Professional Certificate of Competency in Operational Automation and Smart Monitoring in Mining Materials Handling Plants

Course Duration
Duration
  • 3 Months
Course Study
Study Mode
  • Online
  • Industrial Automation
  • Mechanical Engineering
Course Location
Location
  • Online
Course Code
Course Code
COM
Course Intakes
Intakes
  • 27 January 2027
  • 10 August 2027
Course Type
Course Type
  • Professional Certificate
  • Industrial Automation, Instrumentation and Process Control
  • UK
  • Mechanical Engineering
Course Fees
Fees

Course Overview

As mining operations become increasingly automated, engineers need the skills to optimize plant performance while reducing downtime and equipment failures. Discover how automation and smart monitoring improve the reliability and efficiency of materials handling plants.

This course equips engineers and plant personnel with practical knowledge of automation and smart monitoring systems in mining materials handling plants, improving reliability, equipment protection, and operational performance.

Course Benefits

  • You may be eligible to claim CPD points through your local engineering association.
  • Receive a Certificate of Completion from EIT.
  • Learn from industry experts from around the globe.
  • Flexibility of attending anytime from anywhere, even when you are working full-time.
  • Interact with industry experts during the webinars and get the latest updates/announcements on the subject.
  • Experience a global learning with students from various backgrounds and experience which is a great networking opportunity.

After completing this course, you will be able to

  • Explain the role of automation systems in mining materials handling plants and evaluate how monitoring, interlocks, and protection systems contribute to operational stability and equipment reliability.
  • Interpret instrumentation data, alarms, and equipment protection logic to identify operational issues and support troubleshooting and maintenance decision-making.
  • Assess automation strategies for conveyors, crushers, screens, storage systems, and dust control systems, and recommend practical improvements to enhance plant performance, equipment protection, and operational efficiency.

Course Details

This course provides an industry-focused understanding of automation systems used in mining bulk materials handling plants, with emphasis on preventing downtime, protecting critical equipment, and maintaining production stability. It covers the application of automation across conveyors, crushers, screens, feeders, storage systems, and dust extraction systems within real operational environments.

Participants will learn how sensors detect mechanical failures, how interlocking logic prevents cascading shutdowns, and how throughput and load monitoring improve plant performance. The course also explores alarm strategies, condition monitoring fundamentals, and energy-aware automation principles, enabling participants to interpret automation systems and apply them to improve operational reliability and maintenance response in mining plants.

The course is composed of 12 modules. These modules cover a range of aspects to provide you with maximum practical coverage in the field of Biomedical Engineering.

Module 1: Automation in Mining Materials Handling Plants – Operational Objectives & Failure Prevention

  • Overview of typical mining materials handling circuits
  • Common failure scenarios (blocked chute, slip, overload, overflow)
  • Role of automation in preventing cascading shutdowns
  • Protection vs monitoring vs control
  • Automation architecture (field devices, PLC, SCADA)
  • Block diagram of plant automation structure

Module 2: Instrumentation in Conveyors, Crushers, Screens & Storage Systems

  • Conveyor protection devices (slip, drift, speed switches)
  • Crusher monitoring (motor current, vibration, temperature)
  • Screen vibration monitoring
  • Storage level measurement systems
  • Plug and overflow detection
  • Dust system monitoring sensors
  • Practical sensor placement considerations

Module 3: Interlocks, Sequencing & Equipment Protection Strategies

  • Start-up and shutdown sequencing philosophy
  • Permissive and trip logic concepts
  • Conveyor–crusher–feeder coordination
  • Blocked chute shutdown strategies
  • Restart delays and cascading trip prevention
  • Logic flow diagrams (non-programming)

Module 4: Monitoring Throughput, Load & Material Flow Stability

  • Belt scale fundamentals
  • Basic TPH calculation
  • Feeder load coordination
  • Identifying bottlenecks through trend data
  • Flow imbalance detection
  • Operational performance monitoring

Module 5: Condition Monitoring & Early Fault Awareness

  • Reactive protection vs condition-based alerts
  • Basic vibration awareness
  • Bearing temperature trending
  • Motor current trend interpretation
  • Escalation from alert to maintenance action
  • Introductory predictive awareness

Module 6: Automation of Storage & Feed Systems

  • High and low level alarm strategies
  • Overflow prevention logic
  • Feeder coordination with crushers
  • Preventing empty running
  • Level-based control diagrams

Module 7: Automation of Dust Extraction & Environmental Control Systems

  • Fan interlocking with plant equipment
  • Differential pressure monitoring
  • Pulse cleaning control concepts
  • Spray activation logic
  • Alarm thresholds and shutdown integration

Module 8: Energy-Aware Automation & Load Protection

  • Concept of VSD operation
  • Soft start vs direct-on-line systems
  • Load spike management
  • Motor overload protection
  • Basic power awareness concepts
  • Trend monitoring for load stability

Module 9: Alarm Management & Maintenance Escalation Strategy

  • Alarm vs event distinction
  • Alarm prioritisation principles
  • Nuisance alarm reduction
  • Alarm flooding scenarios
  • Escalation workflows
  • Operator decision support concepts

Module 10: Automation in Brownfield & Harsh Mining Environments

  • Retrofitting instrumentation into existing plants
  • Legacy PLC constraints
  • Environmental challenges (dust, vibration, heat)
  • Practical upgrade strategies

Module 11: Commissioning & Functional Validation of Protection Systems

  • FAT and SAT overview
  • Loop and I/O testing
  • Interlock validation
  • Trip simulation
  • Restart verification
  • Documentation and handover

Module 12: Integrated Review & System-Level Recap

  • Review of automation architecture in mining plants
  • Recap of instrumentation across:
    • Conveyors
    • Crushers
    • Screens
    • Storage systems
    • Dust systems
  • Integration of interlocks and protection logic
  • Relationship between monitoring and maintenance
  • Alarm strategy integration with plant operations
  • Energy-aware automation recap
  • Brownfield upgrade considerations summary
  • System-level block diagram bringing all components together
  • Preparation for final assessment

This course is ideal for professionals responsible for ensuring reliable, safe and efficient operation of mining materials handling systems.

  • Mechanical engineers
  • Maintenance engineers and supervisors
  • Reliability engineers
  • Mining project engineers
  • Plant engineers
  • Automation technicians
  • Operations supervisors
  • Professionals involved in bulk materials handling systems

To obtain a certificate of completion for EIT’s Professional Certificate of Competency, students must achieve a 65% attendance rate at live, online fortnightly webinars. Detailed summaries/notes can be submitted in lieu of attendance. In addition, students must obtain a mark of 60% in the set assignments which could take the form of written assignments and practical assignments. Students must also obtain a mark of 100% in quizzes. If a student does not achieve the required score, they will be given an opportunity to resubmit the assignment to obtain the required score.

For full current fees in your country go to the drop down filter at the top of this page or visit the Fees page.

Payment Methods

Learn more about payment methods, including payment terms & conditions and additional non-tuition fees.

Our courses are delivered by experienced engineers and technical experts from around the world. Many have tackled real-world engineering challenges and bring practical, applied knowledge directly into the classroom.

We draw from a global pool of instructors and lecturers across our organisation. Explore our full team of expert educators on the Instructors & Lecturers page here.

Please note: Not all lecturers and instructors listed on this page will teach every course. The team teaching your course will be confirmed as part of your course enrolment.

You are expected to spend approximately 5-8 hours per week learning the course content. This includes attending fortnightly webinars that run for about 90 minutes to facilitate class discussion and allow you to ask questions. This program has a 65% attendance requirement in the live webinars in order to graduate from the program. If you are unable to attend the live webinars, you have the option of watching the recording of completed webinars and sending a summary of what you have learnt from the webinar to the Learning Support officer. The summaries go towards your attendance requirement for the program.

This program is run online on a part-time basis and has been designed to fit around full-time work. It will take three months to complete.

We understand that sometimes work commitments and personal circumstances can get in the way of your studies, so if at any point you feel that you are struggling with the pace of the course or finding a particular module challenging, you are encouraged to contact your designated Learning Support Officer for assistance.

Please ensure you book your place at least one week before the course start date.

If the course is not currently scheduled, please contact us. We can let you know when it will be offered next, or explore the possibility of creating a special intake if there is a group.

Hear from our students

  The delivery methodology and the information available in the e-library can’t be beaten. The other important aspect of online education is recorded lectures. You can review the tutorial and lessons on repeat when you need to understand the concept.  
M Masemola, South Africa
  What I liked most about the course and EIT is the flexibility is offered regarding education. It gave me the opportunity to study and work full-time.  
C Groenewald, South Africa
  I enjoyed interacting with students all around the world, and seeing how the principles I have learned applies to them as well.  
S Zeelie, South Africa
  My line of work requires me travel quite often. I could not attend every class due to my remote locations, but still I could recap and stay on top of the study material thanks to the recordings. Also, all the Instructors were world class.  
P Pretorius, South Africa

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