RAATHS, L. Dragline and drill production monitors.

6th International Symposium on Mine Mechanization and Automation, South African Institute of Mining and Metallurgy, 2001.

Dragline and drill production monitors

L. RAATHS
Optimim Colliery, Ingwe Coal (BHP/Billiton) Pullenshope, Mpumalanga, South Africa

This paper outlines the process of improvement utilizing performance monitors and GPS systems on an opencast strip mine. Its primary focus is to maximize coal exposure by draglines and secondly to improve on those processes impacting directly on the dragline operation. The Aquila (DM2/5 system) navigation and monitoring systems were installed on the overburden drills. Their main function is to eliminate manual staking and positioning thereby ensuring a regular pattern being drilled. Holes drilled to planned depth reduce drill metres and it minimizes coal losses and contamination at the coal interfaces. The CAES (Computer Aided Electronic System) will be installed and evaluated on the Caterpillar D11 dozers at Optimum. This system ensures a correct dragline pad elevation through the use of planned elevations and GPS technology to achieve the optimal pad elevations for draglines consistently. The draglines are equipped with a Dragline & Operators Performance Monitor. This monitor allows the operator to control his own performance. It reports on all productivity, method and poor operating techniques. These monitoring systems send critical operational information back to the office. This source data resides in central databases from where it is converted and integrated into management information. To manage an operation means that you as a manager must be able to set objectives and targets and to achieve your goals the activities involved must be measurable.

Introduction
Optimum Colliery is part of the Ingwe Coal Corporation, the South African coal division of BHP/Billiton. Optimum is a major mining operation located 230 km east of Johannesburg. Optimum employs 1 500 people and an additional 700 contractors. The mine operates eight draglines, ten overburden drills and fifteen track dozers on coal exposure operations. Drilling of overburden together with dragline/dozer assisted exposure had become the biggest constraint in the mining processes. The overburden is drilled, castblasted and removed by dozers and draglines to expose the 4L and 2 seam coal on a double bench operation. The working cost for an opencast mine on the coal exposure operation is directly related to the strip ratio (cubic metres of waste to a ton of coal)and will remain as such until fundamental changes are made. At Optimum Colliery it has become a culture to follow a route of continuous improvement. The history shows several quantum leaps in the production profile of the mine. This was due to innovative changes in the mining processes. To maintain ones position as a benchmark operation, you must continuously challenge the effectiveness and efficiency of your operation. The main restriction in our mining operation moves between drilling of overburden and overburden removal by the draglines. To analyse the problem you as a manager need credible information on all the tasks constituting a process.

Dragline, dozers and drill monitors

GPS and communication network GPS The mine has a central base station GPS receiver (Trimble 4000) and 450 MHz radio. The objective is to act as a single reference point, repeater mast and to eliminate selective availability. Normal survey work is conducted utilizing three Rovers (Trimble 4400). Currently four of the eight overburden drills are equipped with GPS receivers. The remainder will be upgraded when Aquila DM2/5 systems are fitted. Four of the large draglines are equipped with GPS receivers. This is part of positional and elevation control on the dragline. Caterpillar D11 dozers will be fitted with the CAES system. Geo-explorers (handheld data recorders) are utilized on blasting. The planned hole information is stored and actual blasting data is inputted on the blast for statistical and reconciliation purposes. Radio Network The current radio network consists of 450 MHz radios. They are used for portable repeaters on survey work and data transmission on drills and draglines. This radio network will be upgraded to a 900 MHz

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system with IP technology. This new system will cater for all data transfers required by drills, dozers and draglines. Drill navigation and monitoring system (DM2/5 system) The overburden drills are fitted with two GPS radio antennas approximately 20 metres above ground level on the drill booms. The two antennas allow, not only for position, but also for drill orientation. The height of the masts is adequate to ensure reception across the mine. Standard to each drill are two GPS receivers, a DM5 navigation system, a DM2 rock recognition system, industrial PC with LCD monitor on the drill and two-way communications. The drill plans are created in the office environment on a drill and blast module of the Minescape software package. Surfaces are generated from geophysical logging of presplit holes. The holes are uniquely identified with XYZcoordinates and drilling depth. This hole information is uploaded via radio link onto the onboard computer on the drill. The DM5 navigation system utilizes a moving map display to enable the drill operator to position the drill bit on the bench for exact hole position. Figure 1 is an example of the moving map display on the DM5 system in the operators cab.

Figure 2. Screen display from the DM2 rock recognition system

CAES on D11 dozer fleet The Caterpillar D11 dozers in the pushover fleet will be equipped with CAES (Computer Aided Electronic System). The CAES on the dozers will communicate on a 900 MHz radio network with the office. Dozers with the CAES will dictate the correct elevation to the remainder of the dozer fleet. Dragline planners establish the correct pad elevation for the applicable areas. These parameters are established graphically to optimize the dragline operation. The planned pad elevation for the various areas are uploaded via radio link to the CAES-equipped dozers. With the planned information the dozers create a dragline pad, in advance of the draglines, to ensure an efficient dragline operation. This technology will also be employed for rehabilitation of spoilpiles during periods of additional dozer capacity. Dragline planning The draglines, together with the pushover fleet of dozers, dictate the ROM tonnage profile for the mine. Focus on the dragline, drill, dozer and blasting operations is essential for an effective and efficient dragline operation. Dragline methods are planned utilizing Pitboss and 3Ddig. Productivity curves together with the method-related volumes are derived, loaded into the Minestar scheduling package and scheduled on a monthly basis for target setting. This scheduling model is utilized for short, medium and long-term scheduling. It is therefore important to ensure that the planning model is accurate through constant reconciliation with actual dragline performance. The complexity of a dragline operation requires detailed actual information for reconciliation and improvement monitoring. Dragline training The dragline operators are in control of the machine for as much as eighty one per cent of its operating life. The foreman, superintendents and planners have both a proactive and reactive role to play in the dragline operation. It is for this reason that it was decided to focus on the operator in order to eliminate inefficiencies and to minimize engineering as well as operational downtime. All dragline operators, foremen, superintendents and planners have received practical dragline training. This

Figure 1. The display of the DM5 1 map on the operators screen

The DM2 system relates the change in back pressure, pulldown pressure, torque, RPM and rate of penetration to identify the various strata that are intersected hence the rock recognition functionality. Figure 2 displays a typical screen from the DM2 rock recognition system. Information on the hole drilled (XYZ-coordinates, strata elevation, strata blastability indices and hole depth), together with machine production statistics are relayed back to a central database in the office for integrated management reporting. The advantages realized are reduced survey work, accurate hole positions, reduced coal losses due to overdrilling, reduced contamination in the top of the coal seams and improved blasting performances due to regular patterns. Future benefits will be the elimination of geophysical logging and improvement on the placement of explosive charges.

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installation of four DOP monitors with the possibility of four more being installed at a later stage. The DOP monitor The Australian-developed Dragline Operators Performance (DOP) monitor was developed for the simulator with large draglines in mind. The first DOP monitor was installed in July 2000 at Optimum Colliery on their Marion 8200 number 4. Improvement was immediate. Table I reflects the improvement on cycle times for Marion 4. From July 2000 onwards the operators on Marion 4 were able to keep the cycle times below 75 seconds. This was excellent considering the upward trend during the previous months. The unique advantage of the system is the comparison of operators performance. Within the first week of operation with the system it was possible to compare the four operators on Marion 4. It was evident from the number of boom stresses, lever jockeying, stalls, overloads, slackropes, dumps on the fly and production figures that two of the four operators required more training. Improvement in the performance of these two operators and the challenge that the system generated resulted in an excellent performance by Marion 4 on linear advance and coal exposure. Table II Reflects and upward trend on dragline bucket factors. Increased bucket factor with a decrease in cycle time indicates an improvement in material moved by the draglines. The bucket factors reflects are understated as mine surveyors are not able to measure all rehandle incurred in the operation.
Table I. Shows the improvement in cycle times for Marion 4

Figure 3. The simulated cab of the dragline simulator

Figure 4. The scale model used in the dragline simulator

training was conducted utilizing a state-of-the-art dragline simulator. Figure 3 reflects the operator view on the simulator. A wide-angle camera mounted on a scale model dragline follows the dragline movements. The trainee operates the scale model dragline from a real size operator seat and controls. The images captured by the camera are displayed through a digital projector onto a screen in front of the trainee. Figure 4 reflects the scale dragline model. A Dragline Operators Performance (DOP) monitor is connected to the scale dragline and controls. This DOP monitor produces instant visual and audible feedback to the operator. The DOP monitor was designed to train the operators in the art of operating a dragline smoothly and efficiently, minimizing machine damage and to follow a designed dig position plan. Practical training, in a sandpit with a small-scale dragline, was conducted to demonstrate methods, good practices and operational controls. The successes of the training on the simulator and the realization of all the shortcomings of the previous monitoring systems, has led to the development and

Table II. Reflects the improvement on bucket factors for Marion 4

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This system provided management and supervisors with the ability to monitor each individual operators performance on Marion 4 and were able to identify bad operational practices and operating techniques that needed attention to improve the operators productivity. The DOP monitor reinforces positive work practice and prevents machine damage. It monitors poor operating techniques by recording the following list of audible and visual alarms and messages. The negative effect of each is highlighted. Drag stalls: monitors and records drag stalls in excess of 3 seconds. Reducing motor/generator maintenance. Hoist stalls: monitors and records hoist stalls during long swings angles. Reducing motor/generator maintenance. Hoist overloads: monitors and records overloading the bucket by 25%. Overloading can be costly in terms of maintenance and light loading is costly in terms of lost productivity. Hoist slack rope: monitors and records excessive hoist slack rope at the hoist drum, to prevent over-wrap/over spooling. Reducing costly rope replacement and lost productivity due to down time. Drag slack rope: monitors and records excessive drag slack rope at the drag drum, to prevent over-wrap/over spooling. Reducing costly rope replacement and lost productivity due to down time. Tight lining: monitors and records the bucket in this curve during the hoist to dump cycle. Reducing excessive boom stresses. Pre-tight line: (Best path, hoist to dump) monitors and records when the loaded bucket is hoisted within this predetermined curve. Tight-lining slows down the hoist speed, increases cycle time resulting in lost productivity. Over swing left or right: monitors and records the boom point sheave tilt angle during the dig or dump mode and excessive bucket lag or lead during the swinging. This bad operating technique places enormous stresses to the boom and will result in costly boom repairs and lost productivity due to down time. Fly dumps: monitors and records the position of the bucket in excess past the dig-dump radius during the dumping mode, resulting in roller circle, rails and tub repairs, lost productivity due to walking and waiting on the dozer whilst re-leveling the dragline pad. Dragline not level: monitors and records the level of the machine during operation when exceeding 3% and walking up or down ramps in excess of 7.5%. Boom stress: monitors and records excessive shocks to the boom from the bucket via the hoist ropes. This prevents costly boom repairs and lost productivity due to down time. Control lever jockeying: monitors and records excessive hoist control movement. This prevents boom stresses, bucket rigging damage and lost productivity due to down time. The system is designed such that it provides a visual and audible alarm on any of the prior mentioned alarms when triggered. This keeps the operator informed without distracting him from the operation. The system thereby forces the operator into a loop of continuous improvement.

The rope life on Marion 4 exceeds that of similar machines at Optimum by a considerable difference. Table III reflects the drag and hoist rope life comparisons over time. This comparison was conducted on two rope changes on both hoist and drag for the period since July 2000. Engineering records on boom work, generator and motor maintenance, rigging and buckets were analysed but no conclusive trends could be drawn to support savings due to the DOP monitor. These savings will be realised in the medium to long term. Table IV is an analysis on the alarms from lever jockeying. It is clear from the graph that one of the operators was not performing to the required standards. In some cases that specific operator generated up to eighty per cent of the alarms in a twenty four-hours period. The other operators had no problem to contain the alarms generated from lever jockeying. Table V reflects an analysis of boom stress alarms generated on Marion 4. It is obvious that one specific operator is responsible for most of the alarms. The boom stress alarm is triggered by an accelerometer fitted at boompoint. Boom damage can result in costly repairs and can directly impact on coal exposure. Figure 5 reflects the DOP monitors operator performance screen. The operator can see his last swing cycle, the average for all of these and total tonnes and

Table III. Reflects the difference amongst the three large draglines for the last two rope changes on hoist and drag

Table IV. Reflects the lever jockeying. The percentage graph is based on the performance of one operator as a percentage of the total lever jockey alarms generated

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Table V. Reflects the boom stress alarms. The percentage graph is based on the under-performers alarms as a percentage of the total

number of swing cycles per dig hour as well as cubic metres per dig hour, (Dig Rate) Figure 6 reflects the DOP monitors touch screen in relation to the dragline operator. The screen is mounted on an adjustable arm for each individual operators viewing comfort.

Figure 7 reflects the Strip-Block-Dig position screen. This screen comes on automatically after the dragline walks to a new dig position. It ensures that the operator inputs reference information to group the operational digging data in a logical manner within the database. The system allows for all rope, rigging and bucket information to be captured for statistical analysis and storage on the database. Associated with this information is total metres dragged through overburden as well as TCMs (Total cubic metres) moved for the above items. Figure 8: This is the screen where the operator logs-on to the system on the dragline. Each operator is required to logon to the system at the start of each shift. All the operator shift information is available against the operators company number on the database. The DOP monitor allows the operator to set his working production codes by selecting such from a screen indicating a list of available codes. The dragline digging sequences are marked on the highwall and captured on the system through operator input. The various dragline positions on the pad, within a digging sequence, are also captured through operator input. This allows the planner to reconcile actual

Figure 5. Operator Performance screen

Figure 7. This screen comes on when the dragline walks to a new dig position

Figure 6. The touch screen in relation to the dragline operator

Figure 8. Operator log-on screen

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information at specific pit locations to planned/geological data. The GPS currently on the draglines will be incorporated into the DOP monitor for positional and elevation control. Data from this GPS will also be stored in the database for reporting purposes. All information captured electronically and through operator input is relayed back to the office via radio link to a central database on the computer system. Anyone with a PC and network access may analyse the dragline performance by running reports/queries on the server database. A flexible reporting system for the DOP monitor allows the user to draw information per dragline, operator, block/strip or digging sequence. These reports are available in graphical as well as data format with export facilities to various other software packages.

Conclusions
The installation of an electronic monitoring system is a time-consuming process that requires dedication from engineering, technical and mining departments to ensure

the system is functioning properly with a high level of availability. The use of Aquila drill navigation systems and the changeover to electronic detonators in blasting has resulted in a considerable saving in drilling costs and improvement in rock fragmentation. This improvement in fragmentation has assisted the dozer pushover fleet to perform in excess of the annual average productivity. All draglines benefited from the improvement in blasting. The single most important change to Marion 4 that led to the increase in performance was the introduction of the DOP monitor. The success of the monitoring systems has resulted in four large draglines being equipped with the DOP monitor and the possibility to equip the four smaller draglines with it at a later stage. Within the near future all the overburden drills will be equipped with the Aquila drill navigation system. The change-over to the 900 MHz radio system will be done with all new installations and upgrades to existing older radios will be completed. We at Optimum know that for us to stay competitive we have to follow a path of continuous improvement and apply state-of-the-art technology that is available.

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