comms international minetec smarts underground above ground planning management simulation
DESCRIPTION
Planning, Management and Simulation of underground and above-ground mining operations in real-time NOT historical based.TRANSCRIPT
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Mining Transformation: MINETEC´s Underpinning Technologies
Minetec provides the underpinning technology and force mul6plier for mining transforma6on
Our Customers said: “I congratulate Minetec on having the best underground communica6ons technology and the only technology that actually works”
-‐ Codelco Head of Underground Technology Sep 2013
“Minetec outstood its compe6tors not just on a single ver6cal but on all ver6cals for the mechanised and opera6onal requirements. Minetec is our partner of choice to make this happen”
-‐ Anglo American New Mining Technology Manager Oct 2013
WASP
“Whether in my office, or in the muster area, at mine control, or my home in Melbourne, I can see at a glance what is going on in the mine. It is a new world”
– Newcrest Toguraci Mine Manager June 2013
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Mining Industry Status
§ Demand for increased efficiency and innova7on in mining technology through ‘Smart Mining’ due to:
§ Turbulence in Commodity Prices
§ Cost Reduc7on
§ Skills Shortages
§ Asset U7lisa7on
§ Consumable management
§ Increasing demands, driven by the needs of emerging economies, maturing ore bodies and fewer tier-one surface deposits being discovered are forcing migration from surface to underground operations
§ Australia is considered to be the world’s most innovative mining technology
community
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Opera7ons Management
Mining ac7vi7es are projects • they are ac7vi7es designed to produce a result • they are temporary in that they have a defined beginning, end, scope and resources
To deliver the on-‐7me, on-‐budget results they must be expertly managed
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Opera7ons Management
Inputs
Simula1on
Plan
Con1nuous Improvement
Actual
Reports and Reconcilia1on
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Opera7ons Management
Inputs ú Long term mine design and principal mining methods
− U7lising specialised design and visualisa7on tools − Ground support requirements
ú Constraints such as − Schedule, including face availability, linked tasks, crew ingress/egress and breaks − Gear selec7on and availability − Heading priority − Grade control − Environmental − Manpower and skill level − Financial, including consumable costs, fuel costs
ú Short term opera7onal targets updated with most recent actuals results
Inputs
Simula1on
Plan
Con1nuous Improvement
Actual
Reports and Reconcilia1on
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Opera7ons Management
Long term Simula7on ú Sensi7vity analysis ú Visual analysis ú Usually only occasionally done formally – perhaps annual business plan and budget cycle ú Op7misa7on for such things as:
− Equipment u7lisa7on − km travelled − Fuel use reduc7on − Hours worked − Tonnes moved (and handled through individual stockpiles) − Idle 7mes − Traffic management
Short term Simula7on
ú OYen informally done weekly and daily by mining management and/or shiY boss ú OYen also known as “experience” ú Depending on mechanisms of long term simula7on, can be very adhoc ú Detailed task crea7on and review ú Update for actual work done ú Considera7on for opera7onal constraints ú Develop a schedule consis7ng of tasks ú Training and skills requirements
Approve and Communicate the Plan
Inputs
Simula1on
Plan
Con1nuous Improvement
Actual
Reports and Reconcilia1on
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Opera7ons Management
Keeping an eye on day-‐to-‐day ac7vi7es such as ú Tracking changes to the plan ú Communica7ng changes to all affected staff ú Tracking equipment and loca7on down7me and availability ú Tracking and loca7ng staff ú Tracking and loca7ng equipment ú Tracking events as they occur ú Recording PLOD data ú Ensuring skilled personnel are assigned the right tasks ú Reducing delays
Inputs
Simula1on
Plan
Con1nuous Improvement
Actual
Reports and Reconcilia1on
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Opera7ons Management
Standard Repor7ng ú EOD, EOS, EOM ú “Mine Managers” preferred report ú Desire for high amounts of data ú Desire for trends and graphs showing good depth to data
Reconcilia7on ú Rarely mul7 dimensional ú Usually only grade and produc7on schedule against specific plan ú Does not regularly include variance analysis or trend analysis
Inputs
Simula1on
Plan
Con1nuous Improvement
Actual
Reports and Reconcilia1on
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Opera7ons Management
Con7nuous Improvement • Usually done as a specific project • Usually suffers from lack of opera7onal data • Not just a decision on how to get back to target • Decisions on how to achieve the same with fewer resources – efficiency and produc7vity improvements
• Trend analysis on failures to remove root causes • Tradi7onal systems require too much work to get to this stage and insufficient corporate resource available
Inputs
Simula1on
Plan
Con1nuous Improvement
Actual
Reports and Reconcilia1on
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Open Pit Opera7ons Management
§ Mine control and monitoring systems are now common in open pit mining § Why has it become so pervasive over the past 5-‐10 years? § Some game changing technology:
ú WiFi ú GPS device availability and removal of Selec7ve Availability(SA)
§ Sites that have deployed this technology have realised significant increases in opera7onal performance through visibility on performance leading to beder planning
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Financial Opportunity
Variability within a ‘typical’ single heading development model based on development rate:
100 $6,000 $2,400 $3,400 $2,200
$1,400,000
$14,000
2.30
150 $3,960 $1,900 $2,800 $1,500
$1,524,000
$10,160
3.40
200 $3,000 $1,600 $2,500 $1,100
$1,640,000
$8,200
4.50
Development -‐ meters/month -‐ Labour ($/meter/month) -‐ Maintenance ($/meter/month) -‐ Consumables ($/meter/month) -‐ Capital ($/meter/month) Total Cost ($/month) Total Cost per Meter ($/meter) Meters per Man per Month
Benefits 150m/m -> 200m/m: • For 8% increase in overall costs, 30% increase in development rate • Economy of scale reduces cost per meter by 20% • Manpower efficiency rate of 132%
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Open Pit to Underground
How do we leverage the open pit model into the underground environment? Do the ‘game changers’ exist?
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WiFi for Underground
ELF is the Minetec Ethernet-‐over-‐Leaky Feeder solu6on that delivers high bandwidth voice and data (Ethernet) communica6ons for underground applica6ons where RF-‐based systems are not able to be deployed
• Fully Ruggedized: designed for harsh underground condi7ons • High Speed Data, Voice & Ethernet up to 60Mbs • Deliver high bandwidth from the backbone broadband network to the development and opera7onal areas of the mine
• Centralized Management • Rapid Installa7on and Maintenance • Cost Effec7ve & Scalable
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Proximity Awareness
SafeDetect ™ is the Minetec real-‐6me proximity awareness and detec6on system for personnel, equipment and assets in underground and open pit (above-‐ground) mining opera6ons • Simple to use • Sub metre accuracy down to 10cm (proven) • Designed for a wide variety of installa7ons
• Stand Alone or Integrated • Two levels of operator console • Fully integrate-‐able with machine control systems (RS485, RS 422 & I/O) • Data logging for review and analysis
• Highly Configurable • Mul7ple zones with unlimited number of contacts per zone • Configurable alarm sequence and incremental warning • 360 degree contact monitoring • Configurable contact classifica7on and display • Dynamic zone adjustment
• Op7ons include: • Camera interface • Dynamic zone adjustment on machine status
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GPS for Underground
Trax+Tags™ is the Minetec wireless tracking system that enables operators to track the loca6on of personnel, equipment and assets by u6lising WASP technology.
• WASP (Wireless Ad-‐hoc System for Posi7oning) developed in partnership with CSIRO • Centrally managed, low cost, robust technology • Designed for severe mul7path radio environments • High accuracy
• 0.1 m outdoors line of sight (low mul7path) • 0.2 m indoors line of sight (high mul7path, including underground) • Down to 1 m non line of sight • 1D, 2D and 3D
• Features include: • Anchor Nodes – at fixed and known loca7ons • Mobile Nodes – adached to person or object to track • 5.8 GHz (ISM) band, 125 MHz bandwidth, typical 50 mW transmit power • All nodes can provide up to 8Mbps data network capability • Supports mesh installa7on with limited infrastructure requirements • Full historical repor7ng and playback
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GPS for Underground
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UG Mine Management Solution
• Planning & development simula7on • Scenario evalua7on based on knowledge of mine design, asset configura7on and
many other criteria • Create daily ac7on lists based on real-‐7me and recent history performance • Monitor assets, people, task status & comple7on to modify the plan in real 7me • Real 7me repor7ng of performance and progress according to plan • Team management approach, not individuals working in isola7on • Configured for centralized control room or mobile management • Opera7onal data capture of down7me and u7liza7on tracking for maintenance
planning • Leverages Game Changer Technology
SMARTS is a suite of advanced software applications and leading edge hardware devices for integrated real-time mine operation, simulation, management, tasking and reporting.
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NOT a Rear View Mirror Approach
§ Combines long-‐term produc7vity modelling with short term real-‐7me op7misa7on
§ Exis7ng Mine Management & Control (MMC) products cannot do this and typically model produc7vity based on past performance -‐ Rear View Mirror Approach
§ Ongoing simula7on using latest opera7onal data
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Industry Standards
• A Windows ‘Smart Client’ database applica7on with web access portal and repor7ng interface
• Users are able to enter data and report informa7on from anywhere on your network or the Internet.
• Wriden in C#.net and ASP.net • SQL Server database that is open and available for external interface • Reports delivered in Excel or Acrobat (.pdf) • Modular • Scalable • Robust • Integrated
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Indica7ve Costs
For the same development model used earlier:
100 $3,000 $12,000
$17 $33
$20,000
$200
150 $3,000 $12,000
$17 $33
$22,500
$150
200 $3,000 $12,000
$17 $33
$25,000
$125
Development -‐ meters/month -‐ ‘Head-‐end’ Voice Only ($/month) -‐ ‘Head-‐end’ SMARTS add-‐on ($/month) -‐ Consumables Voice Only($/meter) -‐ Consumables SMARTS($/meter) Total Cost ($/month) Total Cost per Meter ($/m)
~1.5% increase in costs …
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Budget 0+12 5+7 8+4
Rolling 13 Week
Month
Week
Day
Shift
Shiftboss: Input Accountable
Superintendent: Input Accountable
Foreman: Input Accountable
Long Term
Short Term
Daily
SMARTS Control Centre
(SMARTcontrol)
SMARTS Mobile Client
(SMARTmobile)
SMARTS Long Term Planning
(SMARTsim)
SMARTS Short Term Planning
(SMARTsched)
Mul7 Level Planning
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Comprehensive Input Capture
• Mine design, including import from exis7ng planning and scheduling tools • Define targets such as financial, schedule, movement, grade control • Apply constraints such as gear type and availability, traffic bodlenecks, face availability
• Update opera7onal targets based on most recent actuals ac7vi7es
Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
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Long Term Simula7on
Complete calcula7ons, view simula7ons and adjust variables to achieve required outcome/criteria Configure for varied mining processes and methods Op7mise for individual plant & equipment usage including
ú U7lisa7ons ú km travelled ú Hours worked ú Tonnes moved (and handled through individual stockpiles) ú Idle 7mes
Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
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Long Term Simula7on
Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
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Short Term Planning
Specify shiY constraints Develop day plan. Approve and communicate to opera7ons Iden7fy training and skills requirements Long term plans and short term schedules § A Schedule consists of Tasks. § Each Task contains a Duty, Loca1on, Start Time, End Time and Asset. § Task are assigned to Assets – any vehicle or group capable of doing a task
Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
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Short Term Planning
Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
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Opera7ons Tracking
Mobile client – Operator View • Ensure training completed and current for equipment • Respond to allocated tasks • Add enter delay and abort tasks • Turn by turn naviga7on • See all equipment and personnel in vicinity
Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
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Opera7ons Tracking
Mobile client – Supervisor View • View en7re opera7on • Respond to alerts on services such as dewatering, power, ven7la7on • View real 7me loca7on and status of all equipment and personnel
• Re-‐alloca7on of people and equipment to new tasks and re-‐priori7sa7on
Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
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Opera7ons Tracking
Control Room • Monitor and react to events and delays
Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
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Real Time Dashboards
• Monitor and report on actual performance • Dashboard performance views • Compare to budgets and plans
Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
Current Status
Event History
Jobs Started
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Regular Repor7ng
• Fully customised reports through SQL Repor7ng Services • Produc7on reports • Daily shiY reports
Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
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Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
Reconcilia7on
Budget 0+12 5+7 8+4
Rolling 13 Week
Month
Week
Day
Shift
Shiftboss: Input Accountable
Superintendent: Input Accountable
Foreman: Input Accountable
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Con7nuous Improvement
• Vast amounts of data available to make well reasoned high level decisions through trend analysis, etc
• Includes decisions on how to get back to target or change target • Decisions on how to achieve the same with fewer resources – efficiency and produc7vity improvements
• Trend analysis on failures to remove root causes • Business is freed from transac7onal ac7vi7es to allow greater focus on opera7onal improvements • Maintenance planning is beder focused on targe7ng equipment in need based on run hours, etc, but also iden7fy troublesome equipment, condi7ons and operators
• Staff skills and training development
Inputs Simula1on Plan Con1nuous Improvement Actual Reports and
Reconcilia1on
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The Next Level
ú A large por7on of a typical underground mine’s energy costs are associated with ven7la7on. ú By intelligently managing secondary ven7la7on fans, the case study indicated up to 30% energy reduc7on ú Automa7c vent fan control based upon factors such as:
− Personnel loca7on using Tagging and Tracking − Time of Day (Scheduling), − Air Quality -‐ Temperature, gas levels, or minimum air veloci7es reaching undesirable thresholds.
Advanced Environmental and Condition Management Case Study - Ventilation on Demand
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Summary
§ Minetec have the experience and track record in engineering and maintaining miner-‐proof solu7ons
§ Minetec products provide high accuracy, in mo7on posi7oning, tracking and collision avoidance throughout the opera7on
§ SMARTS is a cost effec7ve, scalable and extensible management system
§ SMARTS adds a level of mine management and planning to your opera7on through simula7on, data acquisi7on and transparency that will deliver significant improvement in safety, efficiency and costs
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Toguraci Update
§ Elf commissioned .. ~50 wireless nodes, ~15km leaky feeder § Elf over fibre § Trax&Tags v1
ú U7lising mul7 zone electronic tag board
§ SMARTS ú Tradi7onal voice mode dispatch ú Working on simulator integra7on, semi-‐automa7c planning ú Comprehensive repor7ng
− Delay accoun7ng − Task compliance − Material movement − Run hours/equipment hours − Environment temperature monitoring and repor7ng
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Toguraci Update
�13
TecWise Sistemas de Automaçao / Comms International !Phone: +55 31 3019-0129 [email protected]
Rua Rio Grande do Norte, 1164/501 (Savassi), 30.130-131, Belo Horizonte. Brasil
!Phone: +44 207 193 4247 Fax: +44 207 117 4460