Maintenance Project Listing
We were contracted to
study and develop the effectiveness of the maintenance organisation of a
large open cast coal mine, with special emphasis on the results of the
maintenance information system. Several successes were achieved, including
the development of a proper maintenance policy, the establishment of an
integrated maintenance performance measurement process, a change from
operating style management to systems driven management and a general
improvement in the level of maintenance operation.
Contact person: Mr C.J. (Neels)
Telephone: (016) 970 6111
- Replacement study/ maintenance plan –
Basic Oxygen Furnaces, Iscor, Vanderbijlpark Works
The maintenance costs and downtime of the
three Basic Oxygen Furnaces at Iscor’s Vanderbijlpark Works were running
at very high and production-costly levels. The obvious solution was to
replace the units with ones of improved design. Due to the high cost of
such a capital replacement, we were contracted to do failure and capital
replacement studies to determine the best technical and cost efficient
route. The end result was that the units’ outer shells were replaced and
that there was a better understanding of the mechanism of failure.
Contact person: Mr R. (Roald) Rodseth
Radiant Operations International
Telephone: (082) 650 1910
- Statistical Analysis of generation unit
outages at Eskom’s Arnot power station
The Arnot power station near Middelburg is
the oldest of Eskom’s large 3600 MW power stations, consisting of 6
generation units (boiler/turbine/generator set units) of 600 MW each. The
power station is busy revamping and upgrading these units to ensure that a
satisfactory level of continued production capacity could be sustained. As
the capital cost involved is very high, a statistical analysis of the
unit’s production capacity and outages were performed with the purpose of
developing a proper maintenance /replacement strategy.
Contact person: Mr H.A. (Hendrik)
Arnot Power station
Telephone: (013) 97 9868
- Development of a Capital Replacement
System for De Beers
The De Beers mines have
mobile capital assets running into thousands of millions of
Rands. Many of
these machines are fairly old and costly to maintain. The group had no
consistent capital replacement strategy for optimising their equipment
maintenance and replacement. We were tasked with the proposal of a proper
approach to the problem, followed by the development of an Excel based
capital replacement system.
Contact person: Mr G. (Gerhard)
Telephone: (011) 374 7346
- Maintenance Policy – Iscor Mining
The Iscor mines recognised
the need for developing and formalising a proper maintenance policy. We
were requested to facilitate the process and write the policy document.
This took on the format of group work sessions, individual consultations,
and group approval sessions and led to a well thought through maintenance
policy, which is accepted and implemented by all the mines in the group.
Contact person: Mr P.J.
(Pieter) le Roux
Manager: Maintenance Engineering (at the time)
Iscor Mining Headquarters
Telephone: (082) 650 0066
- Pusher Car replacement study
The management of Silicon
Technologies (Pty) Ltd felt they could not live with the high maintenance
cost of the pusher cars they were using at their silicon ovens. M-Tech
did a replacement study, disproving the present replacement of these cars,
pending the availability of more maintenance cost data.
- Maintenance Policy – Reumech Ltd
Reumech is a company that
evolved from the capacities created through Armscor contracts. They are
busy developing new commercial business ventures comprising a variety of
specialised vehicles. They were in dire need of a proper policy for the
maintenance support of their marketing strategy. M-Tech facilitated the
development of such policy.
- Maintenance System Installation
Brandspruit Colliery is
one of the mines of the Secunda mines complex. They bought and installed a
computerised maintenance information system, which did not perform well at
all. M-Tech was commissioned to assist in the effective installation of
the system. The work performed included formalising many parts of the
system such as developing condition monitoring strategies, maintenance
documentation, fault diagnosis diagrams, maintenance procedures and
performing Reliability Centred Maintenance analysis on all the critical
Contact person : Mr F.J. (Frikkie)
Telephone (017) 614 6000
- Maintenance System Project Definition –
When the Secunda Mines
complex contemplated the installation of a maintenance information system
(and following our success at the Brandspruit Colliery), they appointed us
to do the preliminary project definition work. This included a summary of
business objectives, summary of business functions, summary of information
needs, conceptual design, project data model, interface requirements, risk
profile and installation work plan. This enabled the mines’ own project
team in launching the project within known parameter boundaries.
- Maintenance System evaluation – Metro
Metro Rail was
contemplating the purchase of a computerised maintenance information
system. One of their areas was using a present system that was custom made
for their business application. They thus needed a good and independent
evaluation of the functional and technical suitability of the software.
M-Tech was commissioned for this purpose and carried out a detailed
evaluation of the software package.
Non-maintenance project listing
- Computerised production monitoring system
– Cape Gate
The design, project
management and installation of a computerised production monitoring system
at a large wire mill. This included the procurement of all hardware, the
design and writing of all software and the final installation and testing
of the system. The system supplies vital management information on a daily
basis. This system was a pilot scale design study to investigate the
possibility of automating the whole plant in a similar fashion. I worked
extremely well and was followed by the full scale installation of a
commercially available system.
- Simulation Study – Mineral Processes (Gencor)
A simulation study into
the various options for the transport of ore on surface at a large mining
complex. The complex consists of 13 mine shafts that are connected to a
central ore beneficiation plant via a rail network. M-Tech was
commissioned to do a simulation study to enable the management of the
complex to do long term planning. Decisions that had to be taken during
the planning process included shaft and additional plant location
decisions as well as rail network design. The simulation work was done in
a commercially available simulation language SLAM.
- Simulation System – Mineral Processes (Gencor)
The development of a
custom built simulation to handle the above-mentioned problem. The system
is fully commercialised and can handle any similar simulation problem. The
simulation process is handled using 13 multifaceted matrices and 2 history
files. Customised reports are available for each simulation run to
facilitate comparisons between different rail configurations.
- Simulation System – Elandsrand Gold Mine
The development of a
simulation system to simulate the transport of ore in a deep underground
gold mine. The mine group, for whom the system was developed, had to take
decisions concerning the possibility of deeper mining activity without
sinking new shafts. This has the effect of increasing the load on the
transport system, which had to be investigated.
- Heat pump studies – National Energy
Two projects relating to
the use of heat pumps as viable alternative for resistance and other type
of heating. One of these comprises a market survey and techno-economical
evaluation of heat pumps as an alternative heating method, while the other
is a study of the effect of heat pumps on domestic power consumption.
These projects were undertaken for the National Energy Council.
- Long Term Capital Study – Liebenberg,
Jenkins and Partners
The civil engineering consulting firm,
Liebenberg, Jenkins and Partners, was involved in major pump station and
water reticulation designs (Lesotho Highlands Project), but needed the
ability to forecast the long term capital flows of different design
alternatives. M-Tech was commissioned to develop custom made algorithms
and computer spreadsheet solutions for the application.