SCHOOL OF MINING ENGINEERING
MINE4610 Mine Asset Management & Services
Course Outline
SESSION 1, 2010
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UNSW Mining Engineering COURSE OUTLINE
CONTENTS General Course Information ................................................................................................... 3 Course Convenors ................................................................................................................. 3 Course Description ................................................................................................................ 3 Assumed Background ............................................................................................................ 4 AIMS, LEARNING OUTCOMES & GRADUATE ATTRIBUTES .............................................. 7 Recommended Texts and Resources .................................................................................... 8 University Policies ................................................................................................................ 10
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GENERAL COURSE INFORMATION
Course Title: Mine Asset Management & Services Semesters Offered: Semester 1 Level: Undergraduate Number of Units/Credits: 6 (UNSW) Contact Hours per Week 4 contact hours to be utilised for Activity Based Learning and Project Support. Contact times are scheduled for:
Wednesday 2pm: OMB G51. Plus it is anticipated that Peter knights will present a number of online lectures in G51 or G38 For up to date information on lectures and workshops, see the Course Calendar in Moodle. Assessment NOTE: Course completion requires that all assessment items be completed. Course Convenors Dr. Peter Knights School of Engineering University of Queensland Qld 4072 Australia Tel: (617) 3346 5620 [email protected] Dr Chris Daly School of Mining Engineering University of New South Wales [email protected] Dr Mahinda Kuruppu Curtin University of Technology West Australian School of Mines [email protected] Assoc Prof Emmanuel Chanda Program Leader in Mining Engineering The University of Adelaide School of Civil & Environmental & Mining Engineering Adelaide SA 5005 Emai:[email protected]
Course Description
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This course covers the principles of maintenance of mining equipment and the design and operation of mine services, including electrical and compressed air distribution systems, mine dewatering systems and mine communication systems. It covers the design of maintenance systems, including preventive, predictive, proactive and corrective maintenance methods, as well as basic reliability theory and models for optimising maintenance decisions.
Assumed Background This course assumes that students have a good understanding of mining terms and descriptions, have been exposed to surface and underground mining methods and are familiar with mining development, operations and production. The completion of the Mining Systems course is hence assumed.
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Content
Mine maintenance and services are responsible for between 40 and 70 percent of the operating cost of a surface mine, and 20 to 50 percent of the operating cost of an underground mine. The quality of maintenance programs affects the productive capacity of mining operations. In the course of their professional careers, Mining Engineers will find themselves dealing with maintenance and service related issues such as: working with teams to de-bottleneck productive processes; preparing and checking maintenance budgets; administrating maintenance contracts; and deciding on mine dewatering or electrical distribution layouts. The proposed course covers the principles of mine maintenance and services, including electrical and compressed air distribution, mine dewatering and mine communications. It covers the design of maintenance systems, including preventive, predictive, proactive and corrective maintenance methods, as well as basic reliability theory and models for optimising maintenance decisions. Specific topics to be covered include: PART 1 Mine Maintenance Management
a. Physical Assets The purpose of physical assets Performance requirements
The life cycle of physical assets Value through asset management
b. Asset Management Strategy
Strategy, tactics and resources
The maintenance process Determining equipment priority Maintenance maturity model
c. Asset Management Tactics
Functions, functional failures and failure modes Failure intensity functions Maintenance tactics Selecting tactics
d. Asset Management Process and Organisation
Key asset management processes Work Order Management Maintenance forecasting, planning & scheduling Organisational structure
e. Asset Management Measurement, Control & Improvement
Performance measurement Continuous improvement Root Cause Analysis
Operator Driven Reliability
f. Spares and Repairs Management Spares classification
High rotation spares
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Low rotation spares Advanced sparing decisions
g. Contracts and Contractor Management
Contract types Work scope Agreed performance measurements Risk sharing
PART 2: Mine Services a. Electrical distribution systems (Mahinda Kuruppu )
a. Motor fundamentals and selection b. Transformer and distribution losses c. Power factor calculation d. Power consumption and costs
b. Hydraulic systems (Chris Daly) a. Power hydraulics and circuits b. Hydraulic motors and actuators c. Mine case study
c. Compressed Air (Chris Daly) e. Compressor types and sizing f. Equipment air requirements and air line losses g. Air leg drilling and other applications
d. Mine water management (dewatering) (Mahinda Kuruppu) h. Pump characteristics and selection i. Frictional head losses in pipes j. Case study
e. Mine communications (Chris Daly) k. Bandwidth requirements l. Open pit communication technologies m. Underground communication systems
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AIMS, LEARNING OUTCOMES & GRADUATE ATTRIBUTES
Course Aims This course provides an overview of the principles and application of the major underground and surface mining methods and equipment, and the conceptual design of the major materials handling and transport systems and support infrastructure. Specific topics to be covered include:
Surface mining methods Underground mining methods Materials handling and transport systems Systems infrastructure and site requirements.
Learning Outcomes
After completing this course, it is intended that the students will be able to:
appreciate the value of maintenance as a profit driver and not solely as a cost centre
identify the life cycle stages of mining equipment and related management processes
Identify the role of maintenance planning and scheduling to quantify demand for maintenance resources and allocate these resources
Identify the principle maintenance strategies and appreciate the importance of applying proactive strategies.
identify the principle condition-based maintenance strategies used in the mining industry and critically evaluate their applicability to mining equipment
describe and define key maintenance performance indices, and appreciate the impact these have on mining operations
apply basic reliability theory to practical mining examples, including failure rates and how these dictate maintenance tactics
assess in-house versus contractor approaches to delivering maintenance services
Identify the principles of electrical power distribution, water management, compressed air, hydraulic and communication systems and associated management strategies and hazards.
apply the principles of risk management to the maintenance of equipment and services
Graduate Attributes
appropriate technical knowledge
having advanced problem solving, analysis and synthesis skills with the ability
to tolerate ambiguity
being able to think and work individually and in teams
listening, influencing, motivating and communication skills
basic business and management skills
awareness of opportunities to add value through engineering and the need for
continuous improvement
being able to work and communicate effectively across discipline boundaries
having HSEC consciousness
being active life-long learners.
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RECOMMENDED TEXTS AND RESOURCES
Reference Texts
Campbell, J.D., 1995, “Uptime: Strategies for Excellence in Maintenance Management”, Productivity Press, Portland, OR, 192 pp.
Campbell, J.D. and Jardine, A.K.S., 2001, “Maintenance Excellence: Optimizing Equipment Life-Cycle Decisions”, Marcel Dekker, N.Y., 495 pp.
Kelly, A., 1997, “Maintenance Organization & Systems”, Butterworth Heinemann, Oxford, 280 pp.
Kelly, A., 1997, “Maintenance Strategy”, Butterworth Heinemann, Oxford, 262 pp.
Lawrenson, J., 1986, “Effective Spares Management”, international Journal of Physical Distribution & Materials Management, Vol 16, No. 5., 111 pp.
McDermott, E.E., Mikulak, R.J., and Beauregard, M.R., 1996, “The Basics of FMEA”, Productivity Press, Portland, OR, 74 pp.
Moubray, J. 1992, “Reliability-Centered Maintenance”, 2nd Edition, Industrial Press Inc., NY, 414 pp.
O’Conner, P.D.T., 2000, “Practical Reliability Engineering”, 4th Edition, John Wiley and Sons, Chichester, UK., 431, pp.
Parr Andrew, 1999, “Hydraulics and Pneumatics: A Technician’s and Engineers Guide”, 2nd Edition, Butterworth Heinemann, Oxford, pp.244
Smith, D.J., 2002, “Reliability, Maintainability and Risk”, 6th Edition, Butterworth Heinemann, Oxford, pp.335
Online and Other Resources As this is a cross institutional MEA course we will use Moodle this semester. Please go to elearning.mea.edu.au Your logins should be current from S2 2009.
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Learning Activities and Methods Learning Activities Summary for S1 2010
Week Activity Area Content Presenter
1 Lecture Physical Assets
L1: The purpose of physical assets L2: Performance requirements L3: The life cycle of physical assets L4: Value through asset management
PK
2 Lecture Asset Management Strategy
L1 Strategy, tactics and resources L2. The maintenance process
L3. Determining equipment priority L4. Maintenance maturity model
PK
3 Lecture Asset Management Tactics
L1 Functions, functional failures and failure modes
L2 Failure intensity functions L3 Maintenance tactics L4 Selecting tactics
PK
4 Lecture
Asset Management Process and Organisation
L1 Key asset management processes L2 Work Order Management L3 Maintenance forecasting, planning &
scheduling L4 Organisational structure
PK
5 Lecture
Asset Management Measurement, Control & Improvement
L1 Performance measurement L2 Continuous improvement L3 Root Cause Analysis L4 Operator Driven Reliability
PK
6 Lecture
Management Spares classification
L1 High rotation spares L2 Low rotation spares L3 Advanced sparing decisions
PK
7 Lecture
Contracts and Contractor Management
L1 Contract types L2 Work scope L3 Agreed performance measurements L4 Risk sharing
PK
8 Lecture Electrical distribution systems
L1 Motor fundamentals and selection L2 Transformer and distribution losses L3 Power factor calculation L4 Power consumption and costs
MK
9 Lecture Hydraulic systems
L1 Power hydraulics and circuits L2 Hydraulic motors and actuators L3 Mine case study
CD
10 Lecture
Compressed Air
L1 Compressor types and sizing L2 Equipment air requirements and air line losses L3 Air leg drilling and other applications
CD
11 Lecture
Mine water management
L1 Pump characteristics and selection L2 Frictional head losses in pipes L3 Case study
MK
12 Lecture Mine communications
L1 Bandwidth requirements L2 Open pit communication technologies L3 Underground communication systems
CD
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UNIVERSITY POLICIES
Assignment Submissions Assignments must have attached a completed and signed copy of the School Assignment coversheet. This can be downloaded from the web at http://www.mining.unsw.edu.au/Courses/student_info/menu_student_info.htm. Most submissions in this course will be a digital sub Submission of assessable materials must conform to the School Policy on Assignment Submissions. The Policy details information relating to penalties for late submission of assignments. See http://www.mining.unsw.edu.au/Governance/policies.htm for further details regarding the Policy. Resources for Students Support material for this course including, whenever available, copies of lecture notes, recommended readings, assignments and results for assignments etc can be found on Moodle at http://elearning.mea.edu.au. All correspondence with students will be achieved using the internet mail facility within Moodle. Changes in the lecture schedule and assignment dates will be posted on the calendar in Moodle. Most of the reference books are available in the UNSW Library. Academic Honesty and Plagiarism The University has certain expectations in terms of academic behaviour related to study and research. This is expressed in the University Policy on Academic Misconduct. Students should be aware of and understand this Policy. Links to this and other University and School Policies can be found at http://www.mining.unsw.edu.au/Governance/policies.htm. Plagiarism is the presentation of the thoughts or work of another as one’s own1. Examples include:
direct duplication of the thoughts or work of another, including by copying work, or knowingly permitting it to be copied. This includes copying material, ideas or concepts from a book, article, report or other written document (whether published or unpublished), composition, artwork, design, drawing, circuitry, computer program or software, web site, Internet, other electronic resource, or another person’s assignment without appropriate acknowledgement;
paraphrasing another person’s work with very minor changes keeping the meaning, form and/or progression of ideas of the original;
piecing together sections of the work of others into a new whole;
presenting an assessment item as independent work when it has been produced in whole or part in collusion with other people, for example, another student or a tutor; and,
claiming credit for a proportion a work contributed to a group assessment item that is greater than that actually contributed2.
1 Based on that proposed to the University of Newcastle by the St James Ethics Centre. Used with kind permission from the
University of Newcastle.
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Submitting an assessment item that has already been submitted for academic credit elsewhere may also be considered plagiarism. The inclusion of the thoughts or work of another with attribution appropriate to the academic discipline does not amount to plagiarism. Students are reminded of their Rights and Responsibilities in respect of plagiarism, as set out in the University Undergraduate and Postgraduate Handbooks, and are encouraged to seek advice from academic staff whenever necessary to ensure they avoid plagiarism in all its forms. The Learning Centre website is the central University online resource for staff and student information on plagiarism and academic honesty. It can be located at www.lc.unsw.edu.au/plagiarism The Learning Centre also provides substantial educational written materials, workshops, and tutorials to aid students, for example, in:
correct referencing practices;
paraphrasing, summarising, essay writing, and time management;
appropriate use of and attribution for, a range of materials including text, images, formulae and concepts.
Individual assistance is available on request from The Learning Centre. Students are also reminded that careful time management is an important part of study and one of the identified causes of plagiarism is poor time management. Students should allow sufficient time for research, drafting, and the proper referencing of sources in preparing all assessment items. Continual Course Improvement Periodically student evaluative feedback on the course is gathered, using among other means, UNSW's Course and Teaching Evaluation and Improvement (CATEI) Process which is an anonymous, on-line survey system. Student feedback is taken seriously, and continual improvements are made to the course based in part on such feedback. Significant changes to the course will be communicated to subsequent cohorts of students taking the course. Correspondence and Email Messages A policy of the University is that it expects students will regularly check their email accounts. The School assists in this by providing free access to computing facilities and the internet. In line with this policy, messages will be sent to students through their Moodle account. Students can retrieve these messages from the mailbox in each Moodle course account.
2 Adapted with kind permission from the University of Melbourne.
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Administrative Matters Students should ensure they are familiar with the various policies related to expectations of students. Links to the Policies can be found on the School web page at http://www.mining.unsw.edu.au/Governance/policies.htm Equity and diversity: those students who have a disability that requires some adjustment in their teaching or learning environment are encouraged to discuss their study needs with the course convener prior to, or at the commencement of, their course, or with the Equity Officer (Disability) in the Equity and Diversity Unit (www.equity.unsw.edu.au/disabil.html). Issues to be discussed may include access to materials, signers or note-takers, the provision of services and additional exam and assessment arrangements. Early notification is essential to enable any necessary adjustments to be made. Information on designing courses and course outlines that take into account the needs of students with disabilities can be found at www.secretariat.unsw.edu.au/acboardcom/minutes/coe/disabilityguidelines.pdf