Auslec Solutions 06

ISSUE 6

PP255003/09661

AUTUMN 2011

“... only 56 Series can handle his daily grind.”

Craig and his workmates at Penrice Soda’s Angaston Mine process more than 11,000 tonnes of limestone a day. From blasting to grinding, their switchgear must handle the harshest of mining conditions and withstand daily exposure to heat, dust, chemicals, impact and water. Only 56 Series can handle this rigorous environment day in day out, all year round.

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56 Series provides true performance in power and is manufactured from premium grade materials, specifically designed to handle the most extreme work environments.

If you require switchgear that can handle the daily grind, insist on 56 Series.

For more information contact your nearest L&H Electrical wholesaler or visit clipsal.com

© Clipsal Australia Pty Ltd

56 Series superior features and benefits: • • • •

25% stronger socket cover.

Redesigned socket cover latch – easier to operate.

New pivot assembly strengthens cover.

New cover gasket negates the need for #9 caps to maintain IP rating and improves ease of installation.

• Raised ON/OFF indicators – less prone to removal.

• Chemical resistant options to suit different applications.

• Laser printed labelling.

CO NTEN TS

Welcome.

04 Out and about

06 Mining issues in 2011 08 Branching out — Wollongong 10 Finding the right maintenance program in a mining operation 14 A day in the extremes — NZ's Awesome Foursome 18 Product cut 22 Mine's bigger than yours 24 Branching out — Darwin 28 Providing total protection from lightning strikes 34 Mining's second boom

Published By L&H Group A.B.N. 19730 781 473 456 Lower Heidelberg Road, Heidelberg VIC 3084 Australia Ph: +61 3 9243 3555 www.auslec.com.au Editor Paul Stathis Ph: +61 3 9381 2952 pstathis@westwick-farrow.com.au Art Director/Production Manager Julie Wright Ph: +61 2 9487 2700 jwright@westwick-farrow.com.au Associate Publisher Gavin Karthaus Ph: +61 3 9381 2952 gkarthaus@westwick-farrow.com.au

Produced on behalf of L&H Group by

A division of Westwick-Farrow Media.

A.B.N. 29 001 621 861

Was that really January and February that just shot past us? Surely not.

Here at L&H Group, we are genuinely excited about what the rest of 2011 holds for us and our industry. Daily, the people I speak to have a very real belief that we are well past the GFC — many organisations have even come out of 2010 with leaner and more effective operations. I trust you are looking at ways in which you can add real value to both your company and your customers?

Auslec Solutions continues to be a terrific way for us to communicate quality information to our valued customers and your ongoing feedback is helping us to do this. This issue is no exception.

Always a hot topic of debate and discussion is the various styles of maintenance practised by industry.

In this issue, we talk to Stephen Farnsworth, Electrical Maintenance Superintendent at Xstrata’s copper smelter, for his views on optimising maintenance schedules.

Keeping with the mining theme, we also look at some of the bigger aspects of mining — literally. Turn to page 22 to read some amazing stats and facts about some of the massive machinery often used on mine sites throughout our country.

On a different tack altogether, where do you think is the most adrenalin-charged destination on the planet? Quite possibly Queenstown in New Zealand, going by our article starting on page 14. Some of our more adventurous staff here at Auslec completed the Awesome Foursome and you can read about their experiences — just plain crazy if you ask me!

Again, heaps of new and exciting products are featured in this issue, so if you have any questions about any of them, please just drop in to your local Auslec branch and speak with the guys; they’ll help you out.

All the best, Robin Norris Chief Executive Officer L&H Group

© iStockphoto.com/bonnie jacobs

Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 Australia Ph: +61 2 9487 2700 ISSN 1837-8021 All rights reserved. Reproduction in whole or part without the permission of the publisher is strictly prohibited. Copyright L&H Group. Opinions expressed are those of individuals and are not necessarily those of the publisher. All information is believed to be correct at time of publication. All reasonable efforts have been made to contact copyright holders.

All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us.

Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them.

If you have any feedback for us on anything you’ve seen or would like to see in Auslec Solutions, just email us at solutionsmagazine@auslec.com.au

www.auslec.com.au AUSLEC 4

HOW THE AUSLEC TEAM TACKLED the recent Queensland floods This double-page spread in Auslec Solutions normally features news and events that are occurring in our industry under the caption ‘Out&About’ where we get amongst our branches and customers to find out what’s happening in the market.

But as we started talking to various folk to gather industry news, we found

that they were asking us what we’d heard about our people who had been affected by the floods in South East Queensland.

So we channelled all our efforts to find out what had happened up there.

We contacted a few of our staff to get a first-hand account of how they coped, in order to share some of their experiences

with our readers. We also managed to find out what some of our branches went through in the post-flood recovery process.

Some of those we spoke to were happy for us to write about their experiences, while others were prepared to talk about it but declined to allow us to publish it.

They were obviously too traumatised by

discounts to assist with their recovery.

Over 700 government agency accounts with special pricing had been set up throughout the flood-affected region. The Ipswich L&H branch had products flown in from Hobart, Sydney and Melbourne to maintain its supply of crucial equipment to customers.

“If the word ‘flood’ was used, we automatically went into ‘top-priority’ mode,” Michael reflected. “Deliveries were going in and out of the branches on a daily basis, during business hours, at night, on weekends — whenever it was required.”

During our interview, Michael spoke at length about his gratitude to L&H and the support he received, adding very genuinely: “I will never even think of working for another company after this.”

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to have been around 6 m x 10 m at the base and about 3.5 m high.

Displaying that same charitable Aussie spirit shown to him, Michael took time off work to help out at the Murphy’s Creek Command Centre where L&H and some of its suppliers donated lighting, cables, generators and other gear to get power back to the area. One of his customers even donated the services of his 24-tonne loader for three days to ship equipment to flood-affected areas.

At branch level, a number of initiatives were quickly put in place to help with the recovery. Auslec and L&H branches developed a ‘Flood Quote’ system in conjunction with suppliers, whereby any person or company that had been affected by the floods received substantial

AUSLEC

their ordeal to be reminded of it in print, and we respect their request.

We are not trying to repeat any of the news or information that was comprehensively covered in the mainstream media.

Rather, we wanted to share with you the remarkable ‘Aussie spirit’ displayed by the Queenslanders who faced this ‘nightmare’.

The people we spoke with told us how they coped, how they were assisted and how they assisted the community.

Michael Chaplin is a Sales Representative at the L&H Toowoomba Branch. He told us that he was at work when news broke out about the wall of water that was approaching Toowoomba. Fearing for the safety of his wife, who was eight months pregnant, and his two-year-old child at home on their 25-acre property, Michael asked his manager, Troy McCarthy, if he could rush home. Naturally, Troy told him to “just go”.

At the time, his wife was not aware of the impending danger she and her family faced. Unable to contact her, he fretted for an agonising couple of hours as he struggled to make his way home, hampered by several landslides, along with flood waters that were, in some places, running at around 70-80 km/h across the submerged roads along the way.

Thankfully, his wife and children had been rescued by an evacuation team and were safe. In a matter of only a few hours, Michael’s home became an island — it was completely surrounded by the flooded Lockyer Creek. For quite some time, the nearest land to his house was 600 m away.

Unable to re-enter the property for three days, Michael and his family stayed at his boss Troy’s house for a couple of nights. After that, Troy and other workers at the Toowoomba L&H branch, along with some of Michael’s customers, came together to assist him and his family in the massive clean-up. Once the waters subsided, they witnessed the full extent of the flood damage to his property — virtual mountains of soil washed down from the swollen river and all forms of debris from damaged buildings and cars that had been carried for miles through the countryside. One pile of debris that washed up on the property was estimated

5

*issues in 2011

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www.auslec.com.au

© iStockphoto.com/cbpix

Mining

6

An International Council on Mining and Metals (ICMM) survey in September 2010 revealed that environmental and social issues are the biggest challenges facing the mining industry globally.

The ‘2010 Stakeholders Views of Mining and Sustainable Development’ survey ranked stakeholders’ most serious concerns for the future as: environmental (40%), social (28%), governance/regulation (27%), water usage (17%) and financial (at a surprisingly low 13%). Ironically, water usage would be of little concern to mining companies affected by Australia’s recent record floods. Top-of-mind issues were the economic crisis, high-profile accidents, corruption scandals and China’s growing influence.

In total, 847 respondents from the private sector, public sector, institutions, academia and non-governmental organisations in 81 countries (including Australia) participated.

ICMM President Anthony Hodge said: “We often hear suggestions that the mining industry falls short when it comes to sustainable development and responsible business practices, but the survey suggests that the work we’re doing to improve sustainable development performance is being recognised.

“However, this doesn’t mean we should be complacent — people are rightly telling us to reinforce our efforts to promote transparency, respect the values of surrounding communi-

ties and enhance the contribution of mining to people and the environment.”

Notably, the survey observed that meeting market demands was no longer a top issue, likely due to the uncertain economic environment.

Local issues An Australian Mines and Metals Association (AMMA) survey of resource industry employers found a significant decrease in employer confidence with the Fair Work Act (FWA) over the six months to October 2010.

AMMA Chief Executive Steve Knott said the survey found employer concerns rising significantly, while confidence in the new workplace relations system fell: “Previously, issues associated with bargaining for enterprise agreements, including the new union monopoly on agreement making for major projects, were of major concern to employers.

Over the last six months, we saw increased union representative presence on worksites and rising union right-of-entry demands, adding to employer concerns within the sector.

“It’s clear from our latest findings that increased union activity in negotiations and in the workplace itself are having a major impact on confidence levels in workplace relations arrangements under the FWA. “The number of resource industry employers describing their workplace relations environment as either ‘good’ or ‘excellent’ dropped

dramatically from 54.4% to 32.0%, while the number of employers describing their workplace relations environment as ‘barely acceptable’ increased from 4.4% to 29.2%.”

Other concerns raised by respondents included: ··Inflated wage and condition claims and outcomes; ··Prospects of protected or unprotected strike action; ··Termination of employment/redundancy concerns including prospects of unfair dismissal claims; and, ··Transition to modern awards.

The Minerals Council of Australia’s CEO, Mitchell Hooke, recently welcomed the government’s revised consultative approach of the new resource tax arrangements, stating that it vindicated the industry’s call for detailed consultation on taxation reforms: “The Policy Transition Group (PTG) has ended the debate over the crediting of all state and territory royalties under the proposed Minerals Resource Rent Tax (MRRT) by upholding the spirit and letter of the heads of agreement on the tax. It’s now crystal clear that all current and future royalties must be credited against MRRT liabilities.

“It’s imperative that this and other key design features of the MRRT are enshrined in forthcoming legislation and not deferred to regulation.”

with Auslec

out branching *

us looking for a domestic light fitting,

and what is known as the Illawarra

it’s unlikely we’ll have one in stock.

Escarpment, Wollongong is New South

However, if you need two-core mag-

Wales’s third largest city, boasting a

netic cable, well, we’re your supplier!”

population of some 290,000 people.

In conjunction with suppliers, the

With a long industrial and mining his-

Auslec Wollongong branch runs regular

tory, the Wollongong area’s renowned

training days which Graeme says are

steel industry commenced when Port

well received by customers: “We’ve got

Kembla Steelworks was commissioned

great relationships with our customers

in 1927 and operations began in 1930,

and suppliers so it makes sense to

laying the foundations for the area’s

leverage off this and provide educa-

reputation as one of Australia’s leading

tion and advice wherever we can. The

industrial hubs.

training days are a great way for our

Graeme Sneddon, Branch Manager

customers to learn a bit more about

of Auslec Wollongong, explains that

evolving technologies and product

mining also contributes greatly to the

advancement.”

local economy: “We have a pretty in-

The success of the training and

teresting customer mix that we service

trade days has been such that 2011

here, with some pretty ‘heavy hitters’

will see the introduction of road shows

amongst them: Xstrata Coal, BlueScope

to some specific mining customers.

Steel, Port Kembla Coal and BHP Billiton to name just a few.”

With 14 staff and a collective 199 years’ experience behind them, the Auslec Wollongong crew are well positioned to deliver on their motto of “You need it, we get it” as Graeme recounts some of the more unusual requests, such as life-rings for installation in an underground dam, pie ovens for an underground coal mine and even an urgent need to supply blankets to a customer for their company’s workers so as to avert an industrial strike!

Servicing such a diverse and large customer base calls for lots of space; space to stock well over one

Due to travel time constraints, some

million dollars’ worth of products. A

of the Wollongong branch’s custom-

purpose-built branch and warehouse

ers have not been able to attend ‘in

of over 1300 m2 in size was completed

branch’ training, so in conjunction with

in February 2010 and Graeme says

key suppliers, Graeme and his crew

this is critical to the team’s ability to

will be taking the training to them.

service their large geographic area. He

“We service the entire Illawarra area,

adds: “We pride ourselves on process-

the Southern Highlands of NSW and

ing very large volumes of product and

up to Helensburgh in the north. If our

that means we need space. We are

customers can’t get to us, we’ll get to

specialised industrial suppliers and

them,” says Graeme. “We support our

that’s what we focus on. If you call

customers wherever they need us.”

Auslec Wollongong, New South Wales Branch Manager — Graeme Sneddon Branch/warehouse floor space — approx 1300 m2 Number of staff — 14

P: (02) 4271 2214 E: auswollongong@auslec.com.au A: 185 Berkeley Road, Unanderra, NSW 2526

© iStockphoto.com/Joanne Swadling

www.auslec.com.au AUSLEC 8

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www.auslec.com.au AUSLEC 10

Finding the right maintenance program in a mining operation

© iStockphoto.com/alle12

Keeping a major smelter facility functioning optimally requires the balanced deployment of a number of maintenance strategies.

Like most industrial operations, mining sites experience the constant struggle and delicate balance between peak production and peak reliability — keeping the production line going continuously versus stopping the production line to make sure it doesn’t crash. While they’re both vitally important, at times they seem to work incongruously. With demand for Australia’s minerals currently outstripping our ability to supply them, it is natural to focus on output and deal with reliability when the issue arises. After all, shutting down the operations for scheduled maintenance comes at a huge cost to production. But is that a wise approach?

Auslec Solutions sought to gain some insight into this issue to share with our readers, especially those involved in mining.

We spoke with Stephen Farnsworth, who is the Electrical Maintenance Superintendent — Copper Smelter at Xstrata. Stephen has been working at the mine in Mount Isa for 44 years and knows intimately what it takes to keep a 24/7 plant operational and has kindly shared his experiences and views for this article.

The Xstrata facility produces around 20,000 tonnes of copper anode each month, so any downtime has a negative impact to output. The ore that’s mined from the site is fed into a concentrator, processed through a filter and finally fed into a smelter to produce copper anodes.

From the smelter, the anodes are sent by train to a copper refinery in Townsville.

whereas RTF takes up much less of their

tasks and 60% of the collective time

time.

spent on scheduled tasks.

The maintenance department has 10

car. With road cars, you can replace brake

Maintenance choices Stephen’s team employs all three primary styles of maintenance — predictive, preventative and run-to-failure (RTF) — to contribute to peak production at the plant.

Preventative and predictive maintenance are generally driven by planning processes, which take up most of the team’s time,

KPIs that determine its performance —

pads when the mechanic spots them

things like backlog of works and planned-

nearly worn out. But on race cars, they

versus-reactive hours. Every week, tasks

need replacing at predetermined intervals,

are scheduled for the following week. A

say every 30 laps — coinciding with other

key measure of performance is how many

things like refuelling — regardless of the

of these scheduled tasks were completed

wear on them. That’s because time is

and how many hours were allocated to

critical and you want to minimise the time

them. The target is to schedule 80% of

the car is off the track. And it’s the same

“We don’t tend to adopt much RTF

Stephen makes an important suggestion

maintenance,” explains Stephen. “It’s typi-

for readers: “By all means have special

cally deployed on equipment that doesn’t

sensors to monitor the site 24/7, but you

critically impact the operations, like general

need to get in amongst the equipment to

lighting for example, because it has a low

see, ‘feel’ and ‘smell’ what’s going on.

impact that can be easily resolved. How-

These ‘old’ principles are still very valu-

ever, we do run predictive maintenance

able in mining, as it sometimes enables

with sodium-vapour lamps, because they

staff to spot potential problems before

gradually lose their light output over time.

the newer technologies pick them up.

The operational staff are our eyes in the

This is where skilled maintenance staff

plant. It’s common for them to raise work

are really valuable — picking up poten-

orders to replace lamps as they spot them

tial faults before they cause unplanned

out of action.

downtime. Condition-based monitoring,

“Preventative maintenance is normally

on the other hand, often only picks up issues at scheduled inspections.

“With recurring issues, like parts wear-

the overhead cranes that handle 50-tonne

ing, you need to gain control of the under-

pots of molten copper are inspected on a

lying problem. For example, we once had

weekly basis by our electrical maintenance

a situation with a series of steel-meshed

crews. Again, we expect our people to

panels that screened out rocks of various

be observant for things that need repair.”

sizes in the filter plant. The screens would

Stephen points out that predictive

frequently tear and get holes in them and

maintenance is generally applied to more

we’d stop the plant to replace a single

professionally run activities, such as

damaged panel. But now, we replace

monitoring wear on vital components. For

them all at once, to prevent them from

example, in the smelters, brick thickness

getting holes and consequently prevent

is constantly measured to monitor wear

unscheduled downtime. Knowing the

on the bricks. Every 3–4 years, depending

plant’s replacement frequency optimises

on wear, the entire smelting vessel is shut

its performance. The real cost is not in

down to reline it with bricks. Naturally,

replacing the panels, it’s in the downtime

the better the condition of the smelter is

caused by the damaged panels. Criticality

understood, the closer to optimal capacity

is the key consideration.

11

it can be run.

“A similar analogy is the brakes on a

www.auslec.com.au

of a failure is substantial. For example,

AUSLEC

carried out on large plant, where the impact

is fully operational as much as possible.”

“

If you’ve worked

to optimise materials and frequency in your maintenance program, there’s generally no need

AUSLEC

www.auslec.com.au

to change.

12

”

Support in remote locations Due to its isolation, the Xstrata mine needs to be largely self-sufficient in maintaining its plant, rather than relying on third parties to undertake maintenance.

“Our team consists of a number of highly skilled and experienced employees working alongside relatively inexperienced workers,” explains Stephen. “It’s a great place for someone to learn broad-brush industrial skills, but it’s a real challenge to retain them, since located in a remote area.

This high turnover means we’re constantly trying to attract skilled staff to relocate here. That’s not to say we don’t have a local talent pool to draw from, we have a solid apprenticeship program to bring local students into good careers.

“Another challenge we encounter is the mix of old and new equipment. It’s important to have a list of well-defined spares for our most critical services. We’d like to carry lots of spares, but there’s only so much we can carry. That’s where supplier support becomes crucial. We have good working relationships with numerous suppliers to ensure downtime on repairs and maintenance is kept to a minimum.”

Optimum performance “We’re constantly learning how to optimise performance,” says Stephen. “Things generally go well when the maintenance team have been working and learning together for a while. But when staff change, the new people have to be brought up to speed quickly, if we’re to get back to optimal performance.

“There’s also a link between the sequences of staff turnover and equipment wear — which highlights the strength of long-term maintenance teams. When the cycles are out of sync, performance is less than optimal. It’s not uncommon for new workers to change materials or maintenance sequences that had been optimised in frequency and/or materials simply because they weren’t aware conditions had already been optimised.

A case-in-point example is wear plates in our ore chutes — mechanical devices in a harsh environment designed to wear and eventually be replaced. Over the years,

we’ve learnt that ceramic liners last 15 years before needing replacement. A while ago, a relatively new team decided to look for alternative replacements for the wear plates. They chose something inferior to the ceramic plates and ended up replacing them much sooner than expected, resulting in an unscheduled shutdown.

“If you’ve worked to optimise materials and frequency in your maintenance program, there’s generally no need for change,” said Stephen. “Employees need to be aware of this and continue with that program rather than changing it. And if there is an inclination to change something, it must be completely analysed and justified — essentially there must be a very good and justifiable reason for the change. If anything, change frequency before changing materials.”

The fundamentals Stephen’s ‘basics’ for maintenance advice to help optimise production: ··Planned maintenance helps to get the plant to a reliable position, if you take the view that planned shutdowns keep production running until the next planned shutdown. ··Planned shutdowns are essential in order to achieve production goals.

They’re not a hindrance to production. Don’t take the opposite view, ie, achieve production goals and then deal with shutdowns. ··Remember the race car — you can’t win the race without making pitstops. You can be hopeful that nothing will break down or you won’t run out of fuel, but that’s never the case. And when you do make a pitstop, you want your pit crew knowing exactly what needs to be done to get you back on the track as fast as they can. In mining, that same synergy should exist between production and maintenance. ··Reliability is the key to any production facility, enabling it to operate as initially planned. ··Undertake regularly planned shutdowns to achieve production targets and not become totally production driven, in spite of demand for more output or faster production. ··Achieve your reliability targets and you will achieve your production targets.

© iStockphoto.com/flyfloor

for our smelter — it’s critical that the plant

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When you need a break; somewhere to kick back, relax and just leisurely watch the world go by, Queenstown probably isn’t the place for you.

14

A day in the extremes — NZ’s Awesome Foursome

© iStockphoto.com/mountainberryphoto

www.auslec.com.au

matter how brave we all projected ourselves to be, at that point we all started to ‘sweat bullets’, realising that this was perhaps the dumbest thing we’d ever done, and commenced praying to some higher being for protection — any higher being; it didn’t matter.

Standing on the ridiculously small twofoot-square ‘jump spot’ was where each of us started feeling very much alone — just ourselves, a long rope and gravity. Hearing everyone else in the pod yell out the countdown was when you realised that this was the point of no return — “3, 2, 1, bungy!”

Against our better judgment, one by one we each left the relative safety of the pod and threw ourselves off to vast emptiness below.

Freefalling for an agonising 8.5 seconds and accelerating to about 130 km/h, the ground and river below rushed up astonishingly fast, while you hoped the cliffs either side maintained their hold on the high-tension wires above. And about halfway through the descent, a common insane thought hits everyone: “This actually feels great; I’m flying!”

After a couple of recoils, pulling a cable between our legs enabled us to sit in a comfortable upright position and enjoy the magnificent views while slowly being winched back to the platform where the thrill ride all started.

Like everyone else, the apprehension and fear we experienced prior to the jump was quickly forgotten as we revelled in the limelight of what we just achieved. Crazy?

Maybe. Awesome? Absolutely!

With our heads still spinning from the jump, we boarded the bus for the short ride to our next point of departure, the Shotover River to experience the thrill of the world-famous Shotover jetboats. Designed specifically to operate in shallow and fastflowing waters, jetboats can navigate (at speed) places that normal propeller-driven boats can’t.

Our group stood on the shoreline of this magnificent river and watched the group before us complete their final runs through the emerald-green water. Screams of delight could be heard from the occupants of the red ‘water bullet’ as a sheet of water spray engulfed it. At that point, those in our group who earlier opted for the full-length spray jacket gave each other a wry smile — those who didn’t were wishing they had better foresight.

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Had a hard week at work? Need to get away? So where do you go for that perfect escape from the daily grind to recharge your batteries? Forget about relaxing at a spa, or lounging by the pool at a tropical resort. Life’s more fun in the extreme, like a short break in New Zealand’s extreme-sports capital — Queenstown.

Nestled next to Lake Wakapitu on New Zealand’s majestic South Island, Queenstown is internationally recognised as the ‘adventure capital of the world’ — a reputation well earned over the last 20-odd years.

Recently, Auslec Solutions had the good fortune (?) of being invited to experience a white-knuckle, adrenaline-surging day of extreme behaviour in the form of one of New Zealand’s most popular tourist activities — the ‘Awesome Foursome’.

After consuming a hearty breakfast that was intended to help sustain us for the day ahead (some feared it would be violently brought back up later on), we made our way with a mixture of excitement and trepidation to central Queenstown to meet up with our fellow thrillseekers and get a rundown of the day’s agenda.

The anticipation mounted by the minute as the bus’s TV screen displayed image after image of the fools that had gone before us; knowing all too well that we would be facing a similar fate this fine day.

A 45-minute bus ride enabled us to get to know our new friends a little better as it took us to our first destination, the Nevis High Wire Bungy. After getting instructions and having our weight recorded, we signed the obligatory waiver that essentially says: “If you’re stupid enough to try this, we take absolutely no responsibility at all — it’s now your problem.”

Looking from the safety of terra firma, we stared in disbelief at a small pod-like structure suspended by high-tension wires some 380 m across the Nevis River. If that wasn’t bad enough, we were ushered six at a time into a small cable car for a rattling trip out to the suspended platform.

“Oh, this just keeps getting worse,” was the cynical statement from someone in our group as we stared down at the bubbling rapids 134 m below.

The bungy cord was firmly (thankfully) attached and the appropriate amount of cord fed out, based on our individual weight. No

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“

No matter how brave we all projected ourselves to be, at that point we all started to ‘sweat bullets’, realising that this was perhaps the dumbest thing we’d ever done.

” © iStockphoto.com/firehorse

We donned the mandatory life jackets and boarded our red water bullet. These beasts are powered by twin 3.8 L supercharged engines that produce 520 hp. Two jets push out 760 L of water per second and enable these machines to travel in just 10 cm of water at up to 85 km/h.

Leaving the shore, our pilot (that’s what these boat drivers are called) edged the craft towards the middle of the river and accelerated. In an instant, all 15 occupants felt the bow rise and then settle as the boat ‘cruised’ at 80 km/h.

The canyon walls of this river were truly awe-inspiring. Springing vertically out of the water, they towered above us as our pilot (there’s that word again) effortlessly manoeuvred the massive boat to within what seemed just inches of the wall face — so close in fact, you could literally reach out and touch it.

Zigging and zagging around blind bends, one fervently hopes that there are some sort of rules of the river involving ‘giving way’ and ‘one way only’ that these pilots abide by.

Just barely wide enough to fit our boat through, we screamed through a ravine that, for some reason, had all the occupants of the boat ducking for cover. There was nothing directly over the top of us, we just all instinctively ducked!

Our pilot’s nickname was ‘Doctor’. Born and bred on New Zealand’s South Island, he’s one of the most experienced jet-boat drivers on the river and it’s obvious he loves what he does.

Doctor raised his arm, extended his index finger and made a circular motion indicating that the jet-boat’s signature move was about to be performed. We were told the grabrails in the boat are referred to as ‘Jesus bars’ and we found out why as Doctor expertly spun the boat around a full 360°, seemingly within its own length.

The screams of excitement and laughter from all on board were echoes of the ones we heard earlier as we waited for our turn on the shore.

For 25 minutes, we twisted, turned and spun our way along the most amazing water course, our faces aching from the smiling and laughter. Even those who passed on the spray jackets were grinning with delight; drenched, but grinning nonetheless.

Our day of adventure was already half over, but we sensed there was much more to come as we changed into wetsuits and boarded a helicopter for a 15-minute flight to our raft launch site at Skippers Canyon.

As the ground fell away beneath us, our pilot (finally, a real pilot!) banked the chopper to the right and hurtled along the river line. Seemingly doing his best to make the machine fall right out of the sky, he dove abruptly and then retreated to some height before giving all inside an ‘up close and personal’ introduction to the canyon walls.

Our hearts were absolutely racing as the chopper finally set down on a river bed in Skippers Canyon, from where we would embark on our final challenge of the day — rafting the mighty Shotover.

We set off from a calm and inviting river in two rafts and were encouraged by our guides to ‘get wet’ and enjoy the numerous grade three to five rapids that we would tackle. The shoreline was scattered with derelict mining equipment, some of it semi-submerged in the river itself.

Moving into the lower canyon, the river began to bubble and move as we encountered our first rapids. One, fittingly named ‘Toilet’, swirled us around and then flushed us out.

Another, named ‘Pinball’, bounced us to and fro off rocks. ‘Jaws’ and ‘Sequel’ (because everything scary should have a sequel!) had us riding high in the water and precariously balancing between an unwanted exit from the raft and pretending that we were experienced whitewater thrillseekers. The guys who named these rapids either had a quirky sense of humour or partook in a little too much of the local wheat and hops. Thankfully, all in our group managed to maintain their allocated positions within the raft.

Towards the end of our two-hour rafting adventure, we slowly drifted through the eerily dark, 170 m-long Oxenbridge Tunnel — originally built to divert water from the river so gold could be collected from the riverbed. The stillness was soon punctuated by the roar of our final rapid as we emerged into daylight and were tossed into ‘Cascade’, easily the most ferocious rapid of the day.

Somehow finishing with the same number of people that we started with, high-fives and screams of delight were freely exchanged amongst our group — sensational.

If you had to choose one word to describe this adventure, it would have to be AWESOME.

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A v a i l a b l e f r o m & r e c o m m e n d e d b y A u s l e c . U s e t h e locator at www.auslec.com.au to find your nearest branch.

Digital multimeter

AUSLEC

www.auslec.com.au

The BM827 is a reliable, robust, dust- and splash-proof digital multimeter designed for industrial uses, displaying many electrical parameters. The instrument features dual displays, true RMS, 9-9/10 digital 10000 counts, ‘Beep-Jack’ input warning, electric-field detection that detects live voltage without touching, ‘data hold/crest hold’ function, ‘min/max/ max-min/avg’ recording, 600 V HBC fused current range, bargraph and optional USB PC interface and software that allows downloading to or recording of data on a PC. Each unit is supplied with test leads, protective holster, installed battery and operating manual.

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Industrial braided leads The Clipsal 56 Series braided industrial extension leads provide protection from electric shock, especially in work environments like mining where power leads are exposed to being damaged or cut. The earthed braid will instantly activate RCD protection if the lead is cut, preventing exposure to dangerous active wiring. The OHS-compliant leads feature extra-soft flex to avoid tangles and IP56-rated plug and socket ends. They are available in a comprehensive range of lengths from 5 to 20 m with 10 and 15 A rating options.

Cable cleats IPD Industrial Products, in partnership with Ellis Patents, specialises in the design and manufacture of cable cleats to fix, retain and support cables from 415 V right up to 220 kV. Where short-circuit faults are anticipated, correct cleating will protect cable and installation during a fault and enable the circuit to be restored when the fault is cleared.

A safe installation requires cable cleats that are well designed and thoroughly tested in line with EN 50368:2003 and IEC 61914:2009.

AUSLEC

The BMP71 portable printer with Labelmark software is designed to help labelling jobs be done more efficiently. The printer features a large, full-colour graphical display that shows exactly what each label will look like as it’s being created, so there’s no guesswork. Users can choose from 30 different material types and over 400 label parts. With built-in design wizards for electrical, voice/data comms and general IDs, along with material recognition technology and storage space for over 100,000 label files, the printer can save considerable labelling time.

www.auslec.com.au

Portable printer

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Photochromic safety glasses The SmartLens safety glasses feature UV-reactive lenses that respond to UV light, automatically lightening or darkening as needed. The lenses change from clear to dark in eight seconds, reducing light transmission to 22%, and from dark to clear in 35 seconds, allowing 77.5% light transmission in the clear state. The polycarbonate lenses absorb 99.9% UV and feature abrasionresistant hard-coating to extend lens life. The frame features spring-hinged magnesium-alloy temples for narrow/wide fit, soft and adjustable nose bridge for all-day comfort and moulded lens supports that prevent the lenses being dislodged by strong frontal impact.

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Available from & recommended by Auslec. Use the locator at www.auslec.com.au to find your nearest branch.

Hazardous-area metal cable glands

The Swarfega Red Box contains 150 tough, extra-large wipes that are combined with a powerful, heavy-duty hand cleaner that removes oil, grease and grime. They also contain moisturisers to help condition the skin and keep it supple. The convenient, easy-to-use tub can be kept at the work point to be used throughout the day with no need for water or towelling. The sealed container prevents cross-contamination.

AUSLEC

Rittal and Phoenix Contact provide a complementary range of products for electrical and instrumentation applications for the mining industry. Pictured here, the Rittal mining field box is fully installed with Phoenix Contact signal convertors, power supplies, terminal strips, surge protection and safety relays. Rittal and Phoenix Contact combine German engineering with Australian market expertise to provide innovative solutions and cost benefits to the mining industry.

Heavy-duty handcleaning wipes

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Integrated mining solutions

Alco’s new hazardous-area metal cable glands are specifically designed for the mining sector, featuring an extended tail to terminate both a circular cable internally and a protective rubber hose externally.

Manufactured from nickel-plated brass, the glands are available from 20 to 50 mm size terminations, covering a cable outside diameter range of 4 to 42 mm. The cable gland adds to Alco’s comprehensive range of metal cable glands that includes armoured, unarmoured and screened cable glands for indoor and outdoor applications.

Liquid resistance starters The NHP range of Australian-made LRS (liquid resistance starters) has been developed with the mining industry in mind, suitable for industrial wound-rotor motor applications from 200 kW to 12 MW, such as ball and SAG mills, crushers, conveyors, fans, pumps, compressors and mixers. The availability of both fixed- and moving-electrode liquid resistance starters enables selection of the most appropriate technology for the intended application, while minimising capital investments. The highly reliable devices offer optimum control over starting current, torque and motor/load acceleration, but don’t need specialist electrical personnel or equipment to maintain them.

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Everything about mining is big — the landscape, the trucks, the engines, the list goes on.

AUSLEC

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Mine’s bigger than yours …

22

Australia’s mining industry is big - bloody big. Now, that statement in itself isn’t a revelation to anyone - particularly those of you who work in the mines that help produce our country’s biggest export.

In mining terms, ‘big’ generally means: · ·Immense capital investment; · ·Giant holes in the ground; · ·Gigantic excavators; · ·Huge dump trucks; · ·Expansive distances; · ·Fabulous financial benefits to Australia’s economy; and · ·Modest profits for mining companies.

But what does it look like on the ground, where the real work is done? What does ‘big’ really mean?

Greg Miller, National Industrial Support Services Manager for Auslec, knows more than most what it’s like at the coalface (no pun intended), as he and his team work closely with some of our country’s largest mining operations in some of the most remote parts of our land.

sight of enormous yellow trucks, snaking

odd tonne payload capacity. That would

Miller reckons these monsters are the

Huge dump trucks Greg says: “For many, Australia’s mining industry is immediately identified by the

be like towing 200 fully loaded ski boats

most impressive pieces of machinery on a

all in a row! Try doing that in your SS

mine site. “I personally am amazed at the

Commodore and see how fast it goes.

size and capabilities of these machines,” he

their way up and down the haul road of an open-cut mine. While these generically termed ‘mining trucks’ are big in themselves, it’s not until we look at their capabilities do we really get to understand just how massive these machines are.”

‘Popping the hood’ on one of these monsters can reveal a 20-cylinder, quadturbocharged diesel engine that produces 4000 horsepower. To put that into some sort of perspective, Holden’s latest Commodore SS sedan can produce about 360 hp from its normally aspirated 6-litre V8 engine. Add some HSV ‘magic’ and you crank it up to 435 hp - still not even close to the ‘big cat’.

With a top speed when loaded of around

When you’re carting 350 tonne per run, it’s nice to know that your vehicle has the ability to stop. Braking is achieved by engaging up to 15, one-metre-wide discs on each wheel - handy when you’re pulling in to refuel the 3500+ litre fuel tanks. Oh, and draining then topping up the cooling system? Just a lazy 1000 litres or so will do it.

Next time you’re cursing the fact that you need to change a tyre on your 4WD or trailer, spare a thought for the poor soul who has to undo the 47 wheel nuts on EACH of the six wheels on these trucks and replace the 4 m tall, 5300 kg tyres - and be happy that your rolling rubber doesn’t cost the best part of $40,000 each!

Gigantic excavators

67 km/h, you’re not going to challenge

Often working in tandem with these mining

any quarter-mile records in these beasts;

trucks are the equally impressive mining

but when it comes to moving a little dirt

excavators, used, amongst other things,

or iron ore around, you shouldn’t have

to transfer the massive payload from the

any trouble with these behemoths’ 350-

ground to the trucks.

“ The

largest

mining excavator manufactured weighs in at an astonishing 980 tonnes - that’s the equivalent of 375 Toyota LandCruisers and is powered by two,

© iStockphoto.com/hsvrs

16-cylinder engines.

”

says. “Each time the opportunity presents

Expansive distances

itself, I take people who have never been

Often, vast distances need to be over-

associated with this particular railway is the

up close to one to have a look and they

come once our resources are extracted

time it took to construct. The enormous task

are always gobsmacked.”

from either underground, aboveground

was done and dusted in a staggering nine

After scaling the access ladder, the op-

or undersea. In the case of iron ore

months and the 1000th train made its way

erator positions himself in the cab, which

extraction and production in the Pilbara

to port in less than 12 months after that.

is often some 8 m above the ground, to

region of Western Australia, the precious

Added to this is the fact that the Fortescue

commence loading. It is here that their

resource has to make its way to a port

rail fleets movements are controlled more

shift begins and they take control of their

to be exported by ship primarily to our

than 1600 km away in Perth.

multimillion-dollar offices.

biggest customer, China.

The largest mining excavator manu-

Upon being granted federal government

of ‘big’ in terms of our mining industry,

factured weighs in at an astonishing 980

approval, one of Australia’s biggest iron

Auslec’s Greg Miller surmises: “So there

tonnes - that’s the equivalent of 375 Toyota

ore producers, Fortescue Metals Group,

you have it, almost everything to do with

LandCruisers - and is powered by two,

went about constructing its own railway

mining is big; the scale of the operations,

16-cylinder engines that allow it to easily

that would enable the efficient transport

the equipment that it involves and the

attach the massive bucket, along with the

of iron ore from its Cloud Break mine to

number of people needed to ensure that

AUSLEC

After reflecting on the true meaning

www.auslec.com.au

Perhaps the most impressive number

bucket’s 90-tonne load!

the Herb Elliot port some 250 km away.

the mining industry continues to provide

The construction of the Fortescue rail-

23

If you thought refuelling the mighty mining

Australia with its greatest earning export.

trucks would be thirsty work, you’d need

way called for over 11 million cubic metres

That’s why, at Auslec, we focus very heavily

to take out a second mortgage to fill this

of soil, some 19,000 tonnes of rail and

on ensuring that our mining customers get

goliath up. Its fuel tank is an almost end-

nearly 430,000 sleepers. This specially

the products and service they need - we

less 15,000 litres in capacity; that’s about

designed railway has been constructed

are a small but critical link in Australia’s

15 tonnes of fuel alone! And at $1.50/litre,

to carry the weight of locomotives and

mining chain.”

that’s $22,500 every time you visit the petrol

rolling stock weighing in excess of 30,000

Speaking of chains - imagine the size

pump. Using the average Australian car

tonnes and nearly 3 km long. Multiple

of the one you would need to tow out

analogy, that’s a tank of fuel each week in

locomotives are required to pull the 240

one of those bloody big yellow trucks if

your Ford Falcon for just over four years!

ore cars over the 280 km journey.

it got stuck!

with Auslec

out branching *

a non-work setting and they always

country, but when one of our major

seem to get a lot out of it.”

cities is closer to the national capital

It’s not just at the V8s that the cus-

of five other countries than it is to

tomers of Auslec Darwin come together.

its own, you realise just how big

The branch regularly facilitates training

Australia is!

and product demonstrations in conjunc-

The city of Darwin holds this unique

tion with suppliers and manufacturers.

claim to fame and, although vast

Tom believes this to be an excellent

distances separate it from other state

way of adding real value to customers

capitals, it is one of Australia’s fast-

and further cementing the relationship.

est growing capital cities, both from

When Auslec Solutions asked Tom

population and industry perspectives.

if he had any unusual requests from

With Darwin’s mining and energy

customers, he scratched his head and

production mirroring the rest of the

laughed as he revealed the branch

country’s resource growth, the local

is currently supplying one particular

Auslec branch plays a pivotal role in

customer with pallets and pallets of

the supply of industrial products, as

toilet rolls.

Branch Manager Tom Allford explains:

“I can’t bring myself to ask him why

“Mining, oil and gas companies alone

he needs so many toilet rolls,” he muses.

produce over $2.5 billion a year in revenue out of our region. For a population of about 75,000, that’s a pretty decent effort.”

Tom and his team have a varied customer base that takes in Darwin and the surrounding region, but also extends offshore to Timor – only 650 km away.

Commenting on the branch’s customer base, Tom adds: “It’s normal practice for us to service offshore rigs, East Timor or the Ranger Uranium mine down at Kakadu. And with a growing population, Darwin’s building industry is also kicking along, so our

“It just doesn’t seem to fit in with what

contractor and industrial customer

his business is!”

bases are big areas for us too.”

The branch was asked by another

While the branch’s customer base

customer to supply conduit so he

might be mixed, there’s a general

could hang a fake hawk over his bee

consensus when it comes to one

hives to stop predators getting to his

of Darwin’s major annual sporting

beloved bees!

events — the V8 Supercars held at the Hidden Valley raceway.

“It was hard to keep a straight face at that particular request,” recalls Tom.

Tom explains: “All of our customers

“But keeping with our motto of ‘Your

absolutely love the V8s, so we make

World, Our Solutions’, I’m happy to say

that our big event each year where

the bees are safe and sound!”

we take them as our guests. It’s a great chance to get to know them in

Ah, Darwin – doing it their own unique way.

Auslec Darwin, Northern Territory Branch Manager — Tom Allford Branch/warehouse floor space — approx 770 m2 Number of staff — 4

P: (08) 8984 4077 E: ausdarwin@auslec.com.au A: 7 Albatross Street, Winnellie, NT 0820

© iStockphoto.com/Anton Harder

www.auslec.com.au AUSLEC 24

We all know that we live in a big

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Available from & recommended by Auslec. Use the locator at www.auslec.com.au to find your nearest branch.

Miner’s utility kit

The NHP Concept Tough Panelboard is the latest edition to the Concept Panelboard family that includes Concept Plus and Concept Premier. It is specifically designed to withstand the harsh and rugged environments that exist in the heavy industrial and mining sectors. Pivotal to this range is the focus on safety through the LockDIN captive locking systems that provide safe and secure captive locking. This feature is also retrofittable to the entire Concept range.

The Fluke 190 Series II four-channel CAT IV-rated scopemeters enable plant maintenance engineers and technicians to see more and fix more. There are two models in the range: ScopeMeter 190104 (100 MHz) and 190-204 (200 MHz), both of which combine high safety ratings and rugged portability with the high performance of a bench oscilloscope. With an IP51 rating, these tough instruments are designed for use in harsh, dirty and hazardous industrial conditions to test everything from micro-electronics and powerelectronics applications.

www.auslec.com.au

Industrial distribution boards

Scopemeters

AUSLEC

The Exofit NEX Mine Utility Kit is an allin-one kit designed specifically for the mining industry. The kit contains a mine utility belt and rigger’s utility harness with dorsal extension, packed in a convenient equipment-storage bag. Developed to meet the needs of mining industry workers, the kit complements the miner’s tool set, allowing them to attach necessary PPE and other vital equipment to safely perform their work. The belt and harness are also available as separate items.

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Circuit reset system The Legrand STOP & GO is an intelligent and secure circuit reset system. After an electrical fault occurs, STOP & GO checks that there is no permanent fault on the circuit before closing the electrical circuit and resetting it. The device immediately re-establishes the power supply, avoiding the unwanted consequences of permanently losing power to equipment or a building. When a permanent fault is detected by the system, it sets off both audio and visual alarms.

*productcut

Available from & recommended by Auslec. Use the locator at www.auslec.com.au to find your nearest branch.

Drum lifting device DrumGrab is an Australian-made device that offers a safe, easy and reliable way to shift, lift and manoeuvre most 205 L drums. It is self-centring, fast and easy to lock on, and will only come off when required. It fits to most lifting devices and has a rated capacity of one tonne. The device is an efficient method of drum handling and assists in preventing injuries and spills in industrial and other workplaces.

High-quality printing service

AUSLEC www.auslec.com.au

To assist Auslec customers with their specialist signage needs, Hi-Vis has installed a VUTEk GS3200 flatbed and roll-to-roll UV wide-format printer. This 3.2 m-wide printer extends printing capabilities with high-quality imagery, fast production speeds and high-quality colour gamut. The printer accommodates the needs of a wider range of applications, including exhibition graphics, fine art and point-of-purchase displays, as well as the specialised and rigorous signage demands of the mining industry. Contact your local Auslec branch for assistance in coordinating your printing requirements.

26

Electrolyte replacement drink Just like machinery, a worker’s body needs fuel. To ensure peak performance in hot or challenging conditions, Sqwincher is a cost-effective way of maintaining productivity, while helping to lower the number of workplace accidents. Research shows that many workplace accidents attributed to ‘bad judgment’ or failure of safety equipment may, in fact, be caused by heat stress and fatigue. A Sqwincher program can help stop heat stress before it starts in the workplace.

Oxygen self-rescuer The SSR 30/100 oxygen self-rescuer is a small, lightweight (2 kg) and robust respiratory protective device, packed in a stainless steel container, which can be used where the ambient atmosphere may be oxygen deficient or contain toxic contaminants. The apparatus is designed to be carried on a belt, donned in seconds and will supply oxygen to the wearer during escape or while waiting for rescue.

MSA chemical oxygen has a maximum life of 10 years.

Expandable barrier

AUSLEC www.auslec.com.au

Port-a-guard is a portable, expanding crowd-control barrier, finished in red/white or black/yellow powder-coat. Being compact and lightweight, it is suitable for indoor or outdoor use. The extruded aluminium slats and vertical posts are both strong and lightweight, while the injection-moulded plastic feet ensure that the complete unit is durable and corrosion free. Two versions are available that are 3.2 and 5 m wide when fully extended, providing a versatile solution to pedestrian and vehicular traffic-control problems. All Port-a-guard models can be customised with additional slats, base weights, wall mounts, post mounts, warning sign options and castors.

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Breathalyser for mining industries The Andatech breathalyser deploys fuel-cell technology to deliver Âą0.005% BAC accuracy at 0.100% BAC. Being wall mounted, it is suitable for controlling site entry points in mining and manufacturing environments. The instrument features a replaceable sensor module, robust construction and 240 VAC, 50/60 Hz with 0.5 A input or 12 VDC, 1.5 A output power supply, and is certified to Australian Standard SMKH20581. The unit is supplied with 50 mouthpieces.

AUSLEC

www.auslec.com.au

auslec: total protection from lightning strikes

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© iStockphoto.com/artcyclone

Protecting the structure A structural LPS is designed using the ‘Faraday Cage’ principle — as stipulated by most national and international building standards — to channel lightning strikes in a controlled manner to the earth-termination network, through which the current is dissipated to the general mass of earth.

Each state and territory has building regulations that outline how to deal with lightning strikes. Most of these regulations draw from the AS/NZS 1768:2007 lightning protection standard.

A structural LPS consists of three key elements: air-termination system, down conductors and earth-termination system.

All should comprise quality materials and fixings and be properly installed according to standards and equipment manufacturers’ instructions.

Air-termination system The role of this system is to ‘capture’ the lightning discharge current to a specific location on the building that’s linked to earth, rather than a random, potentially unprotected part of the building.

“For simple-shaped structures, the ‘protective-angle’ method is typically deployed,” explains Baker. “Vertical rods protruding above the roof are attached on corners, exposed points and edges of structures. These rods form a ‘protective cone’ for the structure below. The appropriate number and size of rods for specific buildings is determined by mathematical formulas in AS/NZS 1768.

“For complex-shaped structures, the ‘mesh’ method is recommended, where vertical rods are placed along the edges of a roof, no more than 10 m apart, and linked together. Recent research on lightning-inflicted damage shows that the edges and corners

of buildings are most susceptible to damage.

So, on all structures — particularly with flat roofs — perimeter conductors should be installed as close to the outer edges of roofs as is practicable.”

Down conductors These should, within the bounds of practical constraints, take the most direct path from the air-termination system to the earthtermination system.

“The greater the number of down conductors, the better,” Baker adds. “There should always be a minimum of two down conductors — that way the lightning current is shared between multiple paths to ground.

“Ideally, a structural LPS should use existing conductive paths in the building’s structure, like reinforcing bars in the concrete. In these circumstances, building regulations require electrical continuity, calling for the bars to be welded, clamped with suitable connection components or overlapped to ensure they’re likely to carry the lightning current from one length to the next. Electrical continuity should be verified all the way from the air-termination system to the earth-termination system. If there’s any doubt about the continuity, an external down-conductor system should be installed.

“Only use high-quality materials and fixings, since it only takes a single sub-standard component to compromise the performance of a structural LPS.” Earthing A good earthing system starts with a comprehensive survey to determine the site’s effectiveness in dissipating electrical energy.

Soil-resistivity measurements should be taken at numerous locations around the site at various depths for a true indication of the earth conditions.

Baker suggests this is a critical exercise “because inadequate or erroneous soilresistivity readings are likely to result in a flawed design. This needs to be done right, as it forms the basis of the entire earthing design.

“Choose a foundation that suits the system design. Electrodes can be constructed individually from earth rods, earth plates, flat tape, stranded cable, or any combination of these. High copper-content alloy earth-rod clamps should be used to connect earthing conductors to earth rods. Clamps must ensure good electrical contact and resist

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Lightning is one of the worst hazards facing many mining facilities, threatening lives, structures and equipment. But you can provide comprehensive protection.

AUSLEC

The Australian Bureau of Meteorology lists thunderstorms, tropical cyclones and bushfires as its primary concerns in its Severe Weather Warning Services list, reporting that 650 fatalities were registered as being caused by lightning strikes in Australia between 1803 and 1992, while insurance-related claims from thunderstorms between 1967 and 1999 amounted to $5 billion. Not surprisingly, the bureau states that “the protection of people and property from thunderstorms is of great concern”.

Thunderstorms and lightning are a fact of life in regions where many of Australia’s mining operations are situated. It’s something that the mining industry has learned to live with, but can never get complacent about. In mining, the risks are not just damage to property — the costs of operational downtime from lightning-damaged plant can be substantial.

The Bureau’s records indicate that Darwin and its surrounds has consistently been Australia’s worst-affected area, with an annual average of nearly 100 thunder days over the last 40 years. Australia’s mining belt in the north typically gets 40–80 thunder days each year. By comparison, Brisbane averages 25, Sydney 20 and Melbourne 11 days.

Even though lightning discharges are very short (typically 200 microseconds), the energy they dissipate is enormous. Some strikes have been measured as delivering 200,000 A. These strikes can cause substantial physical damage to buildings, while the secondary effects of lightning — short-duration, highvoltage spikes called ‘transient overvoltages’ — can cause equally catastrophic damage to equipment inside.

While we can’t really prevent structures being hit by lightning, we can make them capable of safely withstanding them without damage or injury to occupants.

Most, if not all, mining sites have comprehensive structural lightning protection systems (LPS) to intercept, conduct and disperse lightning strikes safely to earth.

However, as Gary Baker, Global Furse Product Manager at Thomas & Betts, advises: “A reliable lightning protection scheme must encompass both structural LPS and transient overvoltage protection to ensure total protection for buildings, equipment and personnel.

It should be understood that a structural LPS alone will not protect electronic systems from transient overvoltage damage.”

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Internal lightning protection The constant miniaturisation of printed circuit boards (PCBs) in electronic systems means PCB tracks get narrower and subsequently more sensitive to transient overvoltages. The cumulative effect of brief but large voltage increases within the electrical system over many years does cause equipment failure.

Baker adds: “Transient overvoltages can have devastating effects: unexplained network crashes, shortened equipment lifetime and ultimately, costly and unnecessary downtime. They can also cause essential services like fire, security and building-management systems to go offline and introduce potential health and safety hazards caused by plant instability after loss of control.”

Surge protection devices (SPDs) within an electrical system will protect against transient overvoltages from lightning strikes and other electrical anomalies; however, it’s not simply a matter of installing an SPD at the switchboard.

Baker explains: “Lightning-current SPDs form just one part of a coordinated set of SPDs that are needed in total to effectively protect sensitive systems from both lightning and switching transients.

“SPDs protect against lightning electromagnetic pulse (LEMP). LPS systems must be fitted with lightning current or equipotential bonding SPDs to incoming metallic services such as power and telecoms cables that have ‘live cores’ that cannot be directly bonded to earth. However, using these SPDs alone doesn’t provide effective protection against the failure of sensitive electronic systems.

“Installing ‘coordinated’ SPDs will provide more thorough protection. This involves a series of SPDs whose locations and LEMPhandling attributes are coordinated so as to protect the equipment in their environment by reducing the LEMP effects to safe levels.

Coordinated SPDs should operate together as a cascaded system. So, there may be heavy-duty lightning-current SPDs at service entrances to handle most of the surge energy (partial lightning current from LPS and/or overhead lines) with the respective transient overvoltage controlled to safe levels by downstream overvoltage SPDs that protect equipment. Appropriate SPDs should also

“

It should be understood that a structural lightning protection system alone will not protect electronic systems from transient overvoltage damage.

”

be fitted wherever services cross from one lightning protection zone to another.

“Poor coordination could mean that the overvoltage SPDs are subject to too much surge energy, putting both themselves and other equipment at risk from damage.”

LPS designers must consider the following when choosing and applying SPDs: ··Withstand voltage of protected equipment; ··Immunity withstand voltage of equipment; ··Additional installation effects, such as voltage drop on connecting leads; and ··Oscillation protective distance (if distance between SPD and equipment is over 10 m, oscillations could lead to voltage doubling).

In these circumstances, using only standard SPDs could leave the risk of indirect LEMP damage too high. In mining operations, continuous equipment operation is often essential, so enhanced SPDs to deliver lower let-through voltages in both common and differential modes is preferable to standard SPDs. “Standard SPDs may only protect against common-mode surges (between live conductors and earth), protecting against outright damage, but not against system disruption,” adds Baker. “Enhanced SPDs, however, provide lower let-through voltage protection against surges in both common and differential modes (between live conductors) and therefore also provide additional protection over bonding and shielding measures. As terminal equipment tends to be more vulnerable to differentialmode surges, this additional protection can be vital. Low let-through voltage protection in all common and differential modes also means fewer units are required to provide protection, which saves installation costs.

Installers need to be more aware of the application and installation requirements of SPDs than perhaps they may have been previously.”

Conclusion Due to the increased reliance of electronic systems in mining, lightning poses a growing threat to an operation’s operational integrity.

Structural LPS can no longer be used in isolation. Enhanced SPDs provide a practical cost-effective means of protection allowing continuous operation of critical systems during LEMP activity.

© iStockphoto.com/Clint Spencer

AUSLEC

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corrosion throughout their lifetime. The installation should also ensure high-quality, fault-tolerant jointing of materials and fittings.”

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Available from & recommended by Auslec. Use the locator at www.auslec.com.au to find your nearest branch.

The PK series pressure sensors are now available with only one switching output, rated as ‘NO’ with 2% hysteresis, making them suitable for use in hydraulic, pneumatic and refrigeration applications, and where gas pressures up to 400 bar may arise.

The sensor features switchpoint setting via setting-ring and stainless steel measuring cell without separate seal. Ease of operation is enabled through radial setting-rings with unit scale for high readability, allowing users to adjust setpoint quickly and precisely, even without pressure being applied. Due to the possible mechanical locking, inadvertent manipulation is excluded. Two LEDs indicate switching status and readiness for operation.

Bulkhead lighting The NXS bulkhead offers an economical, compact and versatile solution for many adverse lighting applications. Its heavyduty IP65/67 rating makes it suitable for adverse applications in the most arduous environments such as mining infrastructure, collieries, foundries, industrial and heavy engineering sites, processing plants and general security lighting. A stainless steel version is also available for use in extremely adverse conditions, especially where corrosive chemicals are present or near saltwater environments.

Portable capstan winch The Portable Capstan Winch, powered by a 1.8 kW Honda engine with three-stage gearbox, delivers 1136 kg of single-line force at 12 m/min, while doubling the line with a snatch block doubles the capacity to 2272 kg at 6 m/min. An optional drum will pull smaller loads (up to 614 kg) at 18 m/min. The winch can pull cables and lift tools and hardware by anchoring it to trees or posts, or to vehicles with an optional hitch attachment. An internal anti-reversing brake prevents loads from rolling back. The capstan provides constant pulling power and doesn’t accumulate ropes on it, so there’s no limit to rope length. Accessories include various length and diameter ropes, pulley blocks, carabiners, slings, skidding cones and waterproof case with removable casters.

The tough one-piece moulded polyethylene Cable Protector is designed to protect cables from damage and pedestrians from tripping hazards in various situations including construction, renovation or office environments. It is simply fitted by positioning the modules over existing cables or hoses.

The interlocking modules are produced in a hi-vis safety yellow with a slip-resistant surface. It is 1010 mm long x 135 mm wide x 20 mm high and weighs 1.3 kg/m.

Internally, a single channel measures 40 x 12 mm.

AUSLEC

Pressure sensor with one switching output

www.auslec.com.au

Pedestrian cable protectors

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productcut *

Available from & recommended by Auslec. Use the locator at www.auslec.com.au to find your nearest branch.

AUSLEC

www.auslec.com.au

Mark-out paint for mines

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Mine Marking and Mine Marking Non-Flammable aerosols are available in horizontal or upright/inverted (trigger) formats for 360째 application in mines and excavation sites. The horizontal format is suitable for spraying rock walls/faces, while the inverted (trigger) format is suitable for marking the ground and mine ceilings. Mine Marking is a markingout paint formulated for aboveground areas, ore zones in grading control, pit walls and survey-grid layouts. Mine Marking Non-Flammable is formulated for underground coal mines and fire-sensitive situations. A Mine Marking Handle that extends to 6 m is also available for both horizontal and upright/inverted cans for extended non-contact marking in difficult-to-reach mine ceilings.

Fast cut variable-pitch holesaws Starrett Dual Pitch all-purpose holesaws feature hardened and heat-resistant HSS teeth with a positive rake to ensure a smooth cutting action with aggressive cutting ability and swarf removal. The shatter-resistant holesaws will cut equally well on both thin- and thicker-gauge materials including stainless steel, mild steel, wood and many other materials. They are ideally suitable for handheld drills and provide a cutting depth of 41 mm. Starrett holesaws are used in all industries and are popular with electrical contractors worldwide.

Lightweight safety goggle The uvex carbonvision safety goggle weighs just 43 g, yet maintains high levels of resilience to harsh working conditions. The carbon content contributes to the goggle’s antistatic properties, an important requirement for hazardous environments. An injectionmoulded face guard enables it to adapt to different facial shapes for a positive seal and splash-proof protection and to ensure it is comfortable for all-day wear. The low-profile design provides compatibility with halfface masks, helmets and bump caps. The goggle is available in four different lens tints, making it suitable for use in a wide variety of environments.

Magnetic switch

Enhanced RCD protection The C60H RCBO 1P+N RCD range has been expanded with the C60H2 RCBO 2P model, which is able to switch and protect the neutral conductor. This is an essential feature in areas defined as hazardous

by AS/NZS 2381.1, such as in petrochemical and spray-paint applications, car parks, fueldispensing stations, aircraft hangers, laboratories, landfill, sewage treatment and flammable-gas areas. The RCBO can be mounted onto Schneider Electric MSC and Isobar chassis.

The range is available from 10-32 A for 110 and 240 VAC networks and complies with AS/NZS 61009-1.

The Legrand Hypra ranges of industrial plugs and sockets are built for heavy-duty applications and harsh environments. With IEC standard plugs and sockets that are rated from 16 up to 125 A, IP66/67 ingress protection rating and IK09 impact energy rating, these products are well suited to the harsh mining applications.

AUSLEC

Industrial plugs and sockets

www.auslec.com.au

The MagSwitch is a powerful magnetic device that can be turned on and off with a simple turn of a knob to control various functions.

The range includes welding ground-clamps, magSquares, hanging hooks, ‘boomerangles’, 90° angles, hand lifters and heavy lifters.

The switches save time and money by replacing clamps for faster and easier grounding, precise positioning and work holding and welding angles that stay clean.

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*mining's second Auslec's research identifies

AUSLEC

www.auslec.com.au

© iStockphoto.com/David Gunn

boom

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Australia’s mining industry looked grim in early 2009. Newspapers around the world featured headlines like “Alcan slashes jobs and production”, “BHP to lay off 6000 staff” and “Rio Tinto shelves mine expansion”. This scenario was inconceivable two years earlier during our mining boom. When the global financial crisis (GFC) hit, many speculated that the mining bubble had burst, with our major export markets quickly diminishing: the US and much of Europe in recession and China experiencing massive decline in demand for its manufactured goods.

But the impact of the GFC on Australia was surprisingly brief. Despite a cloud of uncertainty still hovering over the economy, our mining industry is experiencing a second boom, with current production at some mines exceeding pre-GFC levels.

Rio Tinto’s Q4 2010 Operations review, for example, confirms that the boom is back. The company’s Chief Executive, Tom Albanese, commented: “Running our operations at full capacity was a priority for Rio Tinto in 2010, in an environment of strong prices for most of our commodities. We set new quarterly and annual production records. During Q4 we approved US$5.5

billion in value-adding growth projects, including expanding our Pilbara iron-ore operations to 283 million tonnes/year.”

Rio Tinto’s global iron-ore operations set a new annual record at 239 million tonnes; Bauxite production increased 9% year on year due to higher demand; Australian coal production was up 20% on 2009, following increased investment in Queensland operations and in spite the recent harsh weather there; and approval of $10.8 billion of major capital projects.

Similarly, BHP Billiton posted strong financial results for 2010. Its Q4 review reports record sales in iron ore, metallurgical coal and petroleum, with the group’s consolidated revenue up 5.2% to US$52.8 billion and profit up 116.5% to US$12.7 billion. The soaring profits are attributable to well-controlled local-currency costs, while continued investment has delivered another five growth projects for the year.

OZ Minerals (merger of Oxiana and Zinifex) commenced production at its Prominent Hill open-cut mine in South Australia in early 2009, during the GFC. The company recently reported copper and gold production there exceeded 2010 targets, with record copper and gold

prices and record gold production for Q4.

Strong throughput rates are expected to continue throughout 2011. The company is also conducting extensive exploration at a number of sites internationally, with positive results indicating potential copper and gold mineralisation.

Even the London Metal Exchange (LME) - the world’s largest non-ferrous metals trading market and where much of Australia’s metals are traded - announced that 2010 set new records, with trading value reaching 2.83 billion tonnes, up 7.4% over 2009. December was a record month with almost two million tonnes traded. In a year when prices also rose strongly, the total notional value of trades surged to US$11.6 trillion, up from US$7.4 trillion in 2009. Steel progressed strongly with 12.4 million tonnes traded, while copper trading rose by 24.5% over 2009 to 33.1 million tonnes.

LME Chief Executive Martin Abbott said: “Despite, or perhaps because of, the volatile global economy, 2010 was a strong year for LME. The early recovery, particularly in Asia and Latin America, generated resumed interest in commodities, resulting in new record highs for a number of metals.”

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Give your switchboard a new lease on life with "Plug & Play" The original Masterpact M chassis is kept (no intervention on the switchboard structure)

Masterpact NW adapted for the "Plug & Play" solution

Masterpact M

30 minutes* to retrofit your air circuit breaker on your main switchboard!

Was your air circuit breaker installed before 2003?

The "Plug & Play" solution delivered by Schneider Electric enables a fast and simple retrofit of your existing Masterpact M device to the latest technology of Masterpact NW. The existing Masterpact M chassis is retained. Busbar and cable connections are not disturbed, only the circuit concerned needs to be isolated (for as little as 30 minutes*). * Typical time for simple installations

Need more information?

Contact your local Auslec or L&H branch

Fast and easy implementation

Certified "Plug & Play" solution

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Continuity of service guaranteed

Electrical Contractors Licences Schneider Electric (Australia) Pty Limited is licensed under the relevant state electrical safety acts: QLD: 66116; NSW: 150195C; VIC: 17615; SA: PGE210184; WA: EC008813; NT: C2356