Projects
Example 1:
PUMP AND BEARING HOUSING REDESIGN:
Original Equipment pumps (5 units) were corroding internally and externally. Madco replaced the cast pump housing with one fabricated from 904L stainless steel sheet. Internal shafting was replaced with 2205 Stainless steel. The bearing housing was replaced with a fabricated unit. Mechanical seals replaced the previous stuffing box. The Madco units are now running with very satisfactory performance and no corrosion. SolidWorks was valuable in helping check the design and providing cut plate shapes for laser cutting.
Example 2:
DAMPER VALVE 1400 DIAMETER:
Madco designed a unit with outrigger bearings to keep process heat away from bearings. The extended barrel facilitated installation into pipe work.
SolidWorks facilitated design and manufacture. Laser cut plates simplify boilermaker’s job and improve accuracy of product.
Example 3:
DAMPER VALVE 2250 DIAMETER:
This was an urgent job. Material ordered in one week from start of design. Material had to be cut from what was left available in the only plate in the country. (See plate nesting below).
The design was complete in 2 weeks.
The valve was delivered in less than 5 weeks from start of job.
Example 4:
COVER FOR PUMP:
Original equipment pump housing was developing cracks and was subject to corrosion from hypersaline mine water.
Madco redesigned the cover using FEA package COSMOS DESIGNER (a SW product) to identify high stress areas.
Madco procured castings to the Madco design from overseas foundry and machined the castings at Henderson for the client.
Example 5:
VACUUM LOADER UNIT FOR ALPHABLAST (a sister company of Madco in the Orontide Group):
Madco designed and built this unit to work with Alphablast’s ultra high pressure water blasting equipment. The unit draws up water and paint and rust debris and collects it in the vacuum vessel. A diesel engine drives a Rootes-type blower. Silencers reduce blower noise to acceptable levels. Solid Works facilitated design and fitment of all components into a compact package. Engineering design calculations of the pressure vessel, isolation mounting and cyclone separator were all done by Madco staff.
Example 6
SCREW CLASSIFIER LOWER BEARING:
Madco designed this unit based on experience with similar units that Madco had repaired and redesigned in the past. This unit operates under abrasive slurry. Special seals are used to exclude dirt from the housing. SolidWorks facilitates preparation of high quality drawings from the 3D models.
Example 7:
PUG MILL BODY:
Madco was asked to rebuild and modify the existing body to incorporate customer’s changed requirements. SolidWorks facilitated cutting of all plates and enabled the customer to readily see and approve the new design. Modified doors were added. Full records of all changes could be provided to the customer.
Example 8:
DRYER HOUSING:
All stainless steel construction replaced clad mild steel structure which corrode from the outside. FEA was performed to check stresses under vibratory loading. SolidWorks enabled check of design and facilitated laser cutting of all plates. Boilermaker’s task was simplified and accelerated by provision of pre-cut plates.
