2010 longwall conference slides
TRANSCRIPT
Longwall improvement at Kestrel Mine
John Coughlan
Acting general manager operations
Location
• Rio Tinto purchased
in 1999
• Extension (KME)
approved in 2007
2 July 2016 3
Kestrel facility
Dev System
LWall System
ROM Handling
Prep Plant
Product Handling
Rail Transport
Shipping
2 July 2016 4
Status as at 30 September 2010
Kestrel longwall equipment
Shearer 1 x Bucyrus EL3000 with 375kw ranging arms
Roof supports 146 x 860 ton capacity supports each kit withPM4
control system
AFC 1 x 855kw CST P drive at Maingate
1 x 855kw CST KP drive at Tailgate
Pump stations 1 x SES pump station 900 litres/min capacity and 1 x
Kamat (Longwall Hydraulics) pump station 900 litres/min
capacity (shared over 2 systems)
1x High set system
Crusher 250 Kw drive unit
BSL 400 kw drive unit
Monorail Macquarie system
Nameplate capacity 2500 tonnes per hour
2 sets of longwall equipment each containing -
Longwall Improvement Projects
0
5
10
15
20
25
30
Salab
le P
rodu
ction
Cur
rent
Sup
port
crew
ass
ist c
uttin
g
Sta
ndar
dize
she
arin
g
She
arer
relia
bility
AFC
& B
SL
relia
bility
Shiel
ds re
liability
Con
veyo
r rel
iability
5S
Inve
ntor
y m
anag
emen
t
Sus
tainm
ent
metr
es/d
ay
Reliability is the
issue
4.1Mt
8.0Mt
3.8Mt
5.5Mt
Other BI Projects
4.4Mt
Longwall improvements
0
2
4
6
8
10
12
14 A
ctu
al
Actu
al
Actu
al
Actu
al
Actu
al
Actu
al
Actu
al
Actu
al
Actu
al
Actu
al
Actu
al
Pla
n
Actu
al
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2010
AIF
R
2 July 2016 7 2 July 2016 7
Recent AIFR history
Actual
Plan
Industry safety benchmarking
2 July 2016 8
Source: Queensland Mines and Quarries, Safety Performance and Health Report 2008-09
Comparison - Lost Time Injury Frequency Rate
Comparison of Lost Time Injury Frequency Rate PerformanceRio Tinto BU's v RTCA Operational Results June 10 YTD
0.0
0.4
0.8
1.2
1.6
Arg
yle
- U
/G D
eve
lop
me
nt P
roje
ct
Be
ng
alla
Ch
ap
ud
i C
oa
l P
roje
ct
Co
pp
er
Pro
jects
Offic
e
Da
mp
ier
Sa
lt L
imite
d
Dia
mo
nd
Ma
rke
tin
g a
nd
Sa
les
Dia
vik
Dia
mo
nd
Min
es
Exp
lora
tio
n
Ke
lian
Ke
nn
eco
tt E
ag
le M
ine
rals
Co
mp
an
y
Ke
nn
eco
tt L
an
d C
om
pa
ny
MT
W
Mu
row
a D
iam
on
ds
Re
so
lutio
n C
op
pe
r C
om
pa
ny
Rio
Tin
to A
lca
n C
orp
ora
te
Rio
Tin
to C
olo
wyo
Min
e
Rio
Tin
to J
ap
an
Rio
Tin
to M
ine
ra P
eru
RT
Co
rpo
rate
Offic
es
RT
Gro
up
Pro
cu
rem
en
t
RT
IO -
Oth
er
Te
ch
no
log
y a
nd
In
no
va
tio
n
QM
M
Ric
ha
rds B
ay
Co
al a
nd
Alli
ed
Ba
uxite
an
d A
lum
ina
Atla
ntic
Ha
il C
ree
k
Rio
Tin
to M
ine
rals
Sim
an
do
u
ER
A
Arg
yle
Bu
sin
ess D
eve
lop
me
nt
IOC
C
Ke
nn
eco
tt U
tah
Co
pp
er
Co
rp
RT
IO E
xp
an
sio
n P
roje
cts
RT
Sh
are
d S
erv
ice
s
RT
CA
Bu
sin
ess U
nit
Pa
lab
ora
Cle
rmo
nt R
eg
ion
HV
O
RT
CA
(Q
LD
on
ly)
Prim
ary
Me
tal A
sia
Pa
cific
Pilb
ara
Min
ing
Op
era
tio
ns
Ba
uxite
an
d A
lum
ina
Pa
cific
Ro
ssin
g
RT
Ma
rin
e
Ro
be
Riv
er
an
d P
ilba
ra In
fra
str
uctu
re
Prim
ary
Me
tal N
ort
h A
me
rica
Prim
ary
Me
tal E
uro
pe
, M
idd
le-E
ast a
nd
No
rth
pa
rke
s
Ke
str
el M
ine
Exte
nsio
n
Ke
str
el
Business Groups
LT
IFR
Structure and organisation
• Start finish times
• Support and maintenance crews
• Single maintenance stoppage
• Rebuild – overhaul rather than fix
The maintenance management process
Operations
Plan
Work Management
Identify Work Plan WorkSchedule
Work
Analyse
Work
Complete
Work
Execute
Work
P
DC
A
Short-term
P
DC
A
Long-term
Business
Improvement
Programme
Execute
Action Plan
Root Cause
Identification
Incident
Defect
Elimination
Loss
Analysis
Reliability
Modelling
FMECA
Analysis
Criticality
Analysis
Define
Tactics
Whole of Life
Plan
Review
Tactics
Tactics
Implementation
(Mtce plan)
Spares
Optimisation
Tactic
Definition
Figure 1 – Business Process Relationships
Six Steps of Work Management
Identify
work
Plan
work
Schedule
work
Analyse
work Complete
work
Execute
work
Cutting practice
• Standardised cutting study
• Automation
2 July 2016 14
Process improvement
2 July 2016 15
Kestrel Longwall start of block
• 4
Time to cut first 100m of block
0
5
10
15
20
25
30
LW
30
1
LW
30
2
LW
30
3
LW
30
4
LW
30
5
LW
30
6
LW
30
7
LW
30
8
days
Floods 2008
• Access to site
• IMT process for recovery
• Water quality
• Emulsion plant outcome
GFC 2009
• Reduced coking coal demand
• Alternate cutting shifts
• Allocation of labour from face
Where are we now
• 93 cut hours per week
• 5.9 million ROM tonnes forecast – 10%
• Saleable tonnes 18% increased on
previous year, 15% increase on previous
best year
2 July 2016 19
Kestrel Longwall average weekly op time
• 1
average weekly operating time
0
10
20
30
40
50
60
70
80
90
100
LW
30
1
LW
30
2
LW
30
3
LW
30
4
LW
30
5
LW
30
6
LW
30
7
LW
30
8
ho
urs
per
week
2 July 2016 20
Kestrel 300 series ROM tonnes with 2010 actual YTD & forecast
• 4
ROM Production
0
1
2
3
4
5
6
20
04
20
05
20
06
20
07
20
08
20
09
20
10
mil
lio
n t
on
nes
2 July 2016 21
Kestrel 300 series saleable tonnes with 2010 actual YTD & forecast
• 4
Saleable Production
0
1
2
3
4
5
6
20
04
20
05
20
06
20
07
20
08
20
09
20
10
mil
lio
n t
on
nes
300 series mining
2 July 2016 22
Kestrel 300 series Longwall retreat with 2010 actual YTD & forecast
• 4
Longwall retreat metres
0
1000
2000
3000
4000
5000
6000
20
04
20
05
20
06
20
07
20
08
20
09
20
10
mil
lio
n t
on
nes
2 July 2016 23
Kestrel historical saleable tonnes with 2010 actual YTD & forecast
• 4
Saleable Production
0
1
2
3
4
5
6
7
19
99
20
00
20
01
20
02
20
03
20
04
20
05
20
06
20
07
20
08
20
09
20
10
mil
lio
n t
on
nes