Study

Case Study 2- Bogie Assembly Rebuild and Standardisation

Camco Engineering was engaged by a large multi site Pilbara operation to retrieve and rebuild site trailer bogie assemblies from a lay down area at an industrial location south of Perth. Once relocated back at our Canning Vale operations it was apparent that the task of rebuilding would present a number of unforeseen challenges.

The semi striped units were missing a large number of components and those existing were in extremely poor condition. Adding to the confusion it was found that some of the assemblies were a mismatch of components. Rebuild difficulties were exacerbated when the drawings provided by the client were actually obsolete and inconsistent with the mixed components provided.

In conjunction with the client and their site staff a rebuild strategy was establish to standardise bogie assembly. Camco provided new drawings that encompass bogie modifications and component design changes to suit application. Camco staff working in conjunction with the client modified and improved current designs to meet the harsh site requirements.

Some of the modifications included:

  • Wheel stud shoulder adjustment and nut size increase to form a more robust design
  • Wheel stud material change
  • Walking beam material uniformity
  • Axle beams uniformity
  • Urethane bushes in the main pivot trunion replaced with Aluminum Bronze bushes
  • The development of a scope of work including hold points during the rebuild.
  • Development of new drawings to standardize future rebuilds and material selection

Working as a partner with our client Camco Engineering supported the establishment of bogie standardisation, new material selection and drawing development to improve the equipment and ensure continuity and quality of future rebuilds.