From design, to manufacture, to repair, it has the expertise and capability in everything from thermal mechanical design, recommendation, and supply of materials, to repairing and fabricating replacement components.

As well as manufacturing, repairing, and servicing parts, it also supplies a large range of stock products.

It holds parts for an extensive range of machinery for heavy equipment, from small coolers right through to large industrial radiators, fans and anything else with components found in cooling or heating units.

OEM parts for Australian conditions

AHT’s highly trained engineers and technicians are specialists in assessing OEM equipment that is either not working efficiently or not compliant to Australian standards. AHT are able to make recommendations including the manufacture of new componentry to ensure that the equipment operates both optimally and meets or exceeds Australian standards.

The new part is generally more suitable to the conditions the machine operates under, giving improves performance than the original and fulfilling the company’s promise to ‘make it better, save money, make it compliant and ensure it works’.

Allied Heat Transfers COO Peter Constantine said that often machinery that has been purchased for a particular function is not actually fit for purpose when exposed to Australian industry conditions.

Machines not designed for the ambient or actual conditions will not function well and parts will fail quickly.

This is particularly prevalent when a machine designed and manufactured in Europe or the US is installed in an underground mine in Australia and expected to function in dusty and overheated conditions beyond its capabilities.

Under these circumstances, componentry within the machine will fail quickly and will continue to fail when replaced with the same part from the OEM.

Allied Heat Transfer offers companies a better alternative than simply replacing the part with an identical component and instantly experiencing the same problems.

It can manufacture and replace the part with an Australian-compliant component that is not just Australian-specific but has site-specific compliance and is environmentally suited to the conditions.

Allied Heat Transfer uses its deep knowledge base in thermal mechanical design, along with experience of the conditions and machinery, to find solutions to the problem of non-compliant imported equipment.

Its capability includes repair and improvement of major oil and gas componentry, such as larger shell and tube units that may be manufactured with exotic materials and constructed using exotic procedures.

When these types of parts fail due to non-compliance or unsuitability to the environment or function, AHT will conduct all procurement in house covering designing, drafting, and engineering.

“We go from a very simple machinery, right up to refinery equipment with extremely specific requirements,” Mr Constantine said.

“Too much performance will cool the fluids too much, yet you can’t cool them too little, and overperformance is not accepted either.  Allied Heat Transfer is an expert at attaining the specific point of accuracy required that meets all parameters.”

Conversation and consultation are key

Engaging in extensive conversations with clients is the key to manufacturing the component specifically as required.

By consulting in depth, the company ensure that they receive all the information they need and that is available.  This includes flows, materials, and the make-up of the fluids.

AHT is unique in being able to use highly skilled non-destructive reverse engineering to establish the materials and design of overseas-made components, and then manufacture a compliant variant component using the correct procedure.

The new unit will meet or exceed Australian Standards and provide increased performance which saves clients time and money and ensures better production performance.

The company has developed a process involving data, material performance and a deep knowledge of thermal conductivity alongside a range of specific testing procedures.

This process allows it to ascertain how and with which material a component is manufactured and thereby reproduce a matching component that performs at a higher level in the machine.

“There is a lot of consultation at that level through all of it,” Mr Constantine said.

“To match the component with the environment, it is important that we understand the exact conditions the machine is working in, whether it is humid, whether it is high altitude or whether it is explosive for example. The environment determines the materials that are used and how the cooling function will work.”

Allied Heat Transfer stands out in the industry by the level of consultation it undertakes and its ability to then create a product rather than relying on off-the shelf units that may not be suitable.

 Meeting compliance and more

Compliance in componentry is becoming an increasingly important issue in Australia.

Australian vessel codes, standards and compliance including site compliance and mine safety is of paramount consideration in the resources industry and is among the strictest in the world.

AHT products are built strictly to Australian Standards, meeting or exceeding boiler and pressure vessel codes on the mechanical side, and TEMA standards for thermal parts.

All pressure vessels need to be assessed for hazard levels.

This involves specific calculations to determine the hazard level assessment of the components, which then establishes the class and the construction requirements.

Once built, the vessel needs to be inspected and registered under the appropriate guidelines.

Allied Heat Transfer is able to perform all the appropriate assessments to meet the necessary requirements.

Its speciality is recreating parts that come from the US or the EU and bringing them up to the stricter Australian standards.

With regular on-site inspections identifying non-compliant units, Allied Heat Transfer has its work cut out for it to keep companies componentry in line with specific requirements.

Ensuring compliant componentry helps customers keep production flowing without unexpected downtime caused by inspectors finding its units do not meet Australian standards.

AHT ‘s comprehensive and versatile services range from a simple part replacement provider to an extreme engineering service, reaching at least six market segments and making it unique in the thermal parts industry.

 Case Studies

• Thermal analysis

Allied Heat Transfer has observed that often imported equipment is not designed to handle the conditions found around Australia, particularly with cooling systems.

As part of its specialisation, AHT has the capabilities to review an existing system that has been identified as not performing, and design and manufacture a unit that will address the shortfall.

In the vast majority of cases it is able to do this in the same or in a smaller footprint.

A client asked for assistance with a number of identical drill rigs imported from overseas in which the radiators were not able to meet the temperature requirements at site.

The cooling packages were combined with radiators, compressor oil coolers, and hydraulic coolers in the same package cooled by a single fan.

AHT assessed and identified that the radiator was too small.

However, the customer could not accommodate a larger cooling package.

AHT solved the issue by designing a replacement compressor oil cooler that was smaller yet provided the same amount of cooling as the larger model.

It was able to supply and fit a larger radiator into the same package, as well as utilising the existing fan and motor.

Allied Heat Transfer provided an upgrade to the existing cooling system to increase the ambient capabilities of the drill rigs without any major modifications, saving costs and downtime.

The customer was able to work continuously without the machine overheating and stopping.

• Compliance analysis

All pressure equipment is hazardous and is required to meet specific regulatory requirements based on the hazard level determined by a competent person.

An observation Allied Heat Transfer has made is that equipment usually considered not necessary to comply with these standards in fact does, such as air compressors on rigs which have oil coolers to maintain a suitable oil operating temperature.

These coolers are rated to the same pressure as the compressor which can be as much as 500psi.

Equipment that is typically recognised as being pressure equipment, such as receivers and separators, is usually operated well within the legislated requirements.

Equipment that is not typically recognised, such as the compressor oil coolers, often is not.

Allied Heat Transfer focuses on ensuring all that the equipment it designs and manufacture is compliant with the requirements and receive full attention to engineering design, type testing, and third-party verification.

An example of a cooler that falls within pressure vessel legislation but may not be realised as such is the compressor oil cooler fitted to most V-Packs.

• Fuel savings from improved intercooler package

The client requested help with a drill rig that was suffering overheating of the charge air cooling circuit, leading to de-rating of the engine and reduced power.

AHT analysed the existing package and found the layout was causing heated air from one cooler to recirculate and preheat the cooling air entering the charge air cooler.

This preheating of the cooling air meant the charge air cooler was unable to perform as required.

To rectify the issue, AHT designed and manufactured a new charge air cooler that could be mounted elsewhere on the rig.

The new design worked so well that the customer reported a saving of hundreds of litres of diesel a day.

The new charge air cooler saved so much outlay it paid for itself in only a few months, after which it provided a saving on expenses.

Allied Heat Transfer’s unique ability to redesign the scope of equipment saves companies many hours of downtime and produces higher performing machines better suited to Australian conditions.

The post Rebuilding better, faster, stronger appeared first on The Australian Mining Review.

CREATING a safe environment for workers in hazardous conditions is one of the biggest challenges in the mining industry.

Apart from obvious hazards like rock falls, explosives and machinery accidents, vibrations, noise and heat can cause ongoing issues for workers.

Pyrotek is committed to providing noise and heat reduction measures through advanced thermal insulation and vibration damping and isolation.

Its range of barrier and composite products work in conjunction with each other to suit the condition, surface and industry and mitigate the effects of noise and heat on the crew and are ideally suited to mining applications.

Pyrotek sound barriers work by effectively reducing noise at the source.

Technical R&D manager, Michael Kierzkowski, said that testing a variety of composites against different frequencies has produced the optimal technology in noise abatement and products that can substantially reduce machinery noise levels, improve health and safety and provide safe, productive working environments.

Mine spec applications are one of its specialities, with products that can be applied to underground installations and process plants and other high noise or heat installations.

Its noise reduction insulating products can also be applied to village and mine office applications for accommodation and computer housing.

Stansfeld and Matheson’s research in the British Medical Research found that noise interferes in complex task performance, modifies social behaviour and causes annoyance.

The study suggested that occupational and environmental noise exposure is associated with hypertension and can be a general environmental stressor and nuisance.

The World Health Organisation also reports that exposure to prolonged or excessive noise can cause a range of health problems ranging from stress, poor concentration, productivity losses in the workplace, and communication difficulties.

The reports conclude that noise reduction in mining environments and processing plants, as well as recreation areas can therefore be beneficial.

According to the study, removing noise stressors can improve production efficiency, reduce downtime and contribute to reduced retrition in the workplace.

Mr Kierzkowski said that noise can be mitigated by the installation of Pyrotek’s advanced coatings or barriers.

Its various composite and barrier products are optimised to produce maximum noise and thermal minimisation.

“Coating products such as Pyrotek’s specialised anti-condensation Decicoat T35 coating, and water-based vibration damping, Decidamp SP80 are the best way to insulate building and construction,” Mr Kierzkowski said.

Pyrotek manufactures a water-based damping compound that performs over a broad temperature and frequency range, achieving significant reductions of radiated structure-borne noise in the mine-site or processing plant.

To reduce noise from pipes, valves, fan housings, and ductwork, he recommends high-performance composite acoustic lagging products such as Soundlag.

Soundlag works by utilising a highly dense and flexible mass vinyl combined with a decoupling layer which breaks the vibration path between substrate and the mass barrier.

This means the vinyl external wrap remains flexible.

External foil facing offers a fire-resistant covering and an excellent surface to join adjacent sheets which reduces noise breakout from waste-water pipes.

HVAC systems can be lined with the company’s polyester alternative, Sorberpoly 3DNW, to reduce internal duct noise.

In large open areas such as processing plants, self-standing noise enclosures are required.

Pyrotek also manufactures a range of standard mass-loaded vinyl barriers that perform this function.

Its dense, thin, highly-flexible, tear-resistant and high strength qualities can serve as a barrier and can reduce noise transmitting through panel constructions such as plasterboard.

Other noise control products feature flexible, mass-loaded, noise barrier, laminated with an aluminium foil facing.

“Quadzero,for example, having low stiffness, shifts its natural frequency and co-incidence dip phenomenon outside the ‘critical bandwidth’ maintaining the transmission loss performance of the system,” Mr Kierzkowski said.

The dense, mass-barrier attenuates noise from mechanical equipment and engines when transmitted through walls, ceilings and floors.

Tests have revealed that altering the thickness of composite that separates the noise barrier from the structure improves the product’s performance in some frequencies without significant increase in overall weight.

The unique structure of Pyrotek’s signature Sorberbarrier targets specific frequency ranges and is the most versatile product for controlling noise in the marketplace.

The high performance of Sorberbarrier is achieved by its unique construction.

Placing the mass barrier between two layers of absorbing composite, keeps the barrier separate from the structure to which it is bonded, allowing it to remain flexible at all times.

Being lightweight and flexible, Sorberdamp readily conforms to irregular surfaces and practices absorption and vibration damping in one product.

It works effectively in enclosed spaces such as engine bays, air-conditioning ducts and generators.

An area that is often forgotten in mining is the all-important IT department.

Computer server rooms need to be well insulated in a mining environment from both the heat and other elements and the dust.

Without the option of data base storage in the city, a server room must be installed in the office environment, requiring thermal and noise insulation so office workers are not affected by the high level of noise generated.

Engineered high temperature materials address noise control challenges and can be customised to individual applications.

Pyrotek’s unique products include water-based, spray-on coating; high density acoustic and thermal glass wool; lightweight high-performance insulation; acoustic absorbers; vapour barriers; composite multi-layered noise absorber barrier and premium, thermal insulation products.

Heat from engines as well as HVAC systems and other piping can be mitigated with removeable covers for high temperature applications.

“Removable insulation means less down time and is more economic over the long term,” Mr Kierzkowski said.

“Energy costs can be reduced as the blanket can insulate from heat transfer and against noise.

“Other benefits of the thermal blanket is protection of equipment.”

Pyrotek’s Thermobreak insulated blanket is manufactured from physically crosslinked, closed-cell polyolefin composite and is designed to maintain thermal performance when exposed to moisture.

It will combat condensation around air conditioning ducts, walls and ceilings and is also available with a facing to protect it from water, oil and other liquid.

Pyrotek has also looked at improving thermal protection on surfaces which lowers cooling costs in underground sites and processing plants.

Its Decicoat T35 is a water-based spray-on thermal insulation coating specially formulated with anti-condensation and corrosion protection properties.

Sprayable properties mean that a seamless application prevents thermal bridging and bonds flush with substrates around uneven surfaces, making it perfect for mining applications.

It has a low odour and has flame, heat and smoke retardation properties and can regulate surface temperatures caused by condensation.

Kilometres underground, or in the hot dusty condition of the Pilbarra, Pyrotek products are reliable and durable, as well as high performance.

“The light-weight composition of Pyrotek products is ideal for duct and piping insulation and provides substantial weight-savings toenergy and fuel efficiency,” Mr Kierkowski said.

Sorberglass is a high-density glass wool board bonded with a thermosetting resin to provide both thermal and acoustic reduction properties and can be used in self-supporting applications.

It has excellent resistance to fire and is heat resistant to 350°C.

Sorberglass is perfect for self-supporting rigid ducting for HVAC, thermal and acoustic applications required underground.

VOC-free, ultralight polyimide composite Sorbermide is currently one of the lightest and most flexible polyimide composites in the market and provides a unique combination of sound-proofing and thermal insulation performance with high fire properties.

Dedicated to creating safe and efficient workspaces, Pyrotek has revolutionised the noise and heat mitigation industry and continue to work with companies to provide unique solutions to insulation in the mining and other sectors.

More information:
Phone number: (1300 928 322; (02) 8868 2000
Email: contact@pyrotek.com
Website: pyroteknc.com and pyrotek.com

The post Pyrotek lowers the heat appeared first on The Australian Mining Review.