Mining Equipment Reliability, Maintainability, and Safety (eBook)

Dr B.S. Dhillon is a professor of engineering management at the University of Ottawa, where he has served as chairman of the Department of Mechanical Engineering and director of the engineering management program for over 10 years. He has been involved in teaching reliability, quality, engineering management, design, and related areas for over 27 years, and he has lectured in over 50 countries; including keynote addresses at various international scientific conferences held in North America, Europe, Asia, and Africa. Prof. Dhillon has served as a consultant to various organizations and bodies and has many years of experience in the industrial sector.

Preface 7
Contents 10
Introduction 17
1.1 The Need for Improving Mining Equipment Reliability, Maintainability, and Safety 17
1.2 Mining-equipment-related Facts and Figures 17
1.3 Terms and Definitions 18
1.4 Useful Information on Mining Equipment Reliability, Maintainability, and Safety 20
1.5 Problems 23
References 24
Introductory Mathematical Concepts for Mining Equipment Reliability, Maintainability, and Safety Analysis 26
2.1 Introduction 26
2.2 Range, Arithmetic Mean, Mean Deviation, and Standard Deviation 26
2.3 Boolean Algebra Laws and Probability Definition and Properties 29
2.4 Useful Mathematical Definitions 32
2.5 Probability Distributions 35
2.6 Solving Differential Equations Using Laplace Transforms 38
2.7 Problems 39
References 40
Introduction to Reliability, Maintainability, and Safety 41
3.1 Introduction 41
3.2 Need for Reliability and Bathtub Hazard Rate Curve 42
3.3 General Reliability, Hazard Rate, and Mean Time to Failure Functions 43
3.4 Reliability Networks 45
3.5 Commonly Used Methods in Reliability Analysis 53
3.6 Need for Maintainability and Maintainability Versus Reliability 61
3.7 Maintainability Functions 61
3.8 Maintainability Design Factors and Maintainability Analysis Tools 63
3.9 Maintainability-Management-Related Tasks During the Equipment Life Cycle 65
3.10 Need for Safety and Safety-Related Facts and Figures 65
3.11 Equipment Hazard Classifications and Common Mechanical Injuries 66
3.12 Safety Analysis Methods 66
3.13 Safety Indexes 68
3.14 Problems 69
References 69
Mining Equipment Reliability 71
4.1 Introduction 71
4.2 Reasons for Improving Mining Equipment Reliability, Factors Impacting Mining System Reliability, and Useful Mining- Equipment- Reliability- Related Measures 71
4.3 Open-Pit-System Reliability Analysis 74
4.4 Programmable Electronic Mining System Failures 78
4.5 Designing Reliable Conveyor Belt Systems and Methods of Measuring Winder Rope Degradation 79
4.6 Fault Tree Analysis of Shovel Machine 81
4.7 Dump-truck Tire Reliability and the Factors Affecting Their Life 83
4.8 Problems 83
References 84
Human Factors and Error in Mining 85
5.1 Introduction 85
5.2 The Need to Apply Human Factors in Mining and Common Roadblocks to the Introduction of Human Factors in an Organization 86
5.3 Human Sensory Capacities and Human-Factor Considerations in Equipment Design 87
5.4 Human-Factor Formulas 90
5.5 Useful General Human Factors Guidelines for Application in Mining Equipment Design 92
5.6 Classifications and Causes of Human Errors Leading to Fatal Accidents in Mines 92
5.7 Typical Mining Equipment Maintenance Errors, Factors Contributing to Maintenance Error, and Useful Engineering Design Improvements to Reduce Mining Equipment Maintenance Errors 93
5.8 Types of Chemicals Released in Human-Error-Related Events in the Mining and Manufacturing Industries and Factors Responsible for Failing to Reduce the Occurrence of Human Error in Mines 94
5.9 Human-Error-Analysis Methods for Application in the Area of Mining 95
5.10 Problems 101
References 101
Mining Equipment Maintainability 103
6.1 Introduction 103
6.2 The Meanings of Mining Equipment Maintainability and Design- induced Maintainability Problems of Mining Equipment 103
6.3 Advantages of Improved Mining Equipment Maintainability Design 105
6.4 Mining Equipment Maintainability Design Characteristics 106
6.5 Maintainability Measures for Mining Equipment 107
6.6 Common Maintainability Design Errors and Useful Maintainability Design Guidelines for Mining Equipment 111
6.7 Conclusions: State of Maintainability in the Underground Mining Industry 112
6.8 Problems 112
References 113
Mining Equipment Reliability and Maintainability Testing 114
7.1 Introduction 114
7.2 Reliability Test Classifications 114
7.3 Success Testing 115
7.4 Accelerated Testing 117
7.5 Confidence Interval Estimates for Mining Equipment Mean Time Between Failures 118
7.6 Documents on Reliability Testing 121
7.7 Planning and Control Requirements for Mining Equipment Maintainability Testing and Demonstration 122
7.8 Test Methods to Obtain Maintainability-related Test Data for Mining Equipment 123
7.9 Test Methods for Demonstrating Diverse Maintainability Parameters 123
7.10 Useful Guidelines for Avoiding Pitfalls in Maintainability Testing of Mining Equipment 125
7.11 Problems 125
References 126
Mining Equipment Maintenance 128
8.1 Introduction 128
8.2 Maintenance-related Facts and Figures 128
8.3 Maintenance Engineering Objectives, Total Productive Maintenance, and Reasons for Its Performance 129
8.4 Factors Contributing to Equipment Maintenance Cost in Mines 131
8.5 Maintenance of Explosion-protected Switchgear in Mines 132
8.6 Useful Maintenance Measures for Mines 133
8.7 Mathematical Models for Performing Mining Equipment Maintenance 136
8.8 Problems 145
References 145
Mining Equipment Costing 147
9.1 Introduction 147
9.2 Reasons for Mining Equipment Costing and Methods for Making Mining Equipment Investment Decisions 147
9.3 Cost Estimation Models for Mining Equipment 152
9.4 Life Cycle Costing Concept 156
9.5 Life Cycle Costing Steps 157
9.6 Life Cycle Cost Estimation Models for Mining Equipment 158
9.7 Problems 161
References 162
Introduction to Mining Equipment Safety 164
10.1 Introduction 164
10.2 Facts and Figures 165
10.3 Quarry Accidents and Electrical-, Equipment Fire-, and Maintenance- related Mining Accidents 165
10.4 Causes of Mining Equipment Accidents and Major Ignition Sources for Mining Equipment Fires 166
10.5 Methods for Performing Mining Equipment Safety Analysis 168
10.6 Hazardous Area Signaling and Ranging Device (HASARD) ProximityWarning System 173
10.7 Human-Factor-related Tips for Safer Mining Equipment, Guidelines to Improve Electrical Safety in the Mining Industry, and Strategies to Reduce Mining Equipment Fires and Injuries 174
10.8 General Areas for Safety Improvements in Mines 176
10.9 Problems 177
References 177
Programmable Electronic Mining System Safety 179
11.1 Introduction 179
11.2 Programmable Electronics Usage Trends in Mining 179
11.3 Programmable-electronic-related Mishaps 180
11.4 Methods for Performing Hazard and Risk Analysis of Programmable Electronic Mining Systems 182
11.5 Lessons Learned in Addressing the Safety of Programmable Electronic Mining Systems 187
11.6 Obtaining Programmable Electronic Mining System Safety- Related Information 187
11.7 Problems 189
References 189
Bibliography: Literature on Mining Equipment Reliability, Maintainability, and Safety 191
Introduction 191
Publications 191
Author Biography 206
Index 207