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By John J. Sammarco

Computer-related accidents have caused injuries and fatalities in mining as well as other industries. Normal accident theory (NAT) explains that some accidents are inevitable because of system complexity. NAT is a classic argument in organizational sociology although it has been criticized as having imprecise definitions and lacking criteria for quantifying complexity. These limitations are addressed by a unique approach that recasts this organizational theory into an engineering-based methodology to quantify NAT complexities of computer-based systems. In this approach complexity is categorized as external or internal. External complexity is defined by the external behavior of a system, and is quantified by these dependent variables: system predictability, observability, and usability. Dependent variable data contain the perceptions of 32 subjects running simulations of a system. The system?s internal complexity is characterized by modeling system-level requirements with the software cost reduction (SCR) formal method. Model attributes are quantified using 15 graph-theoretical metrics?the independent variables. Five of 15 metrics are correlated with the dependent variables as evidenced by structure correlations exceeding 0.25, with standard errors <0.10 and a 95% confidence interval. The results also show that the system predictability, observability, and usability decreased as NAT complexities increased. This research takes a step forward in operationalizing NAT for computerized systems. The research benefits mining and other industries as well.

Jan 1, 2005

By O N. Savassi

A rigorous methodology for prediction of flotation plant performance is presented, which is based on a standardised batch flotation test called the MFT. The work is part of the FLEET program, developed by MinnovEX with the support of seven large mining firms. The methodology is divided into three key steps: direct measurement of the kinetics of true flotation in the pulp, independent of hydraulic entrainment and other froth effects in the batch cell; benchmarking of the industrial plant over a broad range of ore types and operation conditions; and model calibration to describe froth effects in the plant, with a minimal number of parameters. To date, the methodology has been applied with success at several industrial plants, encompassing copper, gold, nickel, iron, lead, zinc and coal operations. This paper includes a description of the laboratory testwork procedure and scale-up to full industrial circuits. Examples of industrial application are also presented.

Jan 1, 2005

By E. Essadiqi, P. Poruks, D. Boyd, D. Emadi, I. Yakubtsov, T. Turi

This paper reviews the results of an extensive study of microstructures and mechanical properties in bainitic linepipe steels. The research was carried out as a collaborative project between Queen&apos;s, Stelco and CANMET. Basic studies of phase transformations and mechanical properties in these steels established important relationships between processing schedule and microstructure evolution, and between final microstructure and mechanical properties. The best combination of strength and toughness properties is obtained with a microstructure comprising a matrix of intragranularly-nucleated bainite (`acicular ferrite - AF&apos;) and small (~ 0.5 µm) dispersed particles of martensite (`M/A&apos;). We describe this as a dual-phase AF+M/A microstructure. An experimental study on 15-mm thick plate determined the window of steel composition and processing parameters which gives the dual phase AF+M/A microstructure. The minimum strength and toughness properties for Grade 621 (X90) linepipe steel can be achieved by either a lean steel composition (0.04C-1.77Mn-0.04Cr¬0.32Mo-0.31Ni-0.29Cu-0.08Nb) with extreme processing parameters, or by a higher alloy composition (0.04C-2.07Mn-0.50Cr-0.51Mo-0.04Nb) with a more industrially realistic processing schedule. It is proposed how this approach could be extended to obtain higher strength linepipe grades.

Jan 1, 2005

By M. T. Shehata, R. W. Revie, M. Elboujdaini

Environmentally assisted cracks in linepipe steels are initiated either as a result of stresses in combination with environmental effects, as in stress corrosion cracking (SCC), or as a result of trapped hydrogen in the steel, as in hydrogen-induced cracking (HIC). To understand better the mechanism of the crack initiation process, key metallurgical and environmental elements that can affect the cracking phenomena were investigated and are reviewed in this paper. The complexity of both cracking phenomena results from the dependence of SCC and HIC on multiple metallurgical, mechanical, and environmental parameters that may all influence both crack initiation and propagation; e.g., composition, microstructure and non-metallic inclusions in the steel, applied stress, water chemistry in the field, and ionic concentrations in the groundwater near the pipe surface to name a few for SCC. In addition, for HIC phenomena, one can add the concentration of H2S in the fluids transported in the pipe as well as concentration of CO2, pH, etc. In this paper, cracking of linepipe steels is analyzed critically, with particular attention to the crack initiation process. The paper is divided into two parts: The first part covers SCC and the second covers HIC.

Jan 1, 2005

By J. W. Coetzee, H. E. Deist

Carbon-in-pulp (CIP) and Carbon-in-leach (CIL) processes are used extensively in the gold mining sector to recover aurocyanide from solution. This paper discusses the modelling of these operations, using various simplifying assumptions, in order to simulate the effect of changing operating conditions on the dynamics of the system. It is assumed that the adsorption and leaching rates are a function of concentration difference between the source phase and recipient phase. The simulation was set up using Matlab&apos;s Simulink interface. Plant variables are solved using a medium scale Newtonian search algorithm in Matlab, where the differences between the actual and predicted plant outputs are minimized on a continuous time-line.

Jan 1, 2005

By Steve Kral

Most innovations in the mining and processing industries have come from the need to produce more for less. Extracting minerals from the ground is expensive. And it is a constant struggle for mine operators to maintain the line between profitability and loss. The same holds for equipment suppliers. To maintain competitiveness, mining equipment manufacturers are building their machines with an eye to what the customer needs. Equipment makers know that if they do not supply machines that are productive and cost efficient, their competitors will. The result has been that the mining industry can now produce more ore with fewer people and more productive equipment. But, for all of the advances made in equipment, mine operators still demand machines that produce even more, are safer for workers and the environment, require less maintenance and can do the job at lower costs. And equipment manufacturers keep responding with larger, smarter and more technologically advanced machines.

Jan 1, 2005

By David D. DiPonio, John DiPonio, Roger Van Omen

The greatest opportunity to attain the most favorable prices for underground construction projects occurs during the competitive bidding period. The Owner, Engineer, and Contractor need to have a thorough understanding of the project’s design concept, how it is going to be built, and what it is going to cost. This paper presents the opinions of three engineering professionals who are well established in their sectors of heavy civil underground public works construction. This paper will outline and summarize the considerations that the three principal contracting parties of Owner, Engineer, and Contractor need to make to obtain good price quotes at the time of bids.

Jan 1, 2005

Coal mining legislation makes frequent reference to æSafety Management SystemsÆ but there is a chronic shortage of useful guidance material as to how these might be applied to hazardous exposures. Several studies have indicated that for each death that is reported as a result of an industrial æaccidentÆ, there are five deaths that caused by occupational exposures. Because the deaths from occupational exposures do not occur on site and often well after employment has ceased, they are generally unreported. Improved access to mortality data from coroners, the Australian Institute of Health and Welfare and superannuation service providers (early claims from death and total permanent disability), has given rise to some analysis of death and disability data that provides evidence that there are emerging opportunities to develop and improve safety management systems for hazardous occupational exposures. Issues explored include how safety management systems might be developed in relation to dusts and chemicals and other hazardous exposures to ensure the risk of disorders with long latency periods are reliably assessed and the exposures effectively managed. The current standards and guidelines which refer to safety management systems in general or to management of exposure related hazards are examined. Many standards are based on dose-response studies that provide for an acceptable percentage of workers to suffer adverse health outcomes. An alternative management system might be to apply dose-response relations to health surveillance to identify æat riskÆ individuals and effectively manage health and related safety risk at an early stage.

Jan 1, 2005

By J P. Moodie

Recent trends in flotation technology are briefly reviewed. These show that considerable development has been made as the operators, suppliers and technologists have responded to the challenges of the industry. Most of these advances have been based on empirical and phenomenological methods. There is a considerable opportunity to make further advances through a more fundamental, scientific approach. Some of this work is discussed and, although progress is being made on this front, industrial uptake has been somewhat slow. A number of specific issues facing the industry are discussed.

Jan 1, 2005

By D. Berkley

"Economic and environmental constraints drive more and more industrial organizations in using energy management as one of the means for addressing these issues. The recent increase in energy price could even make energy management a matter of “survival” in some cases.Experience shows that energy management is successful when the energy is managed like a resource, i.e. continuously, systematically, and in an organized manner, not like an expense, paying the bills once a month. This requires the development and implementation of an energy management program (EMP).This paper outlines some of the barriers, keys to success, components, and approaches to a successful energy management program, plant- or corporation-wide."

Jan 1, 2005

As students progress further into a degree, the decision of vocation selection, and even more importantly û securing employment in a particular industry sector, can become quite daunting. However, with a little initiative, students can overcome these issues by not only researching what employment opportunities exist, but by applying for summer vacation employment. Undergraduate vacation employment, especially with a world-leading hydrometallurgy research organisation such as the Parker Centre, can dramatically alter a studentÆs perspective of particular industries and possibly even alter their selection of vocation pursuits upon graduating. Students can also use vacation employment to enhance their networking capabilities, technical skills and knowledge by dealing with challenging new topics such as sulfur dioxide leaching, which is also discussed in this article.

Jan 1, 2005

By G. Zeng

Although the solubility of oxygen in zinc electrolyte is less than 9 mg/L, the effect on deposit stability and zinc-dust consumption can be significant. Sodium sulfite is used to deoxygenate the electrolyte. The effect of the sodium-sulfite concentration on cobalt removal is investigated. The results show the reduction of sulfite to elemental sulfur that adhered to the zinc dust surface forming a passivating layer, and small amounts of sodium sulfite have no effect on cobalt removal. The optimum amount of sodium sulfite is 100 mg/L. It is an important consideration in purification circuits to use sodium sulfite as an additive to cobalt cementation.

Jan 1, 2005

By B B. Beamish, M S. Kizil

The processes that take place during the development of a heating are difficult to visualise. Bulk coal self-heating tests at The University of Queensland (UQ) using a two-metre column are providing graphic evidence of the stages that occur during a heating. Data obtained from these tests, both temperature and corresponding off-gas evolution can be transformed into what is effectively a video-replay of the heating event. This is achieved by loading both sets of data into a newly developed animation package called Hotspot. The resulting animation is ideal for spontaneous combustion training purposes as the viewer can readily identify the different hot spot stages and corresponding off-gas signatures. Colour coding of the coal temperature, as the hot spot forms, highlights its location in the coal pile and shows its ability to migrate upwind. An added benefit of the package is that once a mine has been tested in the UQ two-metre column, there is a permanent record of that particular coals performance for mine personnel to view.

Jan 1, 2005

By Eric J. Foell

The Offshore Technology Conference (OTC) was founded in 1969 when a group of scientific and technical societies organized an annual conference and exhibition dedicated to technologies used in the offshore oil, gas and mining industries. Currently, OTC is sponsored by 12 industry organizations and societies. These include: American Association of Petroleum Geologists (AAPG); American Institute of Chemical Engineers (AIChE); American Institute of Mining, Metallurgical, and Petroleum Engineers (AIME); American Society of Civil Engineers (ASCE); ASME International Petroleum Technology Institute; Institute of Electrical and Electronics Engineers/Oceanic Society (IEEE-OES); Marine Technology Society (MTS); Society of Exploration Geophysicists (SEG); Society for Mining, Metallurgy, and Exploration (SME); Society of Naval Architects and Marine Engineers (SNAME); Society of Petroleum Engineers (SPE); and The Minerals, Metals, and Materials Society (TMS). OTC also has two endorsing organizations, the International Association of Drilling Contractors (IADC) and the Petroleum Equipment Suppliers Association (PESA), as well as 6 supporting organizations that include the American Petroleum Institute (API), the Independent Petroleum Association of America (IPAA), the Institute of Marine Engineering, Science, and Technology (IMEST), the International Association of Geophysical Contractors (IAGC), the National Ocean Industries Association (NOIA), and the United Kingdom Offshore Operators Association (UKOOA). From its earliest years, the OTC has been held during the first week of May in Houston, TX, initially at the Albert Thomas Convention Center where OTC?69 drew 4200 attendees and 200 exhibitors. As the conference grew and became established as the world?s foremost event for the development of offshore resources in the fields of drilling, exploration, production, and environmental protection, the venue was changed to the Astrodomain Complex, with technical paper sessions and most exhibits taking place in the Astro Hall. The numbers of attendees and exhibitors varied somewhat over the years, primarily in accordance with the fortunes of the international oil and gas industry. At its height in the early 1980s, OTC registered attendance exceeded 100,000 with more than 2500 exhibitors forcing expansion into the Astro Arena and even the Astrodome.

Jan 1, 2005

By J. Chae, D. Pecha, R. Andrews

The Henderson/ML King CSO Project is a major combined sewer overflow (CSO)reduction project for the Department of Natural Resources and Parks of King County, Washington. The central element of the project is the 3100 lineal feet long, 14&apos;-8"diameter 42nd Ave S Storage/Treatment Tunnel. During the course of the project, the owner and consultants evaluated numerous elements of the tunnel including the alignment, geotechnical conditions, tunnel liner, and settlement monitoring requirements. The contractor utilized innovative shaft construction methods for the tunnel portals, and adhered to strict contract requirements in successfully constructing the tunnel. This paper provides an overview of the design and construction elements of the 42nd Ave S Storage/Treatment Tunnel that led to the successful completion of the project.

Jan 1, 2005

By M. Wu, G. Plascencia, A. E. M. Warner, A. Vahed, T. A. Utigard

Nickel oxide granules formed by pyrohydrolysis of a chloride solution, were reduced in hydrogen. Below 400 °C, an incubation period was observed, followed by very slow reduction. In the temperature range from 400 to 600 °C, the rate of reduction increased with increasing temperature and increasing hydrogen pressure. Microscopic analysis showed that in this temperature range the reaction followed the shrinking core model. Above 600 °C, the reduction rate decreased noticeably before suddenly becoming very fast at and above 950 °C. Microscopy showed inner bands of metallization inside the outer metallic rim, indicating partial blockage of the interface between the reacted and un-reacted NiO core. At these temperatures, particle agglomeration and sintering were also found to take place. Surface segregation of sulphur may account for the slow down in reduction rate above 600 °C. From an industrial point of view, reduction should be carried out from 550 to 600 °C with as high a concentration of hydrogen as possible. If sintering and agglomeration are not of any concerns, reduction can be carried extremely fast at about 1000 °C.

Jan 1, 2005

By A. J. DeArdo

Linepipe steels have come a long way in the past forty years. In fact, modern, high strength steels for large diameter linepipe applications represent one of the seminal accomplishments in metallurgy of the past half-century. The synergy of advanced steelmaking, alloy design including microalloying, hot rolling, and interrupted accelerated cooling has led to the marvelous steels being used today. The drive for higher performance pipelines has been motivated by the energy sector of our global economy who wanted both higher throughput capacity, i.e., larger diameters and higher pressures, and lower material cost, i.e., relatively thinner gauge wall thicknesses. These requirements led to new steels with higher strengths, better toughness and improved weldability. The goal of this paper is to trace the evolution of linepipe steels from the X60 grades of the small diameter pipelines of the 1960s to the (X80 - X120) grades used in the large diameter pipelines of today. The metallurgical triumphs permitting this success story, e.g., clean steel practices, controlled rolling, microalloying with Nb, and using IAC to obtain low temperature transformation products, will be highlighted and discussed.

Jan 1, 2005

By Joel Moskowitz, Jan Cermak

"New York City has unique geologic conditions which must be considered when designing pile foundations. Where shallow foundations are not feasible, the City's subsurface conditions require a variety of deep foundation systems, ranging from high capacity rock socketed piles, to piles end-bearing on bedrock, to friction piles bearing in alluvial or glacial deposits. Pile load testing is essential in confirming pile capacities as pile analyses include assumptions on soil and soil-pile response, and pile driving equipment. Load test results must be interpreted to estimate the long-term pile behavior. Except for lightly loaded driven piles, the New York City Building Code (the Code) requires that pile capacities be confirmed by static load testing. The Code provides the number of static load tests required, test procedures, and acceptance criteria. In the last few decades, methods other than static load testing have been developed including dynamic and rapid (pseudo-static) load tests. Recently, those methods have also been employed on several projects in New York City. The traditional approach to pile load testing in New York City is discussed herein including engineering involved in the analyses of test data with examples. In addition, several projects which included non-static load testing are discussed INTRODUCTIONPile load testing complements the subsurface information and pile design by providing further data on pile-soil interaction for the selected pile type and installation method. Traditional approaches to pile load testing in New York City involve static load tests to verify the design capacity of the piles for a given minimum factor of safety.In the late 1950's, Dr. Phillip C. Rutledge summarized his views on the philosophy of pile foundations in an unpublished, in-house document. He viewed pile foundations as good illustrations of pertinent and impertinent aspects of geotechnical engineering. In the analyses of piles he divided engineering into four general types:(a) Theoretical engineering in which decisions are made based on theoretical analyses. This represents ideal engineering, in which all factors affecting the pile design are well established or, at least, few simplifying assumptions with known effects on the analyses are made."

Jan 1, 2005

Safety remains a critical priority for the Australian mineral resource industry and will receive increased focus in the future. This is particularly evident in underground coal mines where reserves are becoming deeper and more hazardous to extract. The CSIRO, through its Exploration and Mining Division, have recently delivered on two projects aimed at providing step-change capabilities in real-time risk management and hazard control. This paper describes the key outcomes of these projects.

Jan 1, 2005

By Huw Williams

"Power companies are always looking to increase the carrying capacity of existing transmission lines, and the preferred method is to string heavier capacity conductor lines. However this results in higher wind loading and the potential for towers overturning, if the existing foundations do not have the tensile capacity. On older lines, there is often a lack of information on construction type and dimensions and in practice the as-built foundation can differ considerably from design drawings, due to unforeseen ground conditions along the line route, and no record of the resulting change in design being made.Following successful trials in New Zealand, integrity testing with Frequency Response and impedance profiling techniques is now being used in the region to check concrete foundation properties in-situ and are enabling power companies to get the most out of their assets. INTRODUCTIONIn most regions of the globe, the US included, there is generally a requirement to upgrade transmission line capacities, to cope with increasing power consumption. Problems with under capacity only come to light for the public when blackouts occur, even in developed countries.A large number of transmission line towers are designed with a certain capacity redundancy and will be able to carry greater loads than originally designed for. Power companies are therefore looking for ways to assess their assets and to minimize the costs of upgrade work.Re-assessment of tower foundation capacities using design drawings may not be valid , as constructed foundations may differ considerably from design drawings, to accommodate local difficulties and in some instanced, particularly with earlier lines, there is no information whatsoever. This complicates efforts to determine the capacity of foundations considerably."

Jan 1, 2005