Page 1 f 5 RUSSELL SMITH Cntact Details: Email: russell.smith@quantise.cm.au Mbile: 04 8808 8174 Years f Experience: 32 Qualificatins: B.E. (Mech.), University f Newcastle (1986) Fitter and Turner (1983) Prfessinal Affiliatins: Chartered Prfessinal Engineer (CPEng) Member f Engineers Australia (MIEAust) Natinal Prfessinal Engineer Register (NPER) Registered Prfessinal Engineer f Queensland (RPEQ) Fields f Cmpetence: Mechanical Testing, Strain Gauging, Analysis Mechanical/Structural Design and Design Audits Manufacturing and Testing Prcedures Trubleshting and Prblem Slving Hydraulic System Analysis EMPLOYMENT SUMMARY Feb 2014 - Present Managing Directr (funder), Quantise Cnsulting Engineers Pty Ltd. Jun 2011 - Feb 2014 General Manager - Machinery, Directr, BMT WBM Pty Ltd. Aug 2000 - Jan 2014 Directr, BMT WBM Pty Ltd Jun 2003 - Mar 2006 Chairman, Directr, WBM Pty Ltd Jan 1994 - Jun 2011 Newcastle Business Unit Manager (Machinery), WBM Pty Ltd Feb 1992 - Jan 1994 Plant Engineer, Webster Manufacturing Limited, Elizabeth SA. Sep 1988 - Feb 1994 Senir Engineer, WBM Pty Ltd, Brisbane Qld. Jan 1986 - Sep 1988 Design Engineer, BHP Rd & Bar Prducts Divisin, Newcastle NSW Jan 1979 - Jan 1986 Trainee Engineer, BHP Rd & Bar Prducts Divisin, Newcastle NSW PO Bx 539 KOTARA NSW - Ph 04 8808 8174
Page 2 f 5 PROFESSIONAL EXPERIENCE QUANTISE Quantise Cnsulting Engineers was funded in February 2014. Quantise prvides engineering test & measurement, analysis, design, and expert witness services t manufacturers and industry in and arund Newcastle NSW. BMT WBM is a specialist cnsultancy fcusing n the applicatin f leading edge technlgy in the fields f engineering and envirnment. BMT WBM PTY LTD Test & Measurement Testing f 2000+ hydraulic fitting cmpnents t establish the fatigue perfrmance characteristics and imprve lngwall hydraulic safety. Strain gauge testing f drill rigs, draglines, excavatrs, rpe shvels, stckpile machinery, haul trucks, and ther mining and heavy industry equipment t establish perating stress ranges and undertake fatigue life assessments. Static strain measurements (200+ channels) t verify stress analysis results n passenger rail vehicles. Measurement f cupler lad distributin alng 1.5km lng cal freight trains t help understand fatigue damage distributin. Measurement f lads in dragline rller slew bearings t assist with life predictin and scheduling f bearing replacement. Verificatin f pressure vessel design by strain measurement during hydrstatic testing. Measurement f trque in rtating shafts using telemetry, including cnveyrs, mining vent fans, dragline swing, and dragline prpel drives. Testing f undergrund rf supprt structures using a 5000 tnne capacity frging press. Using trque measurement t characterize lad sharing prblems between primary and secndary cnveyr drives. Fatigue cycle cunting n mbile machinery structures using laser survey equipment and lng term data lgging. Fundatin cncrete strength testing. Measurement f in-service stresses and lads in lngwall rf supprts. Investigatin f pressure transients in lngwall rf supprt hydraulic systems. Design and Analysis Design f mdificatins fr ff-rad haul truck water tanks t eliminate premature fatigue failures. Design f 200 tnne tensin and cmpressin test rig fr rail vehicles (passenger and freight). Design f shafts fr large mine ventilatin fans. Develpment f lng term data lgging installatins. Design f structural repairs fr fatigue failures in ff-rad haul truck structures and mbile bulk materials handling equipment. Design f quick filling statin fr ff-rad haul truck water tankers Mveable access platfrm design fr shipladers. Design mdificatins t address fatigue prblems in dragline masts. PO Bx 539 KOTARA NSW - Ph 04 8808 8174
Page 3 f 5 Design f shafting fr prcess machinery. Mdificatins t lngwall rf supprt structures t crrect premature failures. Designed and specified specialised unit handling machinery fr metal refineries. Designed and specified cmpnents fr aluminium melting furnaces. Designed basic electrnic equipment fr specific testing applicatins. Designed machinery and cmpnents fr hypersnic wind tunnels fr the American Natinal Space Plane (NASP) Prject. Failure Investigatins Investigatin f structural cracking, bearing failures, hydraulic cylinder failures, and gearbx failures in mining machinery (undergrund and surface). Identificatin f prblems in hydraulic cylinders used in undergrund mining equipment and ff-rad cal haul trucks, and recmmendatin fr rectificatin. Examinatin f pen gearing failures in draglines and pwer shvels. BMT WBM PTY LTD (cntinued) Investigatin f shaft failures in high speed rtating machinery. Assessment f perfrmance deficiencies in fluid cuplings. Cmpnent failures in varius prcess machines. Investigatin f cracking in prtal reclaimer structure, shvel car bdy and crawler frames, dragline tri-structure and dragline fairlead supprt structures. Design Audits Rail freight vehicle bgies. Vibrating screens fr mineral prcessing. Dragline structures. Undergrund rf supprt structures. Safety audits n rail munted mbile materials handling vehicles. Undergrund lifting equipment. Specificatins, Wrks Supervisin and QA Specificatin f high strength ally steel frgings fr bucket wheel excavatr shafts and centrifugal ventilatin fans. Supervisin f structural repairs and nn-destructive testing f large mbile bulk materials handling equipment. Specificatin f hydraulic leg cylinders fr undergrund rf supprts. Quality assurance surveillance fr lngwall mining machinery Prepared, evaluated and supervised NDT prcedures fr large high strength ally steel frgings. Superintendent f repair cntract fr Brisbane wharf side cntainer crane, cntract value $750,000. Cnducted quality assurance prgrams n cmpnents being manufactured in Japan and USA. PO Bx 539 KOTARA NSW - Ph 04 8808 8174
Page 4 f 5 BMT WBM Lngwall Rf Supprt Hydraulic System Audits Develped sftware t assess lngwall hydraulic systems. The sftware inputs include delivery and return hse details, pump and accumulatr details, and the rf supprt hydraulic cylinder details t calculated critical prductivity and rf security perfrmance. All parameters can be mdified t assess the impact f changing cmpnent details r perating strategies. Over 70 hydraulic system studies were cmpleted, with mre than 10 including calibratin by pressure and flw measurement at the lngwall. WEBSTER MANUFACTURING LIMITED Webster Manufacturing Limited prduced fractinal hrsepwer electric mtrs, primarily fr dmestic appliance applicatins (dishwashers, washing machines, pl pumps etc.). Managed and supervised tl rm peratins. Designed tling, jigs, fixtures and specialised machinery fr the mass prductin f mtr cmpnents. Prgrammed and set-up a 16 tl CNC machining centre fr prductin wrk Designed, detailed, and installed an autmatic part catcher fr a Mazak Quick turn 15N CNC Lathe. Identified zer psitin errr prblems with an autmatic winding machine, designed, detailed and installed a zer psitin detent device. Truble shting f pressure die casting prblems bth with die design and casting practice. Arranged and assessed qutatins frm equipment suppliers fr prductin and materials handling equipment. BHP STEEL INTERNATIONAL ROD & BAR PRODUCTS DIVISION Design Engineer Prepared specificatins, evaluated tenders, and supervised the design and cnstructin f varius cmpnents f plant and equipment. Rectified maintenance prblems in varius plant departments. Cnstructin inspectr fr steelmaking furnace replacement cntract - ttal furnace weight 1000 tnnes, cst $70M. Respnsible fr the design and drawing f mechanical and structural cmpnents. Analysed structural designs using cmputerised stiffness matrix methds. Analysed failures f varius plant and equipment. Designed and tested experimental equipment t evaluate varius plant prblems. Calculated and analysed thermal mvements f large (3m diameter) high temperature gas pipe wrk and designed supprt systems. Prgrammed cmputers fr use by persnnel in administrative and design disciplines. Cmpleted lcatin selectin studies, warehuse capacity and layut studies fr the Sydney Mini Mill. Trainee Engineer A number f separate psitins were held under this title. These included: Service Shps Draftsman 1985-1986 Respnsible fr design, supply and installatin f items including strage and lading facilities, structures and accesses. Designed tls and dies fr the mass prductin f varius cmpnents by upset frging. PO Bx 539 KOTARA NSW - Ph 04 8808 8174
Page 5 f 5 Designed machinery fr spraying a unifrm ceramic cating nt blast furnace stave cling pipes. BHP STEEL INTERNATIONAL ROD & BAR PRODUCTS DIVISION (Cntinued) Designed varius tls and attachments fr the machine shp and frging shp machinery. Cnstructin Inspectr fr N. 3 Blast Furnace Rebuild ($40M) 1984 1985: Respnsible fr detectin f cnstructin errrs and subsequent eliminatin by site mdificatin. Wrte and supervised site cntracts t crrect design and/r fabricatin errrs. C-rdinated cnstructin wrk with nrmal plant peratin t avid lss in prductin and cnstructin delays. Engineering Assistant 1983-1984: Respnsible fr small maintenance, repair, and design jbs. Planned rutine maintenance shutdwns and rganised manpwer in varius plant departments. Rutine testing and supervisin f equipment in varius plant departments. Apprentice Fitter & Turner 1979 1983: Basic training in fitting and turning, gas and arc welding, gas cutting, and general fabricatin. Basic training in fluid and pwer transmissin including experience in fitting and verhauling hydraulic cmpnents, and designing, installing and maintaining hydraulic systems. Trained in the peratin f many cmmn metal wrking machines. Operated the fllwing machines during high vlume prductin runs f varius cmpnents and tls: hrizntal milling machine braching machine - turret lathe shaper pwer band saw (hrizntal & vertical) radial drill surface grinding machines RESEARCH PUBLICATIONS Lngwall Hydraulics Staple Lc Staple Fatigue Assessment, ACARP Prject C19011, 01/08/2012. Review f Regenerative Technlgies t Increase Lngwall Advance Speeds, ACARP Prject C12022, 15/11/2004. PO Bx 539 KOTARA NSW - Ph 04 8808 8174