CHEMICAL METERING SKID

PROJECT PROPOSAL
MECH5552 Mechanical Engineering Design 2
Due Friday 19thAugust 2016 6pm

Matthew Bee
Mark Hawkins
Angela Heng
Elliot Stokes

21135655
21111289
20951059
20815414

Tutorial: Wednesday 12:00 - 2:00 pm

Tutor: Chris Sayer

School of Mechanical and Chemical Engineering

The University of Western Australia
Table of Contents
LIST OF ACRONYMS............................................................................................ 1

PROPOSAL......................................................................................................... 1
1. WHY CHOOSE SES?.........................................................................................1
1.1
1.2
1.3
1.4
1.5

TEAM CAPABILITIES......................................................................................................... 1
TEAM LIMITATIONS.......................................................................................................... 2
IN-HOUSE TECHNICAL CAPABILITIES.................................................................................2
ACCESS TO TEST EQUIPMENT AND RELEVANT FACILITIES...................................................2
ACCESS TO RELEVANT EXPERTISE.....................................................................................3

2. ASSUMPTIONS............................................................................................... 4
2.1 TABLE OF ASSUMPTIONS................................................................................................. 4
2.2 LIMITATIONS AND EXCLUSIONS......................................................................................... 5
3. PROJECT TEAM............................................................................................... 5
4. RELEVANT EXPERIENCE...................................................................................6
5. CLIENT REQUIREMENTS..................................................................................8
6. RISK-BASED DESIGN PROJECT MANAGEMENT PLAN...........................................9
6.1 PROCEDURE FOR GENERATING THE RISK REGISTER...........................................................9
6.2 CONTROL MEASURES INCORPORATED INTO PROJECT PLAN...............................................10
6.3 REPORTING ON DESIGN PROJECT RISKS AS DELIVERABLES..............................................10
7. PHASE 1 DIRECTION DEVELOPMENT...............................................................11
7.1 STAGE 1 PROJECT INVESTIGATION AND PLANNING........................................................11
7.2 STAGE 2 RESEARCH AND CONCEPT DEVELOPMENT.......................................................12
7.3 STAGE 3 FINAL COMPONENT DEVELOPMENT................................................................13
7.4 STAGE 4 ASSEMBLY PLAN AND TECHNICAL DRAWINGS..................................................14
7.5 FINAL DESIGN SUBMISSION........................................................................................... 14
7.6 STAGE 5 - ASSEMBLY OF COMPONENTS, ENGINEERING VERIFICATION AND PRODUCT
DOCUMENTATION................................................................................................................. 15
7.7 STAGE 6 DELIVERY, INSTALLATION, COMMISSIONING AND FINAL HANDOVER..................16
7.8 GENERAL EXCLUSIONS................................................................................................... 16
7.9 PROJECT COST SUMMARY..............................................................................................17
8. BENEFITS, LIMITATIONS AND COMMERCIAL VALUE OF THE DESIGN STUDY.......18
9. REFERENCES................................................................................................ 19
10. APPENDIX A SKID SIZE AND COST CALCULATIONS......................................20
11. APPENDIX B QUALITY FUNCTION DEPLOYMENT..........................................21
12. APPENDIX C RISK REGISTER......................................................................22
13. APPENDIX D PROJECT GANTT CHART..........................................................23
14. APPENDIX E SCOPE CONTROL DOCUMENT..................................................24

List of Acronyms
PAX
QFD
SES
UWA

Potassium amyl xanthate

Quality function deployment
Student Engineering Solutions
University of Western Australia

Proposal
This proposal outlines the work required for the design of a chemical
metering skid for use in a medium-sized mineral processing plant, as
detailed in the project briefing document (Trevelyan, 2016).

1. Why choose SES?

SES is committed to providing high quality engineering designs, tailored to
the individual needs of clients. Along with SES broad engineering knowledge
and design capabilities, the team have significant research skills and a desire
to learn from all new projects and activities undertaken. Due to affiliations
with The University of Western Australia (UWA), the team at SES have access
to a wealth of expertise and resources.

1.1 Team Capabilities

SES possess the skills necessary to get the job done right, on time and to the
pre-specified cost. The skills that SES can bring to this design project include:
Dedication to the project SES is committed to providing you with the
best solution possible.
Creativity This will ensure all possible failure modes are considered and
mitigated against. You will also receive a unique product that is safe to
operate, robust, fully certified in accordance with Australian Standards and
performs as specified.
Software experience Microsoft Excel, Word, PowerPoint, MATLAB,
Wolfram Mathematica and finite element software including Abaqus.
Engineering science Excellent understanding of technical engineering
requirements and calculations.
Organisation SES pride themselves on organisational skills to ensure the
mitigation of lag and scope creep to ensure timely delivery of the project.

Excellent report writing Collectively, team SES has a wealth of

experience in writing reports in an academic context. Communication is
essential and all of the necessary information will be conveyed in a concise
and logical manner.
Drawing skills The team at SES have excellent technical drawing skills.
Research ability The necessary research for a successful design will be
done efficiently and effectively.

1.2 Team Limitations

Despite the broad range of skills SES can offer, SES acknowledges there are
a select few skills that the team does not have. These include:

Limited experience in using software for computer-aided design.

SolidWorks is the only program that has been used. All engineering
drawings will therefore be performed by hand.
Limited experience in engineering design.

1.3 In-House Technical Capabilities

SES have the following in-house technical capabilities and access to
engineering software for relevant analysis and design:

Static and dynamic analysis

Fluid flow analysis
Stress analysis
Fatigue analysis
Control systems analysis
Finite Element Analysis software (Abaqus)
Computer-Aided Design software (SolidWorks)
Mathematical computing and control systems software (MATLAB)
Symbolic mathematical computing software (Mathematica)
Spreadsheet program (Microsoft Excel)
Gantt chart program (SmartSheet)

1.4 Access to Test Equipment and Relevant Facilities

Additionally, SES has access to the following in-house test equipment,
prototyping capacity and laboratory facilities:

Instron mechanical testing machine

MIG, TIG, stick and spot welders

Lathe
Drill press
Milling machine
CNC machine
Fluid mechanics laboratory
Centre for Water Research at UWA
3D printing facilities

1.5 Access to Relevant Expertise

SES is also able to obtain advice from the following experts, consultants and
specialists when required:

Chris Sayer, a senior engineer, who has decades of industry experience

in mechanical engineering design.
Dr. Andrew Guzzomi, an experienced mechanical design engineer,
whos research interests are in agricultural engineering and applying
kinematics, dynamics, vibration and mechanical design skills to that
field.
Dr. Adam Wittek, an experienced user of Finite Element Analysis
software such as Abaqus.
Dr. Melinda Hodkiewicz, a BHP Billiton research fellow and UWA lecturer
with industry experience in risk, reliability and safety.
Lab technicians available at UWA engineering workshop.
Dioxide Pacific, a multi-disciplinary engineering company specialising
in the design, supply and installation of chemical dosing, water
treatment and water disinfection systems.
Weiyun, a manufacturer of chemical dosing skids based in Chongqing,
China.

2. Assumptions
2.1 Table of Assumptions
Table 1 - Assumptions

Referen
ce
A1
A2

A3
A4
A5
A6

A7

A8

A9
A10
A11
A12

A13
A14
A15
A16
A17

Assumptions
The PAX powder is delivered in bags of 1000 kg and pierced open (SNF
Flomin, 2013)
The skid will need to be able to accommodate the intake of powdered
PAX (Trevelyan, L 2016). Based on this it is interpreted that the scope
of the project begins at the intake of PAX where the bags are first
pierced. Handling and transportation of PAX prior to the opening of
delivered bags will not be considered.
The project scope ends at the flange connecting the metering skid to
the inlet of a flotation separation reactor tank.
Mixing and storage of the PAX will take place on the skid itself.
From preliminary research, SES found that PAX is most commonly used
for copper sulphide froth flotation separation.
Only one skid is necessary for the processing plant. The skid has a
single outlet for feeding all reactor cells at the plant. That is, each
reactor cell would receive the same concentration of PAX.
The skid must have functionality to vary the concentration at the
outlet, which will be controlled through an integrated feedback loop
within the existing processing plant.
Based on the images of the scoping document provided, and assuming
ample overhead clearance, the dimensions of the workspace required
for the skid are approximately 5 m x 3.5 m x 7.5 m.
The lifting system of the bags containing PAX power is outside the
scope of this project.
Fresh water will be available for connection to the skid. The filtering of
plant water will not be considered as part of the scope of this project.
The quality assurance of the provided PAX powder is outside the scope
of this project.
The client has not stated where the skid will be located. It is assumed
that it will be placed at ground level in a dry and arid environment,
sheltered from direct rain water (typical ground floor of a mineral
processing plant). The maximum ambient temperature range is
assumed to be 10 45 C.
Transportation of the skid is by means of overhead lifting.
Ample room and the appropriate lifting equipment are in place to
position the skid into its designated workspace.
The quantity of PAX used per tonne of ore is accurate to 1 g.
The mineral processing plant will be in constant operation such that
PAX powder and PAX solution will be stored no longer than 30 days.
Based on initial calculations for the skid size, the output flowrate of the
required skid would be 7240 L/hr and corresponds to an approximate

A18
A19

cost of $AUD 48 000 for the skid (Alibaba, 2016). See Appendix A for
the supporting calculations and related assumptions.
SES hourly charge out rate is $170/ hour (including consultation and
commissioning). SES work 8 hours a day, 5 days a week.
A medium-sized mineral processing plant consists of 10 reactor cells
(Metso, 2015)

2.2 Limitations and Exclusions

The main exclusion from the provided scoping document is the size and
specifications of a medium-sized mineral processing plant. SES have had to
make assumptions as to what ore and the amount of ore to be treated and
the flow rate of water to provide. To ensure scalability of the solution, all
calculations will be performed in an Excel spreadsheet such that the solution
can be scaled up or down to accommodate the clients requirements.
The client has not specified the location of the skid or size constraints of the
existing plant facility. As such SES have proceeded on the assumption that
the limitation on the size of the skid is 5 m x 3.5 m x 7.5 m and will be affected
by transportability. Altering the size of the skid will be a simple task through
Excel calculations once any relevant data from the client is received. The
handling and transportation of PAX prior to it entering the skid has been
excluded from the scope. The provision of a fresh water supply and the
quality assurance for the purchased PAX are also excluded from the scope of
this project.

3. Project Team
Matthew Bee - Client Liaison
Master of Professional Engineering Mechanical Specialisation
Bachelor of Science, Majoring in Engineering Science
Mark Hawkins - Secretary
Master of Professional Engineering Mechanical Specialisation
Bachelor of Science, Majoring in Engineering Science and Physics
Angela Heng - Planner
Master of Professional Engineering Mechanical Specialisation
Bachelor of Science, Majoring in Engineering Science and Economics
Bachelor of Law
Elliot Stokes - Coordinator

Master of Professional Engineering Mechanical Specialisation

Bachelor of Science, Majoring in Engineering Science and Management

4. Relevant Experience
Matthew Bee
I have significant engineering work experience in both mining and refining
environments through a total of 6 months working for Alcoa of Australia in
WA. Particular experience and knowledge of refinery operations, procedures
and equipment was gained through this work experience, which was heavily
involved in Calciner plants. Along with the experience in writing work
methodologies, designing equipment upgrades and conducting Confined
Space Entry vessel inspections, I also had practice in the use of Australian
Standards and interpreting engineering drawings. I also have extensive
hands on experience (i.e. use of power tools and manual labour) and
practical construction knowledge, gained through part time work over 5
years in the construction industry in Perth and regional WA.

Mark Hawkins
I have previously designed a plate flipping mechanism in a design course at
UWA. From this I have gained experience in preparing Excel spreadsheets to
perform necessary calculations based on fundamental engineering science
principles. I have had a lot of practice in preparing engineering technical
drawings by hand. Additionally, I have designed a pressure vessel in a course
at UWA in a design team, which involved the use of many Australian
Standards. From this project I gained experience in interpreting,
understanding and applying standards to facilitate design. I have a solid
understanding of the fundamental principles of engineering science, and am
eager to apply this knowledge in the context of mechanical engineering
design. I have been using MATLAB, a mathematical computing software
package, for a number of years to solve an array of problems in engineering
and physics. This program can be of great benefit in design projects due to
its efficiency in numerical computation.

Angela Heng
Engineering work experience in liquefied natural gas and marine operations
through working with Woodside Energy Limited over the summer holidays.
6

Particular experience in negotiation of contracts, reviewing tender

documentation, procurement of goods and services and drafting of scoping
documents. Over the past 4 years I have gained experience understanding
technical documents and searching through patent databases from working
at an intellectual property firm. Through my university studies I have been
exposed a numerous design projects including pressure vessel design,
designing a shaft for a planetary gear box, designing a plate turner and the
construction of the Bassendean train station carpark. I have gained
experience in understanding and interpreting Australian Standards,
modelling using ANSYS and technical drawings.
Elliot Stokes
While at UWA I have been involved in a number of projects including design
of a large pressure vessel, design of a gear shaft for a planetary gear box,
and design of a machine to flip a large sheet of steel. These projects gave
me experience in technical calculation, writing scoping documents,
interpreting design standards and technical hand-drawing. I have also had
work experience in mechanical contracting for the commercial building
industry, with particular emphasis on HVAC; my time there taught me how to
interpret technical drawings from engineering consultants and architects. I
also gained additional experience in reading scoping documents and
standards, and how to create tenders. I am currently employed at a
mechanical engineering consultancy firm where I have gained experience in
client liaison, 3D modelling, technical drawing, writing specifications based
off AS/NZ standards, and sustainable design. I regularly use excel and
Bluebeam as my primary software for calculations and engineering design.

5. Client Requirements
Below is a table containing the client requirements and their associated
importance weightings that team SES have designated. These have been
included in the QFD analysis provided in Appendix B. These client
requirements have helped develop the objectives of this design study by
means of the QFD analysis.
Table 2 Customer requirements cross-checking table

Customer Requirements

Importan
ce
Weight
Factor

Safe handling of PAX in form

provided

Delivery of aqueous PAX solution

Fits into existing plant

infrastructure (spatial constraints)
Self-contained with pumps and
appropriate instrumentation
Includes adequate safety features
Capacity for medium sized
mineral processing plant
Accurate flow metering of PAX
solution
Can withstand existing
environmental conditions

Client
Approv
al
(yes/n
o)

Client Comments
(if applicable)

5
5
5
5
4
4

Easily transportable

Contains internal catchment pan

Materials in skid must not

degrade

Cost Effective

Allow for variable output of PAX

Allow for variable input of water

Allow for variable input of PAX

Ease of maintenance

Skid, components and mountings

are structurally sound

Aesthetically pleasing

Double-walled containment vessel

6. Risk-based Design Project Management Plan

The major design uncertainty factors and risks for this project have been
identified in a risk register similar to the template provided by (Trevelyan,
2016), but with a clear separation of the technical design risks and project
management risks (see Appendix C). The aim of creating this risk register
was to identify any potential hazards or threats involved with the design
project and quantify them with risk ratings. Then upon understanding the risk
ratings, controls can be considered to reduce the consequence and likelihood
of the event to reduce its risk rating to an acceptable level.

6.1 Procedure for Generating the Risk Register

To create this risk register, SES used the following procedure:
Step 1: Identify a design task or activity which could involve a hazard,
event, threats or opportunity which could negatively affect the project.
Step 2: Describe each event and its foreseeable consequences.
Step 3: Referring to the Consequences Table (Trevelyan, 2016), assign the
threats the appropriate consequence ratings from 1 (Insignificant) to 5
(Catastrophic).
Step 4: Use the best engineering judgment of the SES team to assign the
hazards/threats the appropriate likelihood ratings from A (Highly likely) to D
(Remotely likely), see Figure 1.
Step 5: Using the Risk Rating Matrix (Trevelyan, 2016), shown in Figure 1,
the Risk Ratings can be identified for the associated Likelihood and
Consequence Ratings. Risk ratings can be L (low risk), M (medium risk), H
(high risk) or E (extreme risk).
Step 6: Using creativity, engineering judgment and other resources identify
Consequence Modification Controls, to reduce the severity of the events if it

were to happen, and Likelihood Modification Controls, to reduce the

likelihood of the events occurring.
Step 7: Reassess the new After Treatment Consequence rating, likelihood
rating and the corresponding risk of the events.
Step 8: Assign a Team member to be responsible for the implementation of
the Risk Control which has just been identified and specify the documents to
be implemented and the required implementation date.
Step 9: Repeat steps 1 8 for all possible Technical Design tasks and Project
Management tasks for which the team can reasonably foresee to contain
risks.
All risks and events in the risk register were identified by the SES team by
brainstorming and careful review of the scoping document.

Figure
Risk

Consequence/

1:

2:

Likelihood

Minor

Small

A: Highly likely
B: Moderate
C: Unlikely
D: Remote possibility

L
L
L
L

M
L
L
L

3:
Mediu
m
H
M
L
L

4:
Large
E
H
M
L

5:
Extre
me
E
E
H
M

2rating

matrix (Trevelyan, 2016)

6.2 Control Measures Incorporated into Project Plan

This risk register was also then most importantly incorporated into the
project plan as much as possible. This is especially the case for particular risk
control measures which were reoccurring throughout the risk register and
also some of the tasks/events with risk ratings of E or H. Some key examples
of these controls which have been included in the project plan/timeline
include:
Contact client early to discuss scope of project This was a likelihood
control for several tasks/events especially those which are related to the SES
team having to make assumption and having lack of understanding. By
contacting the client early on in the project will allow the correct assumptions
and information to be obtained. Contacting and liaising with the client has
been made a priority in the project plan and starts soon after the submission
on this proposal, see Appendix D for the project Gantt chart.
Scope change/creep register - Keeping track of any scope creep or scope
changes in an official way such as a scope change or creep register is
important to ensure the project stays on task and can help identify possible
ways to minimise the effects of the scope creep (see Appendix E). Allowing

10

time to develop a scope change register has been incorporated in the project
plan along with an allowance for potential scope creep has been made by
planning a buffer week for the project (see Appendix D for the project Gantt
chart).
Reviewing of designs - Ensure designs are reviewed by other members
and/or client to identify poor designs early. This has been incorporated in
multiple stages of the project timeline especially with regards to the final
design report submission where SES has allowed 5 days for proof reading.

6.3 Reporting on Design Project Risks as Deliverables

The design risks for this project have been incorporated as part of the project
deliverables through the use of the aforementioned Risk Register. The Risk
Register will be specified as a key deliverable to the client during all stages
of the design project. This is to ensure that SES captures any changes to the
design risks throughout the project and they will be effectively
communicated to the client as the changes occur. Having the Risk Register
regularly updated by SES and reviewed with the client throughout the
project, rather than submitted only at the end of the project, will guarantee
that SES and the client are aligned in their understanding of the design risks
and help both parties effectively control the risks.

7. Phase 1 Direction Development

The QFD given in Appendix B highlights the requirements of the client. It is
the purpose of the stages given below to break down the design tasks over a
specified time range. This time range is shown in the form of a Gantt chart
provided in Appendix D. It is the intention of SES to provide full clarity so that
the client can identify any short falls early in the design process. It is hoped,
from the QFD, that the major interests of the client are addressed below.

7.1 Stage 1 Project Investigation and Planning

Key Tasks
1. SES to make initial contact with the client. Ensure the Risk Register is
reviewed and approved by client.
2. SES to review relevant documentation as supplied by the client.
To include:
-

Performance requirements
The size of the processing plant that the skid will operate in

11

- The expected climate conditions the skid will operate in

- The limitations with regard to the dimensions of the skid
- How the skid will be transported
- The type of surface the skid will be placed on
3. If any of the above information is unable to be found then assumptions
will need to be made and agreed upon by both parties involved.
4. SES to create a scope creep/scope change register.
5. Review all relevant documentation and bring forward any assumptions
made so as to allow for the development of a comprehensive project
scoping document.
To include:
-

Initial information as supplied by the client as well as any

mutually agreed assumptions.
Required performance, dimensions, layout of skid and how the
skid will be transported (provided by the client).
The hazards associated with the environmental working
conditions of the skid (PAX reactivity).
The health and safety, and environmental risks associated with
PAX.
Safety of design for operator and environment.
Adaptability of design and known limitations.
Initial research of components and patents.

Proposed Labor Cost:

Estimated Time to Complete:
confirmation.

$6,800
1 week from award of written

Objectives:

Collect all relevant document so as to

develop an initial project plan. Agree on
assumptions
where
there
is
no
documentation. Determine performance
criteria and required dimensions of the
skid. Agree on an initial schedule.

Deliverables:

Project Gantt chart, summarized meeting

minutes, design overview document.

Outcome:

Schedules and assumptions clearly

defined before initiation of concept
design.

12

7.2 Stage 2 Research and Concept Development

Key Tasks
1. Initial engineering calculations used to determine flow rates and
concentration of PAX solution using documentation and assumptions
agreed upon in stage 1.
2. 2. Research patents and available off-the-shelf options for components
and materials for the required duty.
3. Concept brainstorm.
To include:
-

Initial design including number of pumps required, pump sizing,

pipe dimensions and the size of the tank for the PAX solution.
Selection of acceptable materials.
Key performance criteria.
Safety features required due to the toxicity of PAX.
The need for back-up systems in case of safety breach or
maintenance requirements.
Manufacturing and assembly options.
Environmental impact and sustainability analysis.
User functionality.
Integration of current business functionality.
Research
available
off-the-shelf
control
units/electronic
components.
Mobility requirements (how the skid will be transported) as
discussed with the client during stage 1.
Develop candidate solutions for each design component.

4. Contact client for concept and risk register review and feedback.

Proposed Labor Cost:

Estimated Time to Complete:
confirmation.

$23,800
3.5 weeks from receipt of written

Objectives:

To create a concept design of the skid

that is ready to be presented for review
and feedback to the client.

Deliverables:

Report development of ideas to the client

and required components and materials.

Outcome:

The client feedback will be used to

decide on the concept ideas, any

13

changes
to
documented.

the

scope

will

be

7.3 Stage 3 Final Component Development

Key Tasks
1. Develop component selection criteria.
2. Design layout engineered to be within dimension restraints or as
otherwise agreed upon by the client. Considerations will be given
to user functionality and aesthetics.
3. Transportation requirements confirmed with the client and base
frame designed around current skid design.
4. Concept ideas and risk register to be signed off by the client.
5. Fluid flow, stress and pressure analyses will be carried out for
solution flow. Thermal analysis carried out for PAX reactivity with
on-site conditions.
6. Bill of materials prepared for review by the client.
7. Present review documents for feedback from the client.

Proposed Labor Cost:

$13,600

Estimated Time to Complete:

confirmation.

2 weeks from receipt of written

Objectives:

Develop a final concept design and

relevant analyses.

Deliverables:

Bill of materials. Fluid flow, stress,

pressure and thermal analyses. Risk
register and performance expectations.

Outcome:

Finalization of design concept.

7.4 Stage 4 Assembly Plan and Technical Drawings

Key Tasks
1. Liaise with the electronics and control unit suppliers for commissioning
of the skid under the conditions as documented in the project scope.
2. Complete technical drawings.
This includes:
-

Individual component drawings

14

Assembly drawing
Assembly sequence drawing
Isometric drawing

Proposed Labor Cost:

$17,000

Estimated Time to Complete:

confirmation.

2.5 weeks from receipt of written

Objectives:

Complete technical drawings and

develop assembly plan.

Deliverables:

Quotation for commissioning

supplied to the client.

Outcome:

Completed technical drawings.

to

be

7.5 Final Design Submission

Key Tasks
1. Completion of design report.
2. Submit all project deliverables.
3. Client review of deliverables.
Proposed Labor Cost:
Estimated Time to Complete:
confirmation.
Objectives:
Deliverables:
Outcome:
satisfied client.

$10,200
1.5 weeks from receipt of written
Complete report and submit to client.
Obtain client feedback on deliverables.
Final design report.
Completed

design

phase

and

highly

7.6 Stage 5 - Assembly of Components, Engineering

Verification and Product Documentation
Key Tasks
1. Adjustment of design based on feedback from client.
2. Sign off the bill of materials with the client.
3. Order all required components.

15

4. Assemble skid and ensure there are no leaks while being flushed with
water.
5. Ensure each step of the assembly process is documented (instructions)
for future
maintenance requirements. Key tasks required for
this include:
- Organise certification of electrical compliance and testing.
- Build on initial research of control units and contact the supplier for
commissioning options.
6. Using the manufactures recommendations, create a maintenance
schedule.
7. Pressure test the skid under safe conditions using compressed air. Use
gas monitors to check for leaks.
Proposed Labor Cost:

$34,000
$48,0001

Proposed Cost of Components:

Estimated Time to Complete:
confirmation.

Objectives:

Assemble skid and carry out initial

testing
to
verify
the
engineering
calculations. Create the maintenance
schedules and assembly instructions.

Deliverables:
assembly instructions.
Outcome:
for commissioning.

weeks

from

Maintenance

receipt

of

written

schedule

and

Fully assembled skid ready

7.7 Stage 6 Delivery, Installation, Commissioning and Final

Handover
Key Tasks
1. Packaging and delivery of skid to the client.
2. Installation of skid to existing plant facility.
3. The control unit supplier to commission the control unit to operate in
the function as
specified in the project scope. The amount of
solution being metered must be accurate.
1 This is the retail price of the complete skid, including assembly, equipment and
labour costs for construction. See Appendix A for supporting calculations.

16

4. Test the accuracy of the metering skid under safe conditions using
water only for a period of 6 hours. Test each pump separately to
ensure complete operation of the skid. Check for obvious leaks.
5. Test the skid using the PAX solution, and use gas monitors to check
for leaks.
6. Skid sign-off and handover.

Proposed Cost of Commissioning:

$17,000

Estimated Time to Complete:

written confirmation.

2.5 weeks from receipt of

Objectives:
skid under real conditions.

Commission and test the

Deliverables:

Commissioning report.

Outcome:
deployment.

Certified skid ready for

7.8 General Exclusions

The following items have not been included in this estimate:
-

Cost of packaging and delivery of the skid to a location specified by the

client.
Cost of PAX solution for commissioning testing.
Cost of equipment and fees for testing.

7.9 Project Cost Summary

Table 3 Summary of costs for the project

Labor
Stage 1

Compon
ents
$6,800 N/A

Commissio
ning
N/A

Completion Time
1 week

17

Project
Investigation
and Planning
Stage 2
Research and
Concept
Development

$23,80 N/A
0

N/A

3.5 weeks

Stage 3 Final
Component
Development

$13,60 N/A
0

N/A

2 weeks

Stage 4 Assembly Plan

and Technical
Drawings

$17,00 N/A
0

N/A

2.5 weeks

Final Design
Submission

$10,20 N/A
0

N/A

1.5 weeks

Stage 5
Assembly of
Components,
Engineering
Verification and
Product
Documentation
Stage 6
Delivery,
Installation,
Commissioning
and
Final Handover

$34,00 $48,000
0

N/A

9 weeks

N/A

$17,000

2.5 weeks

Totals

$105,4 $48,000
00
$170,400

Grand Total

N/A

$17,000

22 weeks

18

8. Benefits, Limitations and Commercial Value of

the Design Study
It is the intent of SES to work closely with the client so that the design can be
tailored around their requirements, interests, expectations and values.
Through following the stages given in section 7 of this proposal it is expected
that the design study will stay within the major interests of the client; this
will be achieved through regular feedback from the client, scope change
registers, and early agreed upon assumptions as set out in section 2.
SES take safety in design very seriously and as such a comprehensive risk
register that can be regularly updated will be used to ensure the overall
safety of the final product. Safety to the operator and safety to the
environment are two key values that many companies in industry work
towards; SES plans to provide a commercially ready product that will assist in
growing the reputation of the client.
Although it is stated in this design proposal that the assumptions will be
mutually agreed between the client and SES, it is still expected that some
assumptions will be left to the discretion of the design team. If this is the
case SES will use the research skills of the team and all relevant
documentation from the client to determine the most feasible options.

19

9. References
Alibaba (2016) Motor Driven Metering Chemical Injection Skid [online] Available at:
https://www.alibaba.com/product-detail/Motor-Driven-Metering-Chemical-InjectionSkid_60373844125.html [Accessed on 8 August 2016]
Engineering ToolBox (2016) Metal and Alloy Density [online] Available at:
http://www.engineeringtoolbox.com/metal-alloys-densities-d_50.html [Accessed on
12 August]
Lam. K,S. (1999). Biodegradation of Xanthate by Microbes Isolated from a Tailings
Lagoon and a Potential Role for Biofilm and Plant/Microbe Associations. PhD.
University of Western Sydney.
LogiChem (2013) Material Safety Data Sheet Potassium Amyl Xanthate, [online]
Available at: http://www.logichem.com.au/downloads/MSDS%20Xanthate
%20Solution%20[LOGICHEM]%20VER008%20MARCH%202015.pdf [Accessed on 8
August 2016]
Metso (2015) Basics in Mineral Processing, 1st edition, [pdf] Available at:
https://www.dropbox.com/sh/pz02sk43zqgcdun/AABZ3WQRvnFkW4lnC9Goh3La/Mineral%20Processing%20Reference%20Documents/Basics-inminerals-processing.pdf?dl=0 [Accessed on 5 August 2016]
SNF Flomin (2013) Flomin Xanthates [pdf] Available at:
http://www.flomin.com/es/SNF.nsf/Flomin-Xanthates-Design-and-OperatingManual.pdf [Accessed on 5 August 2016]
Trevelyan, J 2016, Week 2 Workshop Risk Handouts, handouts distributed in
Mechanical Engineering Design Project 2 - MECH5552 at The University of Western
Australia, Crawley on 10 August 2016.

20

10. Appendix A Skid Size and Cost Calculations

Calculation
We have selected the reactor model RCS100. This can
accommodate a volume of 100 m3 and a maximum bank
feed rate is 2550 m3/h.
The percentage of copper solids in the feed is between
32-42%. Therefore it is assumed that there will be 36%
copper solid in the feed for the processing plant.

References
(Metso, 2015)
(Metso, 2015)

(LogiChem,
2013)

The density of PAX is assumed to be 0.25kg/m3.

The density of copper (Cu) is 8960 kg/m3.

(Engineering
ToolBox, 2016)

Mass fraction of copper ore is 0.022 kg/tonne.

(Lam, 1999)

Cu feed rate = Flow rate * Percentage of Cu in feed

= 2550 * 0.36 = 918 m3/hr.
Mass feed rate of Cu = (Cu feed rate * Density Cu)/ 1000
= (918 * 8960)/1000
= 8225 tonnes/hr.
Mass flow rate of PAX = Mass feed rate Cu * Mass fraction
of PAX in Cu ore
= 8225 * 0.022
= 181 kg/hr.
Volume flow rate of PAX = Mass flow rate of PAX / Density
of PAX
= 181 / 0.25
= 724 L/ hr.
(Metso, 2015)
The number of cells for a copper reactor cell system is
typically 8-12 cells. It is assumed that a medium-sized
processing plant will require 10 cells.
(Alibaba, 2016)
Total volume flow * 10 = 7240 L/hr

21

Based on details from Alibaba, linear interpolation was

used to estimate the price based upon the retail price of a
comparable product.
Price in USD = 3000 + [ (60 000 3000)/(12 000
0.12)]*(7240 0.12)
= $ 37 000
Price in AUD = 1.3 * 37 000 = $ 48 000

11. Appendix B Quality Function Deployment

See folded document on the next page for the QFD.

22

12. Appendix C Risk Register

See folded document on the next page for the risk register.

23

13. Appendix D Project Gantt Chart

See folded document on the next page for the Gantt chart.

24

14. Appendix E Scope Control Document

Milestone
Project
Investigation

In
Scop
e

Out
Scop
e

Dat
e

Deliverable
Project Gantt chart
Summarised meeting minutes
Design overview document
Scope documentation

Research
and Concept
Development
Final
Component
Development

Technical drawings including assembly

of skid.
Presentation and report detailing the
development of ideas, required
components
and materials.
Bill of materials.
Fluid flow, pressure and
analyses'.
Performance expectations.

Assembly of
Components,
Engineering

Maintenance schedule.

Commissioni
ng and
Testing

Commissioning report.

thermal

Assembly instructions.

Certified skid ready for deployment.

25