An initiative of the Mining Council of Australia incorporating:

ENGG 4103 Engineering Asset Management & Maintenance incorporating MEA elective: Mine Asset Management and Services Lecture 1 Introduction and Course Objectives 1st Semester 2014

Dr. Peter F. Knights

Division of Mining Engineering, The University of Queensland and Program Leader Smart Mining Systems, CRCMining, Brisbane, Australia. p.knights@uq.edu.au

ENGG4103
What is an asset? How do physical assets differ from financial assets? Why should engineers be concerned with physical assets?

Black Saturday Victorian Bushfires, 7th Feb 2009

2009 Victorian Bushfires Royal Commission Recommendations

Recommendation 28 The State (through Energy Safe Victoria) require distribution businesses to change their asset inspection standards and procedures to require that all SWER lines and all 22-kilovolt feeders in areas of high bushfire risk are inspected at least every three years. Recommendation 29 The State (through Energy Safe Victoria) require distribution businesses to review and modify their current practices, standards and procedures for the training and auditing of asset inspectors to ensure that registered training organisations provide adequate theoretical and practical training for asset inspectors. Recommendation 30 The State amend the regulatory framework for electricity safety to require that distribution businesses adopt, as part of their management plans, measures to reduce the risks posed by hazard treesthat is, trees that are outside the clearance zone but that could come into contact with an electric power line having regard to foreseeable local conditions.

Class Action
Thousands more likely to join Black Saturday class action
The Age Date January 11, 2013 More than 10,000 victims of the Kilmore East-Kinglake Black Saturday bushfire could take part in the class action against the electricity company deemed responsible for the deadly blaze, a court has heard. The victims involved come from five municipalities - Nillumbik, Mitchell, Yarra Ranges, Whittlesea and Murrindindi. The legal action is being brought against electricity company SP AusNet, trading as SPI Electricity, who owned and had responsibility for maintaining of the power lines that caused the blaze on February 7, 2009. The fire claimed more lives than any other bushfire in Australia's history, with 119 people killed, 1242 homes destroyed and a total of 125,383 hectares burned. The Victorian Bushfire Royal Commission found the blaze was caused by a faulty powerline owned and maintained by the electricity company, trading as SP AusNet. The total losses sustained in the bushfire was estimated at the Royal Commission hearings as high as $1 billion.

About your course coordinator

28 years experience in construction and mining industries industry and academia B.Eng (Mech) U. Melb, M.Eng (Systems) RMIT PhD (Mining), McGill, Canada 9 years as Associate Prof with Catholic University of Chile Founding partner Reliability Technologies S.A. (Santiago) Invented Jack Knife downtime classification scheme, widely used in Chile. Taught industry short courses in Australia, Chile, Peru, Argentina, Iran, Singapore and Canada.

Course staff
UQ Coordinator (Asset Management) Dr. Peter Knights Ph. 33653915 Email: p.knights@uq.edu.au Room: 43-204 Visiting hours Tues 2:00-5:00 pm UNSW Coordinator (Services) - Dr Chris Daley - C.Daley@unsw.edu.au WASM Coordinator (Services) - Dr Mahinda Kuruppu - M.Kuruppu@curtin.edu.au

Tutors (2013) Munirud Dean Rahul Bose Joshua Brown

About this course

In Semester 1 2013, this course will be run in parallel with the elective course "Mine Asset Management and Services" developed for Mining Education Australia. To achieve this, the course has been divided into three parts A, B and C. Part A (weeks 1 to 7 inclusive) is common to all engineering students and deals with physical asset management fundamentals. Part B (weeks 8 to 12 inclusive) is for students enrolled in Mining Engineering, and focuses on Mine Services. Part C (weeks 8 to 12 inclusive) is for non-mining engineering students and will be run as a series of computer laboratory practicals dealing with advanced asset management issues.

Course Aims (all students)

Engineering assets comprise property (buildings), plant (equipment) and infrastructure (roads, railways, and electrical transmission lines, for instance). Throughout your professional careers, you will find yourselves having to make decisions concerning the design, acquisition, maintenance and renewal of engineering assets. The challenge is to optimise owning and operating costs over the life cycle of an engineering asset. This course aims to impart the fundamentals of: (i) reliability engineering; (ii) maintenance engineering & management; and (iii) optimisation of component and capital equipment replacement decisions to third and fourth year engineering students (non mining students).

Course Aims (mining students)

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 your professional careers, you 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 distribution systems, conveyor systems, hoisting systems and mine dewatering.

Learning outcomes
At the end of this course, the students will be able to demonstrate an understanding of: 1 (Reliability engineering) Distinguish between functions, functional failures and failure modes. Be familiar with basic reliability analysis, equipment performance indices and improvement methods. 2 (Maintenance management) Ability to design and implement maintenance support systems for engineering assets, including specifying preventive, predictive, proactive and corrective tasks within an overall maintenance strategy. 3 (Component and capital equipment replacement) Undertake quantified risk assessments for optimising maintenance decisions and apply life cycle costing and equivalent annual cost (EAC) methods for optimizing capital equipment replacement. 4 Mine Services - Be familiar with electrical power distribution fundamentals, mine dewatering principles, conveyor and hoisting system limitations.

Graduate attributes
This course will contribute to the development of the following 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 ad 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.

Timetable
Loca tion St Lucia Group Day Start End Building Room Start - End Date 7/03 6/06 Start date(s) L Fri 14:00 pm 10:00 am 3:00 pm 4:00 pm 3:00 pm 5:50 pm 11:50 am 4:50 pm 5:50 pm 4:50 pm 42 115 7 March 6 June

P01

Tues

50

N301

15/03, 25/03, 29/04. 19/04 14/03 18/04 26/03, 30/04

P02

Wed

50

N301

P03

Thurs

50

N301 30/04 28/05

27/03, 01/05 30/04 to 28/05 inclusive. These tutorials are for mining students only

Wed

45

204

Notes: L (Lectures) P (Practicals) non-mining students, taught weeks 3, and 7 only T (Tutorials) mining students only, taught weeks 8-12 (Part B Mine Services)

Course outline (all students)

Part A: ASSET MANAGEMENT
Week 1. Physical Assets (3 hours) The purpose of physical assets, Performance requirements, The life cycle of physical assets, Value through asset management Week 2. Asset Management Strategy (3 hours) Strategy, tactics and resources, The maintenance process, Determining equipment priority, Maintenance maturity model Week 3. Asset Management Tactics (3 hours) Functions, functional failures and failure modes, Failure intensity functions, Maintenance tactics, Selecting tactics Week 4. Asset Management Process and Organisation (3 hours) Key asset management processes, Work Order Management, Maintenance forecasting, planning & scheduling, Organisational structure Week 5. Asset Management Measurement, Control & Improvement (3 hours) Performance measurement. Continuous improvement, Root Cause Analysis, Operator Driven Reliability Week 6. Spares and Repairs Management (3 hours) Spares classification, High rotation spares, Low rotation spares, Advanced sparing decisions Week 8. Contracts and Contractor Management (3 hours) Contract types, Work scope, Agreed performance measurements, Risk sharing.

Course outline (mining students)

Part B: MINE SERVICES Week 9 (Wed). Mine Winders (Ed Northcote) (3 hrs) Week 9 (Friday). Conveyor Systems (Rob Krek, SKM) (3 hrs) Design calculations, Operation and Maintenance, Mine case study Week 10 Mine water management and dewatering (Ed Northcote) (3 hrs) Pump characteristics and selection, Frictional head losses in pipes, Case study Week 11. Electrical distribution systems (Alan Robertson + support material P.K.) (3 hrs) Motor fundamentals and selection, Transformer and distribution losses, Power factor calculation, Power consumption and costs

Course outline (non mining students)

Part C: OPTIMISATION OF COMPONENT AND EQUIPMENT REPLACEMENT DECISIONS

Week 10. Materials handling systems Week 11. Life cycle cost estimation Week 12. Asset management standards Week 13. Future maintenance systems

Assessment
ASSIGNMENTS 7 March 7 April Maintenance Strategy Formulation (group) 11 April -5 May Case study analysis (individual) 21 May 6 June Mine Services (mining students only) QUIZZES 9-May 30% 30% 30%

Asset Management (all students)

10%

PRACTICALS (14-219 Sir Llew Edwards Building) (non mining students) 25, 26 &27 March Weibull fitting /component replacement 29, 30 April, 1 May Capital replacement decisions Class divided into P1, P2, P3 according to published list. 15% 15%

Course text
MEA Learning Guide - Mine Asset Management and Services - Part A Mine Asset Management (all students) MEA Learning Guide - Mine Asset Management and Services - Part B Mine Services (mining students) MEA Part B

Recommended texts (library)

Reyes-Picknell, J. & Campbell, J.D. , 2006. Uptime: Strategies for Excellence in Maintenance Management, 2nd Edn., Productivity Press, Portland, OR, 192 pp. Picknell Jardine, A.K.S. and Tsang, A.H.C. 2006 Maintenance, Replacement and Reliability: Theory and Applications, CRC Taylor & Francis, New York, 322 pp. Jardine Kelly, A., 2006, Strategic Maintenance Planning, Butterworth Heinemann, 284pp. Kelly, A., 2006 Managing Maintenance Resources, Butterworth Heinemann, 292pp. Kelly, A., 2006 Maintenance Systems & Documentation, Butterworth Heinemann, 238pp. Lawrenson, J.,1986 "Effective Spares Management, international Journal of Physical Distribution & Materials Management, Vol 16, No. 5., 111 pp. O'Conner, P.D.T. 2001 "Practical Reliability Engineering", 4th Edn., John Wiley and Sons Moubray, J.1992 Reliability-Centered Maintenance, 2nd Edition, Industrial Press Inc., NY, 414 pp.

Useful websites
www.plant-maintenance.org.au Asset Management Council www.amcouncil.com.au The Asset Management Journal www.theammj.com