Compressed Air System Study
Client : Aluminerie Lauralco (2023 to 2024)
Location : Deschambault, Quebec, Canada
Year : 2024
Potential grant: $8.85M
The Deschambault aluminum smelter is renowned for its operational expertise. Its world-renowned laboratory provides aluminum smelter-related systems analysis services to customers worldwide. The Deschambault aluminum smelter is currently working to minimize its energy losses in order to maximize the energy allocated to aluminum production.
In this context, through its partner R. O. Poirier, LDV Consultants was mandated to help optimize their air system as well as to analyze potential heat recovery of the plant's compressors.
LDV has identified a number of energy efficiency measures that could reduce compressed air consumption from 15,500 scfm to 5,700 scfm, with potential financial assistance from Hydro-Québec of up to $8,850,000 if all the measures are implemented. These measures include adding a reservoir and balancing line downstream of the compressors, replacing a pneumatic alumina conveyor with a bucket conveyor, and implementing VFD compressors.
Assessing the Ventilation and Compressed Air Systems
Client : Eldorado Gold (2019 à 2022)
Location : Val-d’Or
Year : 2022
Grant: $2.50M
Eldorado Gold Québec is focused on the expansion and development of the Lamaque underground gold mine, located near Val-d'Or. As the mine is in the process of developing rapidly, investments have been made to implement an on-demand ventilation system.
Within this scope, through its partner R. O. Poirier, LDV Consultants was mandated to assess the ventilation and compressed air systems currently installed at the mine and mill. Once the systems had been assessed, our team produced an energy efficiency report and recommendations for the implementation of an on-demand ventilation system and optimization of the compressed air system. As a result, Eldorado Gold received $2,500,000 in financial assistance from Hydro-Québec to proceed with their energy management improvement projects.
Finite Element Analysis of Highbank Rotor Spider
Client : Trustpower Limited
Location : New Zealand
Year : 2021
Cracks have been found in the rotor spider of the Highbank Power Station. The rotor spider is made of cast steel. The Highbank unit is a 29 MW, vertical hydro turbine designed in the late 1930’s but commissioned in 1946.
LDV was contacted by Trustpower to:
- Verify if the cracked Highbank rotor spider is safe to withstand an accidental runaway event;
- Provide their technical opinion on other ways to get indications on the crack origin;
- Investigate the possibility of improving the structural integrity of the rotor spider.
LDV’s investigation was completed by a thorough investigation process performed by Trustpower and their collaborators on site: NDT inspections, metallurgical investigations, etc.
The conclusion of LDV’s assessment was that:
- The cracks in the rotor spider likely occurred during the original unit commissioning;
- The rotor spider was safe for normal operating condition;
- The rotor spider could not be confirmed structurally fit to withstand a runaway event;
- Practical structural modifications could be implemented on site to make the rotor spider safe under an accidental runaway condition.
R.H. Saunders GS Hatch Covers Refurbishment
Client : Champlain E P&C
Location : Cornwall, Ontario
Year : 2021
As part of the hatch cover refurbishment project for the 16 units of the R.H. Saunders Generating Station (GS) for OPG (Ontario Power Generation), Champlain E P&C, a company specialized in Electrical systems, Protection and Controls for hydro generation plants, commissioned LDV Consultants to be responsible of the mechanical parts. The refurbishment works required to design or modify the opening and closing, sealing, and draining systems of the hatch covers. In addition, seal heaters, guardrails, limit switches, and door latches needed to be integrated.
As part of the refurbishment project of the hatch covers at R.H. Saunders GS, LDV Consultants was responsible to perform the following tasks:
- Calculation of the power chain for the hatch covers opening and closing;
- Evaluation and selection of components;
- Design and integration of mechanical components and systems:
- Opening and closing, sealing, and draining systems;
- Seal heaters, guardrails, limit switches, and door latches.
- Preparation of the fabrication and installation drawings;
- Preparation of installation procedures;
- Site installation support and commissioning.
FEA on a Piping Section to Calculate Stresses
Client : Norda Stelo
Location : Montreal,Quebec
Year : 2021
Norda Stelo is a consulting engineering firm with operations in all engineering disciplines.
The equipment in a section of a nickel plant piping system showed signs of cracks. This equipment, the "desuperheater", produces a very large thermal gradient.
LDV performed a finite element analysis (FEA) and informed Norda Stelo of stresses in two (2) specific sections of the desuperheater piping.
- Carry out solid modeling of the two (2) piping sections;
- Provide gridding data of the two (2) models until convergence of stresses;
- Provide resolution in steady-state condition for the two (2) models to determine the temperature distribution;
- Provide resolution in steady-state condition for the two (2) models to determine the stress distribution, including the impact of bolt tightening at the flange;
- Provide second resolution in steady-state condition for the two (2) models to determine the temperature distribution with shorter transition (sensitivity study);
- Provide second resolution in steady-state condition for the two (2) models to determine the temperature distribution with shorter transition, including the impact of bolt tightening at the flange;
- Extract the von Mises stresses at the two points of interest specified by the client (one per model);
- Produce a technical review describing the model, assumptions and limitations, methodology used as well as stress diagrams with probes indicating the von Mises stresses at the two points of interest specified by the client (one per model).
End Results
Norda Stelo used the results of the analysis performed by LDV to take the necessary steps to repair and extend the life cycle of the equipment.
Refurbish Generating Units of Côte Ste.Catherine Power Plant
Client : Delom Services
Location : Sainte-Catherine, Quebec
Year : 2021
Delom Services was awarded a contract to refurbish the generating units #10 and #7 at the Côte Ste.Catherine power plant, and mandated LDV Consultants to provide the engineering for the following:
- Disassembly and reassembly:
- Provide work procedures and data sheets;
- Prepare hoisting instructions;
- Validate lifting equipment and specialized tooling.
- Repair work to be done in the plant and on site:
- Analyze data from inspection sheets and non-destructive test reports;
- Write reports with recommendations and work instructions;
- Size the parts to be replaced/manufactured;
- Draft the procedures for reassembling the Kaplan wheels in the workshop;
- Resolve anomalies and non-conformities;
- Ensure the presence of a contact person on site;
- Provide engineering support.
Repair Underframe Cracks
Client : Via Rail
Location : Montreal,Quebec
Year : 2021
Via Rail is renown in the passenger railcar industry. It owns and operates Renaissance railcars for long distance intercity transportation.
LDV Consultants was mandated to perform a structural repair procedure on a Renaissance railcar for the purpose of putting it back into service. During its site visits, LDV defined the project needs and took measurements of the surrounding components.
Next, LDV validated the procedure using engineering calculations and producing the shop drawings needed to manufacture the reinforcement pads. In addition, LDV provided support to the Via Rail team during installation of the reinforcement pads.
EPCM for Agents to be Added to the Paper Pulp Process
Client : Confidential
Location : Témiscamingue
Year : 2020
Our client is a world leader in developing innovative processes for the pulp and paper industry to optimize manufacturing processes. When manufacturing papermaking pulp, our customer's minerals are used to control stickies and improve bleaching. Environmentally-friendly, this solution provides the desired chemical composition, whiteness, and viscosity and helps optimize production quality and efficiency. This new process will be integrated into the pulp and paper production of a paper mill in Témiscamingue.
As part of this project, the client mandated LDV Consultants to carry out the project's EPCM (Engineering, Procurement, and Construction Management). Below is a list of the tasks performed:
- Oversee multidisciplinary project management and coordination;
- Obtain the certificate of authorization;
- Evaluate costs (±10%) and outline the project schedule;
- Perform an on-site survey;
- Provide civil/structural/architectural engineering;
- Provide electrical engineering/instrumentation, and control;
- Select the equipment and perform equipment modeling;
- Provide a layout of the piping routing and isometrics;
- Provide the HVAC engineering (Heating, Ventilation, Air Conditioning and Control)
- Provide fire protection engineering;
- Draft the specifications and coordinate equipment procurement;
- Prepare and manage the contract with the general contractor;
- Draft installation specifications and oversee on-site installation.
Greenhouses - Building Services
Client : Confidential
Location : Quebec
Year : 2020
Our client is a company investing in natural resources and renewable energy in Northern Quebec.
As part of its operations, our client acquired a power cogeneration plant to use its thermal waste to heat new greenhouses to produce fruit and vegetables. To carry out this project, the client mandated LDV Consultants to perform various mechanical engineering and building services tasks, such as:
- Provide engineering and drawings of the plumbing and connection to municipal facilities (domestic wastewater, sanitary system, stormwater system, and ventilation);
- Conduct a study on the installation of an oil tank in accordance with industry standards;
- Review the mechanical room layout;
- Review the steam piping drawings and procurement specifications;
- Review the seismic requirements outlined in the RBQ, CSA, ASME, and NBC standards;
- Provide engineering of various equipment;
- Provide oil piping engineering;
- Provide piping and a CO2 tank engineering;
- Draft the compressor procurement specifications and produce the compressed air piping system drawings;
- Provide general layout engineering and drawings;
- Review the hot water piping system drawings and engineering (system safety).
Hull 2 – U1 & U2
Client : Integrated Power Services
Location : Ontario, Canada
Year : 2020
Integrated Power Services is the leading provider of electric motor and generator repair services in North America.
IPS is responsible for the rehabilitation of 2 horizontal generators at Hull 2. The supply includes new winding coils for 2 stators.
LDV's mandate is to support IPS for the duration of the project and manage the interfaces.
- Design of the main and neutral leads to connect the winding to power transformer;
- Instrumentation schematics, junction boxes;
- Special tools for bearing handling;
- Collector rings drawing;
- Procedure for shaft alignment with turbine.
Expertise for Embedded Parts, Air Gap and Model Test
Client : Rio Tinto Alcan
Location : Alma, Quebec
Year : 2020
Rio Tinto Alcan mandated LDV Consultants to carry out analyses and make recommendations on several subjects pertaining to a generating unit at the Isle-Maligne power station:
- Analyze and produce a report on the embedded parts of the turbine by an expert in turbine mechanics:
- Analyze the current condition of the parts;
- Make recommendations for the refurbishment and repair of each of the embedded parts;
- Extend their operating life;
- Assess the impact of the increased turbine power on the embedded parts and make recommendations on the adjustments to be made to the turbine.
- Analyze and produce a report on the evolution of the air gap by an expert in alternator mechanics:
- Analyze the current condition of the alternator in an advanced state of wear;
- Assess the impact of a breakdown on various components due to the state of degradation of the unit;
- Assess repair options to ensure proper operation of the alternator until it is rebuilt;
- Make recommendations on the monitoring and operation of the unit until it is refurbished.
- Express an opinion and produce a report on the anticipated performance based on the digital simulations compared to a model test, by a turbine hydraulics expert:
- Review the characteristics and guaranteed performance of the equipment;
- Make recommendations on the need for a model test while taking into account guarantees, costs, and deadlines.
- Propose a strategy for the upcoming major refurbishing of the 12 generating units to minimize the risks for the plant operator:
- Use new or refurbished parts;
- Plan the equipment downtime for refurbishment;
FEA of a Synchronous Electric Motor
Client : Delom Services
Location : Montreal,Quebec
Year : 2020
As part of one of its projects, Delom Services mandated LDV Consultants to perform finite element analyses on a 1300HP industrial synchronous electric motor. The objective was to determine the various stresses applied on the rotor and stator, shaft, core, rim, casing, magnetic circuit, and magnetic circuit clamping components.
As part of its mandate, LDV Consultants carried out the following:
- Simulation
- Formulate assumptions;
- Review, integrate and simplify the geometry provided;
- Reduce non-critical stresses that will not affect the final analysis;
- Simplify calculations using a symmetrization strategy.
- Engineering
- Apply limit states and stresses;
- Analyze results;
- Produce the reports.
End Results
Based on the analysis results, Delom Services was able to validate that their motor complied with the static stresses of the rotor, find out the minimum coefficients of friction, and confirm that the selected clamping components were adequate. Nevertheless, a torque recommendation was made to limit shear stresses. In the end, Delom Services was able to redesign the motor to optimize it while meeting requirements.
Perform a FEA on Railcar Fasteners and Support
Client : Rail GD
Location : New Richmond
Year : 2020
Since 2012, Rail GD Inc. is a company that repairs and refurbishes passenger trains, Colorado railcars, tourism trains, freight wagons and locomotives.
Rail GD needed to upgrade a Via Rail kitchen railcar. This upgrade involved, among other things, installing new support structures for the water heater and refrigerator compressors located at the "A" end of the kitchen railcar.
LDV Consultants was mandated by Rail GD to perform a finite element analysis (FEA) to calculate the stresses and strains on the fasteners and support structures of the equipment installed by Via Rail:
- All kitchen equipment (oven, fridge, cabinets, etc.);
- Water heater and refrigerator compressors;
- Evaporator-fan unit of the wagon.
This equipment was installed by Rail GD in a Via Rail kitchen railcar.
The project included the following:
- Check the structural integrity of the base metal of the support structures;
- Check the structural integrity of the bolts and rivets that connect the support structures to the kitchen railcar.
All in compliance with the applicable railway standards.
Design the Mining Site Camp
Client : AEX Gold
Location : Nalunaq, Groenland
Year : 2020
AEX Gold is a mining company founded in 2017, specializing in mining gold deposits in Greenland. The Company currently holds seven licenses in South Greenland, covering a total area of 3,356 km². It is the company with the largest footprint and licensing portfolio in Greenland.
AEX Gold plans to begin mining operations in 2021 at the Nalunaq site, where it aims to complete the full gold mining cycle. For the infrastructures of its future camp, it mandated LDV to coordinate the various technical trades to perform the following tasks:
- Provide civil and mechanical engineering;
- Design the fire protection system;
- Oversee water management (drinking water and wastewater);
- Oversee oil management (new and used).
Repair a Wrecked Rail Car
Client : CAD Railway Industries
Location : Montreal,Quebec
Year : 2020
As a result of a collision, one of VIA Rail's fleet of LRC cars sustained damage to the structure's posts and outer shell. CAD Railway Industries was mandated to repair the structural damages.
CAD Railway Industries mandated LDV Consultants to provide the engineering for the following:
- Assess damages;
- Identify the damages on site;
- Visually inspect the damaged areas;
- Take measurements;
- Take dimensional measurements;
- Adapt the dimensions to the deformed components;
- Draw up a repair plan in accordance with APTA PR-CS-S-020-03;
- Use equivalent or replacement parts;
- Design parts with resistances equivalent to those of the original parts;
- Produce final drawings that reflect all phases of the repair plan.
End Results
The suggested way of rebuilding the posts ensured the mechanical resistances were equal to those of the original parts. The client was able to repair the damages and put the rail car back into service.
Platforms for the Installation of Spiral Casings
Client : Voith Hydro
Location : Fort St.John, B.C.
Year : 2020
As part of its engineering, procurement and construction project for the new Site C power plant, Voith Hydro mandated LDV Consultants to design the platforms used to install spiral casings.
As part of the mandate, LDV Consultants carried out the following:
- Design the scaffolding, walkways and platforms used to assemble and install spiral casings in the power plant;
- Calculate and size components according to applicable standards and OH&S requirements;
- Produce manufacturing and installation drawings;
- Provide support during manufacturing.
Feasibility Study for a Cutting and Packaging Workstation
Client : Mat Tech
Location : Granby, Quebec
Year : 2020
Mat Tech is a manufacturer of quality mats for the residential and commercial markets and is renowned to be the Canadian leader in entrance mats, anti-fatigue mats and logo mats.
To optimize the mat cutting and packaging process, Mat Tech mandated LDV Consultants to carry out a feasibility study for a cutting and packaging workstation that would make it possible to find an automated and/or mechanized solution that would reduce and/or facilitate human intervention.
As part of the mandate, LDV carried out the following:
- Take measurements at the Granby plant;
- Design a conceptual model for the cutting systems;
- Design a conceptual model for the handling systems;
- Conduct a summary assessment of the engineering and procurement/manufacturing costs;
- Plan the layout of the cutting and lifting workstations to optimize floor space;
- Produce a detailed report.
End Results
The feasibility study helped the client to assess the technical and financial issues of the various options, to breakdown and schedule the project into phases and to prioritize the work to be done.
Technical Support - Modification of Sill Seal
Client : Major North American Company
Location : North America
Year : 2019
As part of a gate repair project, a major North American company commissioned LDV Consultants to design the modification of the existing intake gate in a hydroelectric facility. The repair work required the addition of a rubber sill seal to control the increasing leakage flow of the metallic seal. In addition, LDV Consultants provided support for the future refurbishing works of the intake gates.
As part of the technical assistance mandate for the intake gates, LDV Consultants has been mandated to perform the following tasks:
- Design of an added rubber sill seal;
- Drawings of new parts;
- Assembly drawing of the new concept;
- Validation of the wheel loads;
- Validation of the operating loads;
- Evaluation of the lifting system capacity;
- Modification of the lifting system to remove the clutch;
- Modification of the control system.
Ventilation System Analysis
Client : Goldcorp (2015 to 2019)
Location : Éléonore Mine, James Bay, Quebec
Year : 2019
Grant: $3.40M
Goldcorp (now called Newmont Corporation) is a gold mining company operating throughout the Americas, mainly in Canada, Mexico and Argentina. One of their mines is the Éléonore gold mine, located in Eeyou Istchee/James Bay, in a remote corner of the Northern Quebec region.
As part of a project to improve the mine's energy management, through its partner R. O. Poirier, LDV Consultants was mandated to assess the currently installed ventilation system to determine the feasibility of implementing an on-demand ventilation system.
A ventilation capacity of 12,000 HP for a total of 112 fans was identified, resulting in considerable energy savings. Hydro-Québec awarded Goldcorp a $3,400,000 financial aid to implement the energy efficiency measures recommended by our team.
Refurbishing the Generator at the Jim-Gray Power Plant
Client : EnerServ - Resolute Forest Products
Location : Saguenay, Quebec, Canada
Year : 2019
As mandated by EnerServ, LDV Consultants performed the engineering required to replace and refurbish the generator and alternator components for the Jim-Gray power plant turbine refurbishing and waterwheel replacement project.
- Provide the engineering needed to disassemble, refurbish and reassemble components:
- Generator alternator shaft;
- Generator instrumentation;
- Turbine case;
- Gate-operating mechanism;
- Generator shaft;
- Generator shaft gasket;
- Guide vanes;
- Head cover;
- Head base;
- Draft tube.
- Provide the engineering for the follow-up of non-conformities during project implementation;
- Provide technical support during disassembly and reassembly;
- Provide hydraulic support during commissioning and adjustment of the ventilation system.
End Results
The existing components were dismantled, inspected, refurbished and reinstalled. The unit was commissioned on time and on budget. The performance of the refurbished unit fully met the client's expectations.
Bear Swamp rehabilitation
Client : Brookfield Renewable
Location : Gatineau, Quebec
Year : 2019
Brookfield Renewable is a world leader in alternative asset management. They are also one of the world's largest investors in renewable energy. They have assets located around the world which include a diverse technology base.
To monitor the Bear Swamp rehabilitation project, Brookfield Renewable mandated LDV Consultants during the design, manufacturing and implementation site phases to deliver the following engineering services:
- Review of all technical documents issued by the manufacturers to validate conformance with the contractual requirements, but also according to the industry’s best practices;
- Participate in design reviews as a Brookfield technical representative to review the proposed design, to identify potential design pitfalls or limitations;
- Review the technical aspects of the derogations, NCR and extra work occurring during the manufacturing process (and later during the site phase);
- Review the manufacturing shops ITP to propose witness points;
- Act as the technical and quality representative of Brookfield for witness point during the manufacturing process.
Engineering Assessment of Wells Damn Hydroelectric Project
Client : Toshiba America Energy Systems Corporation
Location : North America
Year : 2018
Toshiba America Energy Systems Corporation is a leader in the high-technology industry of engineering and construction that provides customer service for all energy platforms (hydro, nuclear, thermal…) like turbine sales, repairs, etc. Toshiba America Energy Systems mandated LDV Consultants to carry out the initial engineering assessment of Wells Dam Hydroelectric Project:
- Review equipment technical specifications, TAES’ refurbishment design drawings and procedure, and units 1 & 2 refurbishment results with the objective of identifying the engineering potential improvement actions and priorities and put them in a report for TAES’s management;
- Assist Toshiba’s engineering to address the top 4 priorities for the Wells Dam Hydroelectric Project with the compilation of all the documentation pertaining the priority being addressed, in depth analysis of the information collected, drafting and review of a proposed action plan with Toshiba and issuance of drawings, procedures and site data sheets necessary to reach the agreed-upon goal;
- Perform limited-scope mandates in support of Wells Dam refurbishment engineering, task details (deliverables, schedule, maximum hours) to be determined for each mandate.
Turbine Shaft Fea Assessment
Client : GE Renewable Energy Canada
Location : USA
Year : 2018
As part of a submittal requisite, the owner wanted to have a preliminary study of the turbine shaft structural integrity in order to assess if the component was robust enough to undergo another 40 years of service life in addition to a power increase.
LDV's Mandate:
- Perform a FEA analysis of the turbine shaft to better understand its physical behavior under its normal and steady state load conditions;
- Calculate by finite element analysis (FEA) the Von-Mises equivalent static stresses in the turbine shaft at full load in normal operating conditions and compare the results against the criteria commonly used in the hydro business;
- Calculate by FEA the Von-Mises equivalent static peak stresses in the turbine shaft for different fatigue cycles and compare the results against S-N fatigue curves commonly used in the hydro business to evaluate the cumulative fatigue damage;
- Calculate by FEA the maximum allowable crack which is not propagated under the maximum load in normal operating conditions using the methodology found in the API579-1/ASME FFS-1 Standard.
The preliminary finite element analysis showed that the base material of turbine shaft is robust enough to withstand an additional 40 years of service life and a maximum allowable crack size was identified.
Technical Support - Gate Wheels Modification
Client : Hydro Tech - OPG (Ontario Power Generation)
Location : Ontario, Canada
Year : 2018
As part of a gate repair project, Hydro Tech commissioned LDV Consultants to design the modification of the intake gate wheels at the Kipling hydroelectric facility. The repair work required the replacement of the bearing elements as the existing wheels were seized. In addition, the original design had to be modified in order to use commercial bearings instead of custom-made elements to limit the duration of the work.
As part of the technical assistance mandate for the design of the valve wheel modification at Kipling, LDV Consultants was mandated to perform the following tasks:
- Selection of bearings;
- Drawings for repairing and modifying preserved parts;
- Drawings of new parts;
- Assembly drawing of the new concept;
- Supply of bearings;
- Workshop assembly procedure;
- Installation procedure for wheels at the site.
New Distillation Line
Client : Diageo
Location : Salaberry-de-Valleyfield, Quebec
Year : 2018
Diageo is a global leader in beverage alcohol with an outstanding collection of more than 200 brands across spirits, beer and wine categories sold in more than 180 countries in the world. To increase production at its Salaberry-de-Valleyfield plant and meet the increasing demand for locally produced beverage alcohol, Diageo decided to add a new distillation line. As part of the mandate, LDV Consultants carried out the following:
- Check, review and provide equipment modeling;
- Design piping routing;
- Analyze critical piping;
- Provide piping isometrics;
- Coordinate work of the various disciplines with the client and suppliers;
- Design and conduct follow-up on the manufacturing of the alcohol and caustic solution tanks;
- Provide support during installation;
- Draw up technical specifications (piping, insulation, support, etc.);
- Draw up procurement specifications and provide support during procurement;
- Write the installation specifications;
- Take measurements in the plant;
- Specify connection points (position, temperature, pressure and flow);
- Describe existing pumps;
- Provide detailed engineering for the CIP (Clean In Place) system;
- Select process components.
Technical Support for the Design of a Snowblower
Client : Confidentiel
Location : Confidentiel
Year : 2018
The Company is one of the largest manufacturers of applications and accessories in North America. In addition to being a leading manufacturer of specialized accessories and applications for Original Equipment Manufacturers (OEMs) in the agricultural, municipal and construction industries for more than 30 years and offering a wide range of winter, summer and specialized accessories as well as customized hitches, the Company has an R&D team that designs and develops customized solutions for Original Equipment Manufacturers (OEMs) and their tractors, utility vehicles, municipal and construction vehicles.
As part of a project to develop a new model of snowblower for sidewalks, LDV Consultants was mandated to carry out the following:
- Design the snowblower;
- Produce the parts and assembly drawing;
- Design the manufacturing templates.
FEA of a MIV
Client : Major North American Company
Location : North America
Year : 2017
As part of a vast rehabilitation and certification project for its production units, a major North American company mandated LDV Consultants to perform a finite element analysis (FEA) of large main inlet valves (MIV) installed in a power plant.
The purpose of the FEA was to determine the best solution, i.e. to replace or rehabilitate the MIV, from an economical point-of-view, but also from a safety perspective as the MIV plays an essential role in the safety and integrity of the turbine parts, generator parts and entire power plant.
To achieve this objective, the stress fields and deformations under several load conditions were calculated by FEA. The different load conditions were then combined to evaluate the theoretical residual operating life of the MIV. The stress and cumulative fatigue damages were calculated and verified in accordance with the ASME Boiler & Pressure Vessel Code, Section VIII, Division 2 methodology and criteria. The FEA was performed using Ansys Workbench 17.2.
Technical Support Côte Ste-Catherine Power Plant
Client : Delstar Énergie
Location : Sainte-Catherine, Quebec
Year : 2017
Delstar Énergie, a subsidiary of Groupe DELOM, is a well-known player in the world of energy, particularly in regard with generator poles and electrical conductor refurbishment or fabrication.
To get the support of hydro generator experts, Delstar Énergie contacted LDV who provided its engineering services for the refurbishment of one 1,6 MW turbine-generator unit, that comprised a Kaplan runner with single regulation.
- Site support for dismantling and reassembly of turbine and generator unit;
- Dimensioning of new runner blade bushings;
- New design of blade seals;
- Shop support for machining of runner components;
- Definition of technical requirements for pressure and balancing tests;
- Recommendation on assembly tolerances and guide bearing clearance;
- Writing of the in-shop runner assembly/disassembly procedure.
In order to provide a high-quality service and to establish an effective collaboration and communication with Delstar’s personnel, LDV's experts made several trips to the plant or the site during the project.
Finite Element Analysis of the Pole and Rim
Client : New Zealand Operator
Location : New Zealand
Year : 2017
Following the inspection of the units of a New Zealand operator's hydroelectric power plant, LDV Consultants was mandated to conduct an analysis on the units of the hydroelectric power plant to draw up a series of recommendations and inspections for future unit shutdown. As part of the project, LDV Consultants was mandated to conduct a finite element analysis on the rotor trunnion pole and rim.
The purpose of this analysis was to determine the actual condition of the rotor's two main components given that the units, that are operational since 1967, have never undergone any major refurbishing.
The purpose of the finite element analysis was to determine the stresses and deformations of the rim and pole under various loading conditions so as to calculate their remaining useful life. Static stress and fatigue damage calculations were therefore performed as per the recommendations in the ASME Boiler and Pressure Vessel Code, Section VIII, Division 2. The analysis was conducted, using ANSYS Workbench r.18.2, on an assembly that included the rim and pole.
Modifications to the Gasti Machine
Client : Danone Inc.
Location : Boucherville,Quebec
Year : 2017
Danone is a French agrifood company that has focused its business on four sectors of activities: fresh dairy based products, bottled waters, medical nutrition and early life nutrition. The company is one of the world leaders in these four sectors of activities. Its products are sold worldwide.
During maintenance of the machine that seals the yogurt jars, operators had difficulty closing the machine because of the gas cylinder that made it easier to open the machine. Furthermore, because this machine is performing repetitive movements, the air intake ducts and electric wiring wear out prematurely. The client therefore mandated LDV Consultants to examine both problems.
As part of the mandate, LDV Consultants carried out the following:
- Take measurements on site and produce a 3D model of the existing machine;
- Provide a diagnosis on component wear and tear;
- Provide a 3D model, drawings and assistance for the purchase of the supports needed to improve the life cycle of the air intake ducts and wiring;
- Perform the analytical calculations for the power needed to open the gas cylinder;
- Propose modifications to optimize the machine closing and opening ratio;
- Produce the machine drawings, including all wear and tear parts.
LDV Consultants' expertise enabled the client to increase the efficiency of its process while rendering it more secure during maintenance work.
Technical Support for the Design of Test Equipment
Client : Héroux-Devtek
Location : Saint-Hubert, Quebec
Year : 2016
Héroux-Devtek is an international company specializing in the design, manufacture and testing of landing gears. The company also conducts laboratory tests to certify existing landing gears. To perform these tests, Héroux-Devtek needed to design a test bench. It mandated LDV Consultants to take part in the design of the test bench.
As part of the mandate, LDV Consultants carried out the following:
- Design interfaces for load application;
- Produce a 3D model of the test interfaces;
- Produce the drawings for the test interfaces.
To acquire the knowledge and work methods advocated by the client, LDV Consultants’ engineer went to Héroux-Devtek's offices in St-Hubert. Afterwards, from its offices in Chambly, LDV completed its mandate to optimize the schedule.
Biomass Boiler Piping Project
Client : C-nergie
Location : Ste-Julie, Quebec
Year : 2016
C-nergie, a business established in 2006, specializes in energetic efficiency. By performing electrical consumption and energetic cost studies, C-nergie provides long-term solutions to reduce their clients’ energy consumption.
C-nergie mandated LDV Consultants to produce a P&ID and the piping arrangement for the building containing the biomass boiler, which supplies steam for Leahy Orchards.
As part of the mandate, LDV Consultants carried out the following:
- Produce two P&ID;
- Design four piping specifications (1 steam, 1 water, 1 washing water (stainless steel) and 1 glycol);
- Produce the heat trace cable specifications and calculations;
- Produce a 3D model of the main equipment;
- Adapt the building with the equipment modeled as per the layout provided;
- Provide 3D routing of piping and connexion lines of the new and old plants;
- Produce the design and structural drawings of ten (10) supports for small equipment;
- Calculate the line head losses to validate the pump preselection;
- Produce the isometric drawings (Isogen);
- Produce the general layout drawings with notes and specifications (specifications on drawings);
- Produce the final drawings.
Provide Design Support and Drawings
Client : Camso Inc.
Location : Magog, Quebec
Year : 2016
Camso is a global leader specialized in the design, manufacturing and distribution of off-the-road tires, wheels, rubber tracks, running gear systems for the material handling, construction, agricultural, motorized sports and defence industries.
Camso mandated LDV Consultants to provide their support in the design and development of a model running gear system.
As part of the mandate, LDV Consultants carried out the following:
- Produce a 3D model of the components using Pro/Engineer CREO 2.0;
- Produce the drawings for the components using Pro/Engineer CREO 2.0;
- Travel to the client's facilities to perform a follow-up and gather data;
- Make changes to the design in accordance with the various development phases:
- Prototype;
- Machining;
- Assembly.
Design, Production and Manufacturing of a Lifting Tool
Client : Blue Solutions Canada
Location : Boucherville,Quebec
Year : 2016
Blue Solutions Canada, a subsidiary of the French multinational Groupe Bolloré located in Boucherville, manufactures one of the most efficient rechargeable batteries in the automotive industry.
Further to a prior project with LDV Consultants regarding the design of a lifting tool, Blue Solutions Canada mandated LDV Consultants once again to produce the manufacturing drawings for this tool.
As part of the mandate, LDV Consultants carried out the following:
- Design the tool;
- Conduct a numerical analysis to optimise the structure;
- Produce the layout of two (2) sub-assemblies and one (1) main assembly;
- Produce the drawings needed to manufacture the parts;
- Manufacture the parts and coat them with black oxide;
- Provide support during manufacturing;
- Inspect the parts prior to delivery;
- Take part in the certification testing.
Gate Replacement of Latchford Dam
Client : Rouby Industries
Location : Latchford, Ontario
Year : 2016
Rouby Industries specializes in the manufacturing of metal structures and structure parts, and more specifically hydraulic structures. During the refurbishing of the Latchford dam, Rouby Industries was tasked with designing, manufacturing and delivering equipment used to control the water level of Bay Lake.
Rouby Industries mandated LDV Consultants to provide assistance during the design and manufacturing of various components, including the gate, embedded parts and hoisting device as well as the steel cofferdams, wood beams and steel guide rails to ensure that the design and manufacturing comply with the client's requirements and Canadian standards (CSA S16). As part of its mandate, LDV Consultants carried out the following:
- Verify and validate the engineering, including the design notes for the components;
- Check and certify the assembly and detail drawings;
- Design and layout of the electrical control panels to heat the gate, embedded parts and gate
- Control system;
- Design and layout of the electrical control panels for the gate hoisting device.
Drawings with Isometrics Views of the Piping for a Heavy Oil Processing Platform
Client : Fractal Systems
Location : Alberta
Year : 2016
Fractal Systems is in the business of processing and upgrading hydrocarbons. During the past few years, the company has developed a new technology that it has tested in a pilot plant in Alberta. Owing to the tried-and-tested technology, Fractal Systems wanted to increase the production capacity of the pilot plant. It therefore mandated LDV Consultants to provide assistance in support of this initiative.
The pilot plant was mainly equipped with pressure vessels installed on modular platforms. Fractal Systems wanted to add two additional modular platforms, which would also mean designing the piping between the pressure vessels.
As part of the mandate, LDV Consultants carried out the following:
- Produce a 3D model of the pressure vessels using SolidWorks;
- Import all components into Plant 3D;
- Produce a 3D model of all the equipment piping on Plant 3D;
- Produce drawings with isometrics views of the piping;
- Prepare a general layout of the plant;
- Design the various piping supports and equipment.
Analysis of Tank Supports
Client : Orica Canada Inc.
Location : Opinaca, Quebec
Year : 2016
Orica Canada is the world's largest provider of commercial explosives and innovative blasting systems to meet the needs of the mining, quarrying, oil and gas and construction markets.
Orica Canada contacted LDV Consultants because one of its mobile tanks was sustaining recurrent damages always on the same spot. This tank was at times moved by a special truck designed by Orica Canada and then left on the same spot for several days. Orica Canada mandated LDV Consultants to find the source of the problem and recommend solutions to resolve the problem.
As part of its mandate, LDV Consultants carried out the following:
- Evaluate the worst load case (being moved or static);
- Conduct a numerical analysis on the tank;
- Validate through numerical simulation the resistance of the tank support;
- Assess several solutions that could solve the problem;
- Produce the detail drawings needed to manufacture the winning solution.
Owing to its expertise, LDV Consultants was able to identify the actual source of the problem and propose to the client minor changes to be made to the tank without having to incur significant costs.
Test Cell Analysis
Client : Confidential
Location : Confidential
Year : 2016
During the development phase of a new turbine, a manufacturer mandated LDV Consultants to confirm that their existing test cell could take on the loads of the new turbine. LDV Consultants hence conducted a finite element analysis on this test cell.
As part of the mandate, LDV Consultants carried out the following:
- Adjust the 3D geometry to conduct the analysis;
- Conduct a mechanical analysis on the test cell during in-service turbine loading;
- Conduct a mechanical analysis of the test cell during accidental turbine loading;
- Conduct a modal analysis of the test cell – turbine assembly.
Further to the analysis, LDV Consultants was able to propose the minor changes required to adjust the existing test cell to the new engine.
Design of a Cap Press
Client : Orica USA
Location : Watkins, Colorado
Year : 2015
Orica, an Australian company, is the world's largest provider of commercial explosives and innovative blasting systems to the mining and infrastructure markets. Orica is world leading supplier of ground support solutions in mining and tunnelling as well as a leading supplier of sodium cyanide for gold extraction.
Orica mandated LDV Consultants to design a semi-automated press for a laser cap impeller in accordance with the client's specifications.
As part of the mandate, LDV Consultants carried out the following:
- Design the press;
- Produce the manufacturing drawings;
- Produce the installation drawings;
- Program the PLC.
At the end of the mandate, the following deliverables were provided to the client:
- Operational design of the semi-automated press;
- Complete set of engineering drawings;
- Operations manual;
- Maintenance manual including a parts list and the product data sheets.
Validation of a Lifting Tool
Client : Bombardier Aerospace
Location : Mirabel, Quebec
Year : 2015
Bombardier Aerospace is a recognized manufacturer in the design and manufacture of business and commercial aircraft.
As part of the project to design a ballast support tool for Bombardier Aerospace, our client wanted to obtain a validation of the load bearing structure of the ballast in order to ensure that the tool meets its design criteria.
The tool must be able to hang weights (ballast) to keep the front of the C-Series aircraft on the ground during finishing assembly operations.
As a result, LDV performed the finite element analyses and manual calculations required to validate the structure, proposed changes and additions to the required locations, and approved the drawings for the tool’s manufacture.
Next-Gen EPS Harmonic and Thermal Analysis
Client : Kongsberg Automotive
Location : Grand-Mère, Quebec
Year : 2015
Kongsberg Automotive, together with its clients from the industrial and transportation sectors, specializes since 1988 in the design, development and manufacturing of integrated quality and high value-added solutions for the field of electronics and electro-mechanics.
During the design phase of an electronic controller, Kongsberg Automotive wanted to make sure that the controller would operate properly. LDV was therefore mandated to perform a finite element analysis to determine displacement with various loads. LDV carried out the following:
- Perform structural analysis with a thermal load to simulate variations in operating temperatures;
- Perform harmonic analysis to simulate potential vibrations on the component during operations;
- Perform modal analysis to validate some of the material properties with the vibration tests carried out by Kongsberg Automotive.
This project allowed us to determine maximum displacement during the electronic assembly operation. It also made it possible to show that the assumptions made by Kongsberg Automotive as they pertained to the materials, did not reflect reality. LDV was able to provide Kongsberg Automotive with more accurate values for this material.
Pumping System Analysis
Client : Résolu Produits forestiers (2014)
Location : Baie-Comeau
Year : 2014
Résolu Produits forestiers is a major manufacturer of various products, such as wood, pulp, tissue and paper, sold in over 60 countries. The company manages about 40 facilities and owns power generation assets in Canada and the United States. To reduce their electrical energy consumption, Resolute Forest Products contacted LDV Consultants to explore potential energy efficiency solutions.
With this in mind, through its partner R. O. Poirier, LDV Consultants was mandated to assess the potential reduction in electrical power used by the water pumping system.
After analyzing the pumping and cooling systems of the mill and foundry, a total of 4,200 HP was identified, with a potential consumption reduction of 28%.
With regard to the energy consumption of the furnace combustion fans, 750 HP has been identified, with a potential reduction of 38%.
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Preliminary Detail Engineering of a Ventilation System for the Nickel Concentrator
Client : Canadian Royalties Inc.
Location : EXPO Mine, Quebec (Nunavik)
Year : 2013
Canadian Royalties is a mining company that operated a nickel and copper mine in Nunavik.
Several contaminants were airborne in the concentrator due to inadequate ventilation. Canadian Royalties mandated LDV Consultants to provide technical support to its engineering team to fix the problem.
In phase 1 of the mandate, LDV Consultants carried out the following:
- Validate the technical solution proposed by a contractor and identify the critical zones;
- Prioritize the work and set a preliminary schedule;
- Analyze the impact of the changes to the ventilation on the glycol and electrical systems;
- Produce a preliminary layout.
In phase 2 of the mandate, LDV Consultants carried out the detail engineering, namely:
- Perform calculations for the fans, glycol pumps, electrical system capacity, piping supports and concrete foundations;
- Specify the equipment to be purchased;
- Design the P&ID for the ventilation and glycol systems;
- Supply the installation drawings for the fans, pumps and electrical connections;
- Provide the isometric drawings.
Design a Cutting Bench for Rubber Mouldings
Client : Conceptromec Export
Location : Magog, Quebec
Year : 2013
Conceptromec is in the business of designing and manufacturing customized equipment for a demanding clientele who manufactures various plastic and rubber extrusions. Victim of their own success for some time now, their internal resources were no longer sufficient to meet the growing demand of their clientele.
Therefore, LDV Consultants was mandated by Conceptromec to develop several projects, including designing a semi-automatic workstation to cut rubber mouldings for the automotive sector.
LDV was in charge, together with Conceptromec, of developing the equipment, validating its feasibility and performance, and producing all the drawings needed to manufacture and install the equipment.
Modification of an Out-Feed Guide to Align Containers of Different Shapes and Sizes
Client : Ultima Foods
Location : Granby, Quebec
Year : 2013
For more than 40 years, Ultima Foods has been recognized as a major player in the manufacturing of yogurt. Its production currently takes place in two plants: one in Granby and another one in Delta, British-Columbia.
In an effort to continually improve its facilities, Ultima Foods regularly makes changes to its production equipment. It is within this context that Ultima Foods mandated LDV to replace the system used to align yogurt containers fed in continuously on a moving conveyor belt. The introduction of new container shapes and sizes justified the need to change the equipment to make it self-adjustable in three positions.
LDV, in consultation with Ultima Foods, was in charge of designing a pneumatically-actuated version of the equipment, validating its feasibility, performance and adaptability to different container shapes and sizes as well as producing all the drawings needed to manufacture and install the equipment. In addition, LDV supervised the equipment installation and commissioning.
Integrate a Cummins Tier-4i Engine in a Haulage Truck
Client : Dux Machinery
Location : Montreal,Quebec
Year : 2013
DUX Machinery is a leading manufacturer of underground haulage equipment. Power mechanization of its equipment needs to change in order to meet the requirements of the environmental regulation.
The haulage truck must be adapted so that a new engine and, more importantly, new air intake and exhaust components can be installed.
LDV was therefore mandated to finalize the selection of the engine options, validate the heat transfer equipment with regard to air intake and engine cooling and adapt the engine compartment to allow installation of a new air filter and exhaust.
Repair a Two-Level Aluminum Railcar
Client : Bombardier Transportation
Location : Los Angeles, California, USA
Year : 2012
Bombardier is a world leader in land and air transportation. Its Bombardier Transportation Division offers one of the world's most comprehensive series of rail vehicles.
Further to an accident, extensive damage was done to one side of railcar #125 owned by Metrolink. Bombardier Transportation mandated LDV Consultants to evaluate the damage and propose a potential repair scenario.
As part of the mandate, LDV carried out the following:
- Inspect the damaged railcar at the maintenance centre;
- Develop a repair scenario together with the Methods Department of the Thunder Bay plant.
Feasibility Study
Client : Osisko Hammond Reef Gold
Location : Atikokan, Ontario
Year : 2011
The Hammond Reef Gold reserve is located approximately 170 km west of Thunder Bay, Ontario. Osisko, owner of the property and mining rights, mandated LDV Consultants to build a 3D model of their concentrator and other facilities, produce instrumentation drawings (P&ID), design the structure and concrete of the main buildings and assist with different tasks related to the feasibility study.
LDV designed the plant using SolidWorks. Integration of various disciplines (such as mechanical, civil, electrical and piping) was carried out using Naviswork. Cross-sectional and elevation drawings of the plant were also produced to complete this feasibility report. The process diagrams and equipment list were updated by LDV, in accordance with the general layout of the plant.
In this project, several layouts and configurations were analyzed in order to minimize the floor space requirements, thus reducing the quantity and cost of the structure and concrete, while providing access to the equipment and optimizing the process flow. The instrumentation diagrams were optimized from original diagrams produced for the Malartic site, also owned by Osisko.
Technical Assistance for the Bloom Lake Expansion Project
Client : Cliffs Natural Resources
Location : Bloom Lake, Quebec
Year : 2011
Cliffs Natural Resources - Bloom Lake is a mining company operating an iron ore concentrator at Bloom Lake, a few kilometers from Fermont. As the expansion project and construction were underway, Cliffs Natural Resources asked LDV Consultants to provide an engineer to join the owner’s team.
During the engineering phase, LDV Consultants’ engineer was responsible for the following:
- Plan the plant layout;
- Oversee all mechanical designs, chutes, pump boxes, etc.;
- Oversee piping routing and design;
- Ensure coordination between engineering and manufacturing of the mechanical equipment and/or components and piping;
- Review the engineering documents;
- Review the manufacturers’ documents.
Tanks and Calcium Chloride System
Client : Cliffs Natural Resources
Location : Lac Bloom, Quebec
Year : 2011
Cliffs Natural Resources - Bloom Lake is a mining company operating an iron ore concentrator at Bloom Lake, a few kilometers west of Fermont. To overcome the freezing of iron ore concentrate in railcars, Cliffs Natural Resources wanted to develop and install an automatic calcium chloride spray system, which would prevent freezing without having to heat the railcars while unloading during winter.
To achieve this objective, Cliffs Natural Resources mandated LDV Consultants to design and support the installation of this system.
Therefore, for this project, LDV Consultants designed the tanks and spray arms, was involved in the selection of the pumps and piping, electrical parts, control methods and instrumentation, and produced detailed drawings and specifications for the installation. In addition, LDV Consultants was mandated to provide technical support for the tendering and construction phases.
Spiral Test Bench
Client : Cliffs Natural Resources
Location : Bloom Lake, Quebec
Year : 2010
Cliffs Natural Resources - Bloom Lake is a mining company exploiting an iron ore deposit near Bloom Lake, a few kilometers from Fermont. Cliffs Natural Resources integrated, into its concentrator, a new test bench for spirals in order to test the effectiveness of different spiral models available on the market.
To achieve this objective, Cliffs Natural Resources mandated LDV Consultants to perform the engineering for the integration of the new spirals with those already in place. Furthermore, LDV Consultants was mandated to provide on-site technical support during the installation.
For this project, LDV Consultants performed the structural drawings for the new spirals, the modification diagrams for the washing water piping, the drawings for the general equipment layout and prepared the specifications for the installation.