Issue 08 - August 2008

In This Issue...

• Welcome from Advitech's Managing Director
• Complex systems - business through a new looking glass
• Advitech launches its ResourceWise Sustainable Business Program
• Billet transfer & weighing system for OneSteel
• Functional safety of machinery - understanding safety integrity levels (SIL)
• Advitech launches its new website
• Sentinex case study video
• Meet our newest people

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MD's Welcome

Welcome to the August 2008 edition of our newsletter. The second half of the year is well and truly underway, and we are keeping very busy thanks to an increasing number of loyal clients. Our staffing is also continuing to grow, and this is presenting us with new challenges!

Complex Systems - Business Through a New Looking Glass

Largely unseen by business and by the public generally is a remarkable evolution of the social sciences and hard sciences that has been gathering momentum for over twenty years. Seemingly disconnected topics such as war fighting, the stock market and chemical reactions have much in common. The basic principles tying these and other topics together are described by complex systems science, sometimes called 'chaos theory'.

It was in the development of computers and the attempt to solve non-linear mathematics where discoveries in complex science began. Initial research concentrated around the extraordinary and beautiful outputs from repetitive application of very simple non linear equations within 'computer space'. Some popular science television programmes have featured the original computer outputs, known as Mandelbrot Sets, which have infinite depth, beauty and repetitive features (see images on right).

More recent work is in an area known as multi-agent systems science, or network theory. Though much work is mathematical in nature and can only be modelled by computer, these sciences are evidenced by remarkable parallels in evolutionary biology and human systems such as those found within business organisations.

Applications within Business

Of particular interest to those in business or the management of large organisations is research targeted around interactions between staff and processes within an organisation, and how outcomes from complexity science can guide management decision making in a time of constant change.

Similarly, businesses exist as agents within an ecology of staff, customers, suppliers, government and other bodies which have an effect on their success. Network theory provides insights into these large complex sets and helps business decision making and risk management processes.

Examples

A simple example is the famous "six degrees of separation" as applied to business. By understanding the connections between organisations, and the strength and nature of those connections, opportunities for advantage become possible. The common concept of 'networking' at business functions is an application of complex systems theory.

Another example is found in businesses that have had terrific success in the growth of their activities. It is often a seemingly serendipitous event which initiated the growth. Some would call this event luck, but complex systems science provides a completely different explanation. Avalanches, power laws and evolutionary pressures all have something to say about these events.

'Mandelbrot Set' images from complex science theory

Advitech & Complex Systems

Advitech has been using complex systems science as an aid to management decision making and the design of its company structure from the early years, with much success.

For further information on complex systems and management theory, contact Larry Platt on 02 4961 6544.

Advitech launches its ResourceWise Sustainable Business Program

Advitech is pleased to announce the launch of its ResourceWise Sustainable Business Program. The ResourceWise program assists organisations to achieve environmental and financial sustainability in a socially responsible manner. It draws upon Advitech's experience in sustainability, resource efficiency, energy management, environmental management and process engineering.

Why ResourceWise?

Phrases like climate change, carbon reduction and sustainability are all over the news, and concern about the environment is at an all time high across the media, government, business and the general community. There are growing regulatory requirements being imposed on businesses, and the planned Carbon and Emission Trading Scheme scheduled to come into effect in less than two years is likely to have even more impact on business than the introduction of the GST.

Resource efficiency is one of the keys to environmental sustainability - minimising water usage, energy consumption and waste output not only helps the environment, but also achieves substantial cost savings for organisations - from major industrial operations to small businesses.

Advitech has assisted organisations to improve their resource efficiency for many years. Since 2000 we've worked with NSW Department of Environment and Climate Change (DECC) within their Cleaner Production and Sustainability Advantage programs. Advitech prepared DECC's current Resource Efficiency module, and is one of only four consultancies accredited to deliver the module on behalf of DECC.

The ResourceWise program brings together Advitech's experience in resource efficiency and environmental sustainability to help organisations improve their operations, meet their legislative requirements, save money, and help the environment. The key benefit ResourceWise offers to clients is an engineering focus. While one of the services offered under the program is energy auditing, we go beyond the audit - Advitech's industry-experienced process and materials engineers provide process design and optimisation services to make real improvements to your operations.

Advitech is in a unique position. Our experienced engineers have the knowledge and practical skills to actually implement improvements. When it comes to the crunch, we don't just talk, we do! Larry Platt, Advitech

Meet the Team

The ResourceWise program is led by two of Advitech's highly experienced consultants - Colin Barker and Jim Kelty.

Colin Barker is a process engineer with an industrial background. He has been working with the NSW DECC since 2000 on its sustainability programs, and has helped many companies reduce resource use, improve efficiency, and as a result save thousands of dollars in operating costs.

Jim Kelty has over thirty years experience in energy procurement and management. He assists clients with energy auditing, energy cost reduction strategies, sustainable development, risk management, and environmental auditing.

About the Program

ResourceWise is tailored to suit each client's individual needs. Facilitators lead participants through a range of activities to identify potential areas for improvement - focussing on energy, raw materials and water use, and waste minimisation strategies. We assist with the development of action plans to address identified areas of need, then help implement the plan.

ResourceWise facilitators are supported by Advitech's team of experienced engineers and scientists, who are available to provide technical assistance as required. This provides a unique advantage to our clients. We help businesses implement real solutions, through our engineering abilities and understanding of resource use. We are not just auditors, we work with you to improve you organisation's performance!

Advitech offers a range of services within the ResourceWise program:

• Resource Efficiency - process engineering solutions, energy procurement
• Management Advice - regulatory assistance and advice, corporate policy development, resource action plans
• Environmental Awareness Training - cultural change facilitation, staff sustainability training
• Monitoring - selection of energy, water and waste monitoring equipment
• Auditing and Assessment - resource assessments, energy audits, Energy Saving Action Plans, Federal Energy Efficiency Opportunity assessment
• Environmental Reporting - carbon footprint estimation, NPI, licensing and compliance, NGER and EEO reporting

For more information visit Advitech's website or contact Jim Kelty on 02 4961 6544.

Billet Transfer & Weighing System for OneSteel - Collaboration and 3D Ensure Project Success

Advitech's Engineering Division recently completed a project for OneSteel to design new equipment to transfer steel billets from the unscrambler bed to the charging conveyor for the reheat furnace at Newcastle Bar Mill.

The Bar Mill unscrambler bed is located in the billet storage yard and receives billets via a magnet crane. The billets are marshalled across the unscrambler bed by walking beams and positioned ready for transfer onto a roller conveyor. Previously, the billets would slide down the ramp at the end of the unscrambler bed and onto the charging conveyor that feeds the reheat furnace. Billets that were outside specifications could be rejected using arms that lifted reject billets off the conveyor rollers and dropped them into a reject bin on the other side of the roller conveyor.

Previously, the unscrambler bed, transfer, reject and charging conveyor operations all required manual control while all other aspects of the furnace operation had been automated. To complete furnace automation, the charging operation required automation and integration into furnace operation. Also, there was no capability to weigh individual billets (only multiple billets) in the charging line prior to the furnace.

Project Drivers

OneSteel has been using a mix of 175mm billets from Whyalla Steel Plant and 127 mm billets from Sydney Steel Mill since the closure of the front end of the BHP steelworks, with an increasing proportion of 175 mm billets. The billets are approximately 12 metres long, with the 175 mm billets weighing 3 t and the 127 mm billets weighing only 1.5 t. The mill was originally designed for billets up to 127 mm.

The charging conveyor was in poor condition due to a long service history under adverse operational conditions. The additional weight of the 175 mm billets dropping from the unscrambler bed was doing further damage to the conveyor rollers, bearings, drives and supporting structure.

OneSteel approached Advitech to assist them in designing a mechanism that would allow automation of this part of the charging process and also reduce the impact caused by billets sliding down a steep ramp onto the charging conveyor. Additionally, the transfer device needed to be able to reject billets that were outside specifications. The reject operation was also very harsh due to the distance through which the billets were dropped.

During development of the transfer device, it was recognised that individual billets could also be weighed at this location. Therefore, the use of weigh cells in the transfer operation was introduced as part of the design.

3D image of Advitech's design for the billet transfer system, and a photo of the final system in operation

The Brief

The billet transfer system was to be capable of transferring all sized billets to the charging conveyor, or rejecting selected billets, without impact loads causing excessive wear and tear. A number of concepts were put forward by OneSteel. These formed the basis of ongoing discussion and development of concept designs. The two companies worked closely together to get a sound understanding of the operational requirements and the engineering constraints to arrive at optimal solutions to various aspects of the design. The basic design requirements included:

• Management of varying sized and bent billets without the need to make set-up changes to the equipment.
• Cycle time requirements to meet mill maximum throughput rates.
• Guaranteed repeatability so that automation would be successful.
• Retrofit the new equipment into the available envelope between the unscrambler bed and charge conveyor.
• Short timeframe to complete detail design, fabrication & installation to meet the next major mill shutdown (5 mths).

The Design

Advitech and OneSteel collaborated effectively to design a transfer system which met all of OneSteel's needs. The system consists of a set of arms with back-to-back dual hydraulic cylinders fitted to allow multiple operating positions for various functions. The arms act as stops for the unscrambler bed while also lifting then lowering billets onto the roller conveyor in a controlled manner. Both cylinders can be fully extended to reject billets as required. Weigh cells are mounted on separate arms with hydraulic cylinders to temporarily lift the billets and take a mass reading before being transferred onto the roller conveyor. Sensors located at various locations on the system allow control of the transfer and weighing operations without manual intervention.

Following is a brief outline of the operations of the device:

• Billets from the feed bed are stopped by the ends of the transfer arms (proximity sensors detect a billet at the stop location and the feed bed is stopped).
• The weigh cell arms then lift the billet off the bed and take a mass reading before returning the billet to its previous position.
• The transfer arms lower, allowing the billet to slide a minimal distance down to fixed stops.
• The transfer arms now lift the billet from the bed and the billet slides down the transfer arms until it rests against the backstop. The cycle above can be repeated such that additional billets are received by the transfer arms.
• Once two or three billets (depending on billet size) have been received by the transfer arms, the arms are lowered, placing the billets in a controlled manner onto the roller conveyor which takes the billets into the furnace.
• If a billet is outside specifications, both cylinders on the transfer arms can be fully extended to pass reject billets over the transfer arm shaft onto reject bed slide rails.

Project Outcomes

Advitech prepared its design as a 3D model (using AutoCad Inventor). This allowed everyone involved in the project to clearly visualise the machine construction and operation. A 'fast track' approach was adopted for design, where drawings were completed on a priority basis to meet concurrent fabrication and installation programs. The project was delivered on time, within budget and with negligible rework required. The design achieved key objectives of automatic weighing and transfer of billets while preventing impact on the conveyor rollers caused by larger billets.

'We now have a transfer and weighing system that works beautifully.'

Tony Barr, OneSteel Bar Mill

A key factor in the success of this project was the collaborative approach that Advitech took with the client. Advitech worked closely with Bar Mill personnel throughout the project to ensure that their requirements were fully understood. This allowed everyone the opportunity to have input into the design. Subsequent operation supports these statements, as the system continues to run with minimal manual intervention and is meeting mill throughput requirements.

For more information on Advitech's engineering design and drafting capabilities, please contact Michael Neville, Manager - Engineering, on 02 4961 6544.

Functional Safety of Machinery - Understanding Safety Integrity Levels (SIL)

Almost all equipment and machinery have control systems and separate safety systems. But how safe are they? How often will the safety system fail? If it does fail, what are the consequences?

In the mining industry, the regulator is encouraging employers to build new, and upgrade current machinery to specified Safety Integrity Levels (SIL) consistent with the assessed risk. SIL is an internationally adopted concept for describing and managing risk reduction aimed at improving safety standards.

Advitech has been leading the way in assisting mining companies to comply with the regulations, and of course, improving the safety of employees. Advitech's practical implementation of a risk management system aligned with SIL concepts raises the bar on safety standards in the mining industry.

The output from each risk assessment and failure modes and effects analysis (FMEA) provides the basis for the safety case (or 'safety file' in the regulator's terminology).

Photo courtesy of Rockwell Automation
and Centennial Coal

The safety file documents the design, installation, operation and decommissioning of equipment. It includes reliability assessments for probabilities of dangerous failure so that operators can assure themselves that acceptable levels of safety will be achieved. To date Advitech has helped prepare 12 safety files for mining equipment, for clients such as Centennial Coal.

Will regulators in other industries follow the lead set by the mining industry? Would you like to be ahead of the game and show employees and industry that you are a pace setter in safety? Advitech has a simple methodology that can be employed in all industry sectors to provide assurance that equipment has been designed to an appropriate safety level.

Contact Mike Taylor on 02 4961 6544 for more information.

Advitech Launches its New Website

Advitech recently launched its new company website. The new site provides more detailed information on each of Advitech's products and services.

You can also access the latest news from Advitech, as well as our regular publications such as the Risk Aware - providing insights into risk management and Enviro Aware - which provides up-to-date information about key environmental issues that may be facing our customers.

The new site was designed by graphic designer Trude Yen of Studio Teto, and developed in house by Advitech's IT personnel, using the 'Drupal' Content Management System.

Sentinex Case Study Video

A video case study has been developed about Sentinex and its achievements in the mining industry. Click here to view the short video.

Meet Our Newest People

Austen Bedingham recently migrated with his family from South Africa to take up a position with Advitech as Senior Engineer-Projects. Austen has a background in mechanical engineering and is experienced in technical aspects of bulk coal/coke material handling and facility operation including upgrade and maintenance. He previously oversaw projects including major facility, plant & equipment upgrades to improve quality and throughput. Austen is currently working on project management tasks for a number of Advitech's clients including Bradken and Orica Australia.

Jim Dooner joined Advitech in June as an Engineering Officer, following a 25 year career as a technical officer with the Australian Defence Force. He spent 20 years in the Royal Australian Navy as a Naval Marine Technician specialising in electrical and propulsion systems, gaining an intimate understanding of associated ship refits/upgrades, maintenance and training. After leaving the Navy, Jim spent five years as Progress Coordinator on the Guided Missile Frigate (FFG) Upgrade and Refit Project. He is now working on a range of projects for defence clients including FFG System Program Office.

Negin Mahmoudi is a process engineer from Iran, and was recently employed by Advitech to assist Orica Kooragang Island with process engineering for its Ammonia Plant Uprate project.