automation @ northparkes rio tinto

8/13/2019 Automation @ Northparkes Rio Tinto

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Automation @ Northparkes


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2

What we will cover today:

Implementation pathways4

Automation trials building the case for LHDautomation

3

1 Vision

2 Context

5 The way forward


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Unincorporated JV Rio Tinto (80% & manager) and Sumitomo Group (20%)

230 staff and 500 contractors

Copper and gold producer

Total production to the end of 2009

715,000 tonnes Cu

985,000 ounces Au

1,630 ha of mine lease within 5,670 ha of agricultural land (+ 2,102 ha nearby)

Current Life of Mine is 2024

Who we are!


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E22

E27

E26

E48

2km

Site Overview

TSF1

TSF2


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Hoisting Shaft

Main

Decline

9800 Level

ConveyorDeclines

Access Decline

9450 Level

S N

E26L1

E48

L2 L2N

L1

Operations based on block-cave mining

L1

First block cave in Australia: E26 Lift 1 commissioned in 1997

E26 L2 in 2004 and E48 L1 in 2010

5.5 - 6.0Mtpa production rate

Industry-leading mine productivity (t/manhour; t/m2 footprint)

800m


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The Northparkes mining concept continuous,

automated & minimal intervention

400t primary

feed bin

400t ore bin

BK Crusher

1050tph conveyor

Hoist to surface

4-Way Tipple


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The Safety Proposition

Removing LHD operators from a

hazardous environment:

Wall collisions

3-4 LHDs to achieve 18ktpd

Each LHD operator will load

300+ buckets in a 12 hour shift

23kph top speed (3.5m wide

machine in a 4.5m wide drive)

Multiple equipment interactions

Dust

Uncontrolled draw point flows

Rock falls

Whole body vibration


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9

History of LHD automation extension of tele-

remote loading

2007 2008 2009 2010200620052004200320022001200019991998

NPM joined AMIRA Autonomous

Underground Mining Vehicle project

First trial in SW quadrant of Lift 1 mine

E48 Project commences construction

E48 Project scope varied to

include autonomous LHDs

Full implementation of autonomousloaders on E48 Production level

Design of compliant barrier systems

Second production trial at Lift 2 mine

1

2


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Concept

Concept to Production

Develop Scope:

Network

Barriers

LHD interface

Conduct RiskAssessment

(each aspect)

Commission and Test:

Proof of concept

Build business case

Handover to production:

Risk register

Operating procedures Maintenance procedures

Documentation

Training systems


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Trials based on a mixture of systems

Sandvik 450E electr ic LHD

3rd party automation system (DAS)


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Operator located in surface control room

Scanning ladars allows machineto monitor its location

Operator is located remotely inthe surface control room

Operator loads in tele-remote

Tramming and tipping functionsautomated (learnt)

Front and rear cameras providevisual control for operator

Audio feedback to allow operatorto feel loading process


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Man-Machine Interface Tactical Screen


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Man-Machine Interface - Strategic


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Trial 1: Proof of concept

Lessons Learned:

Navigation system able toaccurately control the location of

the LHD

Automated haulage and dump

cycle successfully tested

Operator comfortable with tele-remote load function

Aims:

Confirm reliability of navigation system

Confirm ability to operate in the underground environment

Issues raised:

Reliability (sensitivity) of barriersystem

Barrier system required to comply

with AS61508

On-board processing capacity

limits LHD speed to 12-13kph


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Barrier system is THE critical interface for

autonomous mining equipment

Typical Barrier Setup

Barrier system must contain the

LHD under all circumstances

Prevent access of unauthorised

personal and trips the LHD in theevent the area is accessed

Comply with the requirements of

AS 61508 to achieve an

appropriate level of safety


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Trial 2: Building the business case

Trial design:

Automated loader operating incentral two extraction drives on

Lift 2 extraction level

LHD running in 3rd gear

Automated loader responsible for

25% of mine production

Barrier system compliant with AS

61508

Aims:

Test the system as a front line production tool against manual loaders

Evaluate system availability, productivity factors, maintenance costs

9450 L Extraction Level

ED3

ED4Crusher


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Trial 2 didnt start well

Problems encountered:

Steering bias LHD driving into bull noses (cracking loader boom)

Unplanned movements relating to joystick feedback

Whipping trailing cables tripping light barriers

Loss of Rio Tinto network interface Inadequate operator training

Insufficient spare parts

Lack of OEM automation specialist coverage

LHD2 PRODUCTION TRIAL METRICS

0%10%20%30%40%

50%60%70%80%90%

100%

Week1

Week2

Week3

Week4

Week5

Week6

Week7

Week8

Week9

Week1

0

Week1

1

Week1

2

Week1

3

0

200

400600

800

1000

1200

1400

1600

mins

Availability

Utilisation

MTBF

Production metrics:

Max 24hr production of 414

buckets vs 382 buckets/24

hr period in Week 11

Max 12hr production of 212

buckets vs 207 buckets/12

hr period in Week 13

Initial assessment:

Automation system NOT

operationally ready,

BUT, glimmers of hope!


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Trial stopped and issues addressed

Upgraded automation equipment and

software

Additional offsite OEM technical

support 24/7

Upgraded communications between

site and OEM offices

Additional training for both

maintenance and operations

personnel


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Second stage of trial was successful

204.5tph

Manual LHD

restricted to 3rd

gear

206.4tph

Trial Average

(2nd Stage)

Results achieved during 2006:

No additional wall contacts

15% reduction in maintenance costs reduced

gearbox, tyre and cable damage

Peak demonstrated production rate 4,973 t/24 hrs 78% system availability (8 mths) vs 85.9% (manual)

Auto LHD operating up to 22.5hrs/day vs 17hrs/day

manual

221tph

Required*

Product ion Rate

* Assuming 4 LHDs

to achieve 17ktpd

Availab ility & Uti lisation Analysis

0

100

200

300

400

500

600

LHD2April

LHD2May

LHD2June

LHD2July

LHD2August

LHD2September

LHD2October

LHD2Average

ManualFleetYTDAverag

Hours

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

80.0%

90.0%

100.0%

Avail.

&

Util.

Machine Run Hours Availability Utilisation


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Forks in the road

We have demonstrated operability of the automation system

achieving comparable results to manually operated machines!

Do we continue to test and develop the

MineGem automation system?

Improve reliability of the system

4th gear function (speed)

Traffic management (multiple units

interacting)

How does automation fit with

our future plans?

At Northparkes (E48

Project)?

Within Rio Tinto? What are the

alternatives?


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Options review undertaken through Rio

Tinto Underground OEM Directorate

Northparkes

requirements

Rio Tintos

requirements

Available systems

Sandviks AutoMine

Caterpillars MineGem (DAS)

Atlas Copco

Other company implementations

De Beers (Finsch)

Codelco (El Teniente)

Freeport (Grasberg)

REVIEW


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Ertsberg EastSkarn System

Grasberg Pitrasberg Pit

GrasbergUnderground

GrasbergUnderground

Kucing Liarucing Liar

igGossan

Domom

ESZ DOZOZ

MLZLZDeep MLZeep MLZ

re

Final Pit

Automated LHDs are key enabler for

Rio Tintos UG mining ambitions


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Two key alternatives at the time

Fully integrated

OEM LHD-

automation system

Hybrid - LHD + 3rd

party automationsystem

De Beers:

AutoMine on Sandvik truck

Codelco:

AutoMine on Sandvik LHD

Freeport:

MineGem on Caterpillar LHD

Northparkes:

MineGem on Sandvik LHD


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Northparkes decided to change to SandviksAutoMine system based on LH514Es

Fully integratedOEM LHD

automation system

Functional Specification:

1. No speed limitation

2. Full traffic management3. Barrier systems compliant with AS61508

4. Tyre Management (TKPH Calcs)

5. Integrated production planning &

accounting system

6. Remote support

Additional:

7. Support both electric and diesel LHDs

8. Support very large complex mass mining

operations


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E48 Automation

Complete turn key package

with Sandvik

5 x AutoMine-ready LHDs

delivered by Q3 2010

Control room upgrade

Automation install to

commence in Sep 2010 with

Zone 1 commissioning in

Feb 2011

Completion in Jun 2011

Typical ACS Barrier Arrangement


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E48 Automation maximum flexibility

E48 AutoMine Hardware Layout

Barrier design ensures

maximum flexibility for

production teams


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Auto

LHD/Truck

Cave

Management

System

Production

Control

System

Mission

Control

System

Operator

Station

Daily drawpoint tons

Progressive drawpoint tons

Current drawpoint statuses

Cycle time data

Drawpoint status history

Daily draw order

Extraction tunnel priorities

System

Operator

Operating

ManagerManual production list

Auto mission list

Updated drawpoint statuses

SCADA

(Citect)

Fleet status

Production area statuses

Production data

Cycle time data

Mission statuses

Production order statuses

Crusher bin level

Crusher operational statusCrusher bin withdrawal rate

U/Cut pass levels

Rockbreaker status

AutoMine

Production scheduling input

Manual production list modifications

Updated drawpoint status

Drawpoint status

& history reports

Secondary

Breaking

CrewProduction scheduleProduction reports

Missions

(drive orders)

Auto LHD/truck location

Measurements & statuses

LHD bucket weights

Tele-operation commands

Fleet status

Drawpoint status

Automation is an integrated production

system


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HoistingShaft

9100L

9800L

ConveyorDecl

inesMonzonite Stock

9450L

Lift 1

Lift 2/2N

Lift 3Lift 1

Lift 1

Not

mined

Lift 2

Lift 1

1 ki lometre

Concentrator

Step Change Infrastructure

HoistingShaft

9100L

9800L

ConveyorDecl

inesMonzonite Stock

9450L

Lift 1

Lift 2/2N

Lift 3Lift 1

Lift 1

Not

mined

Lift 2

Lift 1

1 ki lometre

Concentrator

Step Change Infrastructure

E26 GRP314 E48E22

NS

Cross Section

E48 + LHD automation not the end of the

line Automation systems a key enabler for Northparkes next stage of mining

Future innovation: LHD loading, secondary breaking, hang-up drilling


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Automation @ Northparkes

VISION

EXPERIMENTATION

+

PERSEVERANCE

+

=

INNOVATION

automation @ northparkes rio tinto

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