ARC FLASH

SKID SYSTEMS

SUCCESSFUL USES OFSKID SYSTEMS

PAGE 4

PPE CAN STOP YOU BEING ‘THE FLASH’PAGE 6

MIDASGAZETTE

ISSUE 46Quarter 2 2015

EDITORLEANNE TRAN

DESIGN/PRODUCTIONLEANNE TRAN

CONTRIBUTING WRITERSMIKE CARTERDAMIAN CONNELLYASHLEY DICKER-LEEBRENTON FITZGERALDCATHY GALLIRONALD KLEIJNSTEWART LONGROCKY VASILE

COVER IMAGEHIGH VOLTAGE POST(MIDAS PHOTO LIBRARY)

MIDAS ENGINEERING GROUP PTY LTD COPYRIGHT © 2015ALL RIGHTS RESERVED

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CONTENTS

Midas Engineering Group (Midas) is a dynamic and innovative consultancy group offering an extensive suite of engineering capabilities. Midas provides engineering disciplines across the group with offices in Perth, Newcastle, Noosa, Melbourne and Brisbane, where our team are focussed on delivering value added engineering solutions. We are committed to providing an extremely high level of personalised service undertaken with the highest integrity and confidentiality. This is reflected in the growth of our brands and their client bases, which have been built over 26 years through referrals and excellence in client focus.

Midas brings a mix of skills and expertise within multiple sectors such as mineral processing, electrical, civil, structural, environmental and building services. The group has served a wide variety of clients including mining, oil and gas companies, the Australian Defence Force, developers, architects, financial service companies, local governments and councils, school districts, hospitals, and medical centers. This wide range of experience developed across many industries, demonstrates the wealth of knowledge and specialised skills that allows the Midas group to consider no engineering project too large or small to consult upon.

MIDAS AT A GLANCE

COVER STORY FEATURES

NEWS

ELECTRICAL SYSTEMSAre You Adequately Managing Your Electrical Power System Risk?

ARC FLASHPPE can stop you being ‘The Flash’

WATER IN MININGWater Management Issues with Processing Magnetite Ores

SKID SYSTEMSSuccessful Uses of Skid Systems

ENVIRONMENTALMine Closure and Rehabilitation

PROCESS AND PLANT OPTIMISATIONHow to Improve Efficiency

RENOVATIONS AND EXTENSIONSSteps to Getting Your Home Council Certified

QUALITY MANAGEMENT SYSTEMCompliance with ISO 9001

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TRAINING

UPCOMING COURSESTraining Courses and Complimentary Insights Sessions

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April 2015

DIRECTOR’S NOTE

Welcome to the 46th edition of the Midas Gazette

This quarter we see the launch of our re-designed websites for the Midas Engineering Group subsidiaries. Our skilled staff have been working towards developing each website to meet the needs of our clients, providing a comprehensive range of service offerings and user friendly navigation throughout the site. There are currently many challenges in the engineering environment, which in themselves will present opportunities for growth. We have done well to achieve the transformation so far in an

Australian market and are a much stronger group as a result, with better geographical spread. I am confident and excited to see what the future holds. In this issue of the Gazette we will take a look at successful uses of skid systems, managing your electrical power system risks, and personal protective equipment against Arc Flash, among other interesting topics.

Kind Regards,

Damian ConnellyDirector / Principal Consulting Engineer

Water is a critical resource in a dry climate with competing uses from farmers, miners and townspeople. There are no large rivers in Western Australia capable of supplying water for processing magnetite ores. If sea water is used there are severe corrosion issues and therefore a requirement to wash the concentrates with potable water. If groundwater is used there is a need to treat the water, and sustainability is an issue for large projects because of potential drawdown of the aquifer.

If sea water is desalinated the cost of the water is high because of the power requirement. At the same time the necessity to conserve water has led to flowsheets, where all of the tailings have to be filtered to minimise the water requirement. Managing the various water qualities and optimising water recovery has resulted in maintaining the water balance and issues meeting environmental obligations.

The availability of water, water conservation and the high cost of water are common themes for magnetite ore processing. Some of the initiatives being implemented are reducing water use, developing new sources, recycling, treatment and water audits.

We take a look at three different magnetite projects; Southdown in a cool climate environment near Albany, Karara in the Mid West and Citic in the Pilbara. Looking at

these three different magnetite projects, we can see that each project has its own unique water issues. A theme that all projects have in common though, is how they see water as a critical resource for processing, and the management of the water resource as being integral with the ore resource. Some notable differences and similarities exist with how each project has developed their water management plan.

For the Citic Magnetite Project; desalination of sea water is the sole source of water at a significant cost of production. As a result, minimisation of water consumption by rapid flocculation at tailings is used to maximise water recovery. The Karara magnetite project relies on good quality groundwater and pressure filtration of tailings to minimise the water consumption required for ore processing. For the Southdown project, climatic conditions create a different scenario where groundwater, pit dewatering water and rainfall will satisfy the water requirements for the project. A conventional tailings dam with tailings water return will be used.

For all projects the quality of water, particularly the total dissolved salts (TDS) on flotation and recirculating slimes will impact on final product grade. In addition, calcium and magnesium salts in a high pH environment are not good for optimum flotation of the silica out of the magnetite concentrate.

WATER IN MINING WATER MANAGEMENT ISSUES WITH PROCESSING MAGNETITE ORES

ON THE COVER:

PPE AGAINST ARC FLASH

NEWS:

QUALITY MANAGEMENT

SYSTEM

Midas Gazette

SKID SYSTEMS SUCCESSFUL USES OF SKID SYSTEMS

Skid systems are transportable structures, with mounted plant, piping, electrical systems and controls, to serve a particular function. They may be standalone turnkey systems or modular units that combine together to serve a larger process. Skid systems allow greater flexibility by being transportable with a small footprint and greatly reduce installation and start-up times. For this reason, skid based systems are increasingly being used not only for temporary or relocatable systems but for new fixed installations.

The increased quality assurance of skid based systems is another benefit over in-situ site erected systems. Most welding, testing and coating systems can be conducted and applied in factory under the company quality control system. Electrical systems and instrumentation can be prewired with full factory acceptance testing. In most instances, systems can be commissioned and any defects corrected before they leave the factory.

Midas Engineering Group (Midas) recently designed and commissioned a 2000L flocculant batch system, which was a standalone turnkey system for mixing and agitating a 1% flocculant solution. The system was designed, fabricated and wet commissioned in Australia before being shipped to South America for install and hot commission. The control system design and commissioning accommodated the site power supply which differed from the local supply in Australia.

CDMS Consulting Engineers, a division of Midas, worked with another global company to develop a Vacuum Enhanced Recovery (VER) system for oil and water separation at a major O&G operation. This consisted of a series of modular skid systems that could be transported offshore, some assembled together, with others plumbed and wired up remotely to complete the full process. The system consisted of a series of wells,

with a water tank skid, oil tank skid, oil and water separator, vacuum vapour extraction skid and a control system / MCC container. The skids were all self bunded and could be installed with no more site preparation than a couple of strip footings per system.

These two examples demonstrate successful use of skid systems for standalone and modular process systems. Similar systems designed include duplex filter skids, pumps skids for fuel handling and offshore seawater pump skids through to subsea skids. Midas is currently working on a modular carbon stripping plant for use on remote and low grade gold mining operations. These flexible systems are adept at meeting changing operations to suit the fluctuation in gold price, as well as make lower grade deposits economically viable with cost savings across the development lifecycle through modular design.

Modular construction is not new but has historically been used for large plant and offshore structures. The advantage of using this modular design for new fixed installations is an important design consideration for competitive advantage in the current economic climate. There may be options on your next project for utilising skid based systems over conventional construction methods.

QualityManagementSystemCOMPLIANCE WITH ISO 9001

In every organisation, both management and the general workforce tend to resist change, whether it is in systems, culture or environment. The change brought about by the introduction of a Quality Management System (QMS) is no exception.

Midas Engineering Group has embraced the change and is committed to ensuring all business units are fully aligned to ISO 9001. This will provide assurance that Midas has been held to the highest standards and practices.

QMS works on eight key principles:

• Customer focus;• Strong leadership;• Involvement of people;• Process approach;• Systems approach;• Continuous improvement;• Decision making based on

facts; and• Creating value for the company,

its clients and its suppliers.

The intent of any QMS is to provide a system for developing or improving processes through a structured approach, effective deployment and better control. Documented processes help in the following ways:

• Processes are optimised when best practices are documented;

• Key activities run smoothly when responsibilities and accountability is clearly assigned;

• Non conformances are easier to capture and eliminate at the earliest stage;

• Prescribed corrective actions can be taken as soon as non-conformances occur;

• Consistent process measures help gauge if everything is performing as it should be; and

• A better understanding of processes ensures compliance in project and service delivery.

The groups’ quality management system will not only provide a structure and framework, it will also ensure the rigor of an audit mechanism that enforces corrective action and continuous improvement.

NEWS

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April 2015

ENVIRONMENTALMINE CLOSURE AND REHABILITATION

Our team at Midas Environmental have worked extensively in compliance and risk management for various clients in a variety of sectors over the past 12 months with pleasing results.

We have also developed mine closure and rehabilitation plans for a number of operational and non-operational mine sites. This has included identification, direction and implementation of ecological studies, stakeholder consultation, rehabilitation management planning and monitoring.

Most noteworthy was the establishment of flora monitoring in a Priority Ecological Community on Banded Ironstone Formations, associated with a historical gold mining operation replete with a suite of environmental legacy issues. Our ecological assessment included mitigation measures to control surface water and soil erosion to reduce dispersion of clays and sediment fanning from historical rehabilitated waste rock stockpiles.

Midas Environmental is working with a team of leading engineers to develop mine closure plans for tailings storage facilities in Western Australia. This has included engaging specialists with whom we have established relationships to contribute to the geochemical and geophysical assessment of available cover materials, informing strategies to reduce costs of closure and improve integrity of the cover design and environmental performance.

Responsible Electrical Engineers are managing ageing electrical systems, diminishing maintenance budgets and broadened duty holder responsibilities. As a consequence, some of the questions being raised are;

1. How does the latest WH&S Legislation impact on how I manage my site’s Electrical Systems?

2. Is there increased liability for myself, or the business, as a result of the latest WH&S Legislation?

3. Should I be more actively managing risks associated with my Electrical Power System?

Compliance with the WH&S Act 2011, the WH&S Regulation 2011, and the WH&S (Mines) Regulation 2014 is mandatory. Codes of Practice, Australian Standards and Guidance Notes offer supporting information but are only a guide.

A duty holder or, a Person Conducting a Business or Undertaking (PCBU) such as the Responsible Electrical Engineer, has the task of identifying and maintaining control measures (measure to eliminate or minimise the risk) including the management of;

1. An electrical power system model depicting electrical component loading, fault level rating and arc flash compliance.

2. Protective relay settings that are co-ordinated to manage the safe supply of power to all parts of the installation.

3. Site Power Reticulation Single Line Diagram (SLD), Protection SLD and Interlocking SLD.

TCT Electrical Engineering is a strong advocate of conducting Electrical Power System Modelling, Protection Grading Studies, Arc Flash Assessments, AS3000 Compliance Audits and Electrical Management Systems for all types of business, including coal mines, quarries, manufacturers, facilities management, industrial and commercial operations.

ELECTRICAL SYSTEMSARE YOU ADEQUATELY MANAGING YOUR ELECTRICAL POWER SYSTEM RISK?

Mandatory

Voluntary Guidance M

aterial

Figure 1: Framework for Compliant Operations

Work Health and Safety Regulation 2011 (extract)

37 Maintenance of control measuresA duty holder who implements a control measure to eliminate or minimise risks to health and safety must ensure that the control measure is, and is maintained so that it remains, effective, including by ensuring that the control measure is and remains:a) fit for purpose, andb) suitable for the nature and duration of the work, and,c) installed, set up and used correctly.

38 Review of control measuresa) A duty holder must review and as necessary revise control measures implemented under this Regulation so as to maintain, so far as is reasonably practicable, a work environment that is without risks to health or safety.

Figure 2: Extract from Work Health and Safety Act 2011

Service personnel are frequently requested to undertake tests, maintenance or checking on switchboards that are ‘live’ and cannot be shutdown. The procedures should follow a prescribed Job Safety Analysis (JSA), however the worker will be exposed to danger. Electrocution is not the main cause of death or injury, but rather an ‘Arc Flash’ due to burns or flash impact. This has been recognised for decades in Europe and the U.S. In Australia, AS4836:2011 and AS3007:2013 make reference to Arc Flash for general installations and equipment in mining environments respectively.

What is an Arc Flash?

An arc flash occurs where inadvertent contact is made with live conductors resulting in an electrical arc, typically through personal contact, dropped tools, equipment misalignment or faulty test equipment. The short circuit produces an explosion of molten material that expands 40,000 times the volume of the solid material. The pressure wave directs the vaporised metal to the operator resulting in severe burn or impact injury. Type ‘Arc flash accident’ into your web browser to demonstrate the explosive power but caution it may be distressing.

The energy in the arc flash is dependent on the arc current magnitude, its duration, and the distance between arc and operator. It can be estimated by calculation (refer IEE 1584:2002). In addition, the operators clothing also has a significant influence on potential injury. A high degree of Personal Protective Equipment (PPE) can greatly reduce the extent of injury. Standards require attendants to wear PPE when working in a potential arc-flash environment, the degree depending on the potential energy of an arc flash.

The guide below relates the upstream transformer rating (which governs maximum potential current) to the minimum level of PPE required. Increasing both the KVA rating and

the protection tripping times requires a significant upgrade in PPE. For all electrical work including those below, coveralls, leather shoes, gloves (Arc-rated where shown), hearing protection and safety glasses must be worn.

Upstream TransformerRatingKVA

Protection Trip Time secs

Est. Arc Fault Current Amps

Minimum Level of PPE

500, or1000

All at0.2s

8, 20013,600

Arc rated long sleeve shirt and trousers andarc rated face shield and arc rated balaclava (or arc flash suit hood)

1500, or2000, or2500

All at0.2s

16,70018,90021,800

All KVA ratings: arc rated long sleeve shirt and trousers, arc rated coverall, arc rated suit jacket, arc rated suit pants, arc flash suit hood, arc rated gloves. rated min. 25Ccal/sq cm

1500, or2000

All at0.5s

16,70018,900

Arc rated long sleeve shirt and trousers, arc rated coverall, arc rated suit jacket, arc rated suit pants, arc flash suit hood, arc rated gloves. rated min. 40cal/sq cm

Arc flash calculations must be undertaken prior to the switchboard manufacture and a warning label provided to advise the minimum level of PPE to be worn while working on an energised switchboard. Ensuring the correct procedures are adopted and equipment used will prevent injury. It is no picnic being in a hospital burns unit.

COVER STORY

“a high degree of PPE can greatly reduce the extent

of injury”

ARC FLASH PPE CAN STOP YOU BEING ‘THE FLASH’

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April 2015

Process and plant optimisation can be used to achieve a range of objectives. These can include, but are not limited to, improved product specification, higher recovery, improved process economics by a reduction in operating costs, increased throughput and greater energy efficiency.

Optimisation analysis can be used to alter a process for a new operating environment such as a change of product specification or a new plant feed. Another common use for optimisation is to improve an existing plant to maximise efficiency. The process can focus on one individual unit or the whole operation. As a result the optimisation process is not limited to any one discipline, and will involve input and action from all areas to ensure the greatest improvements can be achieved.

Plant data is essential to provide a baseline for the study. This information can provide a basis for system modelling. An accurate plant model can take an extended period of time to establish, however once established the model will be beneficial as process changes can be trialled on computer and their effects predicted without disrupting the process plant.

Bottlenecks in the process identified by a plant audit can be seen as opportunities to improve process throughput. It may be possible through making small changes to equipment, such as crusher close size settings, screen deck sizes, mill feed densities or cyclone cut points, to significantly increase the throughput of the plant.

Optimisation testwork can also be used to improve efficiencies. Bench scale testwork can evaluate the sensitivity of an ore to grind size or reagent concentrations to determine points where a cost effective change can be made to improve recoveries, or reduce reagent consumptions. The optimal operating point in a plant is rarely where the recovery or grade of a product is maximised, and will hence be a trade-off between all variables.

FEATURES

As the population increases and vacant land becomes scarcer, the need for infill development in urban suburbs is increasing. This results in the subdivision of larger blocks and increasing house prices. Housing renovations and extensions are also on the rise as a result of a combination of the following factors:

• Older houses that require an upgrade to become more modern and to fix damaged, and/or old features;

• Cheaper for the landowner to develop their existing home rather than selling it and buying another property; or

• Residents are happy with the area they live in and do not want to move, however require more space or a better quality home.

The average property area in previous decades was significantly larger than it is today, meaning that the ratio of house to land was smaller. Depending on the residential design code zoning (R codes) applicable to that lot, it is possible to extend the house.

The procedure for executing an extension or renovation to your house is to initially contact your local council and they will let you know of any specific requirements they have. Engaging an architect, designer or, in some instances, a surveyor would then be required to produce plans, sections and elevation drawings. A structural engineer will then either certify the plans or produce engineering drawings depending on the complexity of the project. A licenced building surveyor can then be engaged to check compliance to the Building Code of Australia for the submission of a certified building application to council. An uncertified application may also be made, however this will take longer for council to approve.

Midas Engineering Group has recently been involved in many renovation and extension projects. One of their clients, the Coptic Orthodox Church of Western Australia, required the removal of an internal load bearing wall to allow for a more open congregation area. Subsequently, Midas was able to provide an engineering report and drawings for the project, which formed part of a successful local council submission for approval.

PROCESS AND PLANT OPTIMISATION HOW TO IMPROVE EFFICIENCY

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Want to Broaden Your Knowledge?

TOP 10 COURSESTop Training Courses for this Quarter1. Mineral Processing Course (2 Days)

2. Gold Extraction

3. Pumping & Pump Fundamentals

4. Iron Ore Processing

5. Solid Liquid Separation, Filtering & Drying

6. Metallurgy for Non-Metallurgists (2 Days)

7. Coal Processing

8. Flotation

9. Crushing & Grinding

10.  Hydrometallurgy

To register attendance, please contact marketing@midasengineering.com.au

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