TY - THES

T1 - IPCC After Commissioning Reliability and Productivity Improvement Methodology

AU - Prinsloo, Pieter Willem

N1 - embargoed until null

PY - 2015

Y1 - 2015

N2 - In traditional Surface Mining Operations, ore transfer is conducted from Pit to Process plant through the use of Shovel and Truck operations. Mine benches and pits are designed to accommodate routes for trucking, and are also flexible when changes in the operations are required due to factors such as Bench or Pit Failures, Maximising higher ore grade production etc. Within these operations, it is imperative to be able to conduct Production and Condition Monitoring on-board the equipment in order to improve Reliability and Productivity. Companies such as Komatsu, Caterpillar and Bell have been very successful in integrating Remote Monitoring Solutions to their Surface Operations. The CAT Minestar and Komatsu KOMATRAX systems are just a few that has been implemented within the Reliability Management Portals of Mine Production and Health Monitoring Services. Other Non-OEM players such as Micromine have also implemented systems (PitRAM, Geobank etc) in order to assist mine production management and maintenance personnel to plan and execute their strategies and improvements more effectively. The Concept of Continuous Mining in Surface Operations (IPCC) is not new, and although a number of systems have been implemented globally, the one area that needs improvement is within the Realtime Monitoring Space in order to improve the reliability of the systems, but also in order to capture Data to support future decisions of selecting IPCC over conventional methods. This is not just important for Mine Operators, but also for OEM’s such as Sandvik who need to be able to motivate and support their value proposition through data anylitics. Being able to monitor equipment performance have benefits to both mine operators and suppliers. Decisions can be made based on information that is real, information can be communicated that is reliable, because it can be measured, and once we can measure the performance of our equipment, it means that we can put strategies in place to Optimise the equipment performance and improve system reliability and productivity. There are many synergies between technologies and systems applied in mining for both the underground and surface, but the most challenging part is in order to change the way we do things, we monitor things, we report things, a Culture Change is required, and that only occurs when mines can see the value associated with improvement suggestions in operations management, productivity and maintenance. This paper will investigate IPCC and present methodologies that can be considered to be employed within the Sandvik IPCC Product environment to ensure Continuous Improvement on IPCC systems but also capture realtime reliable systems data for analysis to assists in Productivity, Reliability and also Sales Potential Improvements. Often information management on mines is associated with high cost of implementation, however once data integrity, or process integrity as a result of data SIMS IV Project Paper: IPCC After Commissioning – a Monitoring Methodology analysis is proven, mines will accept the technology or the changes if it reduces their overall operating and maintenance costs and improve their productivity. This Project will focus on the potential implementation and various aspects associated with Monitoring Systems and how they can be applied related to IPCC systems in operation. Monitoring provides various focal points that can be analysed for both Maintenance as well as Productivity improvement elements, however, there seem to be no single approach when different parameters are analysed, and the interpretation of these parameters. As maintenance practises are driven by data analysis, so there need to be a shift towards improvements to productivity that is driven by data. Further aspects that will be investigated in this paper relates to the application of New Potential Technology in areas such as Risk Management, Rehabilitati

AB - In traditional Surface Mining Operations, ore transfer is conducted from Pit to Process plant through the use of Shovel and Truck operations. Mine benches and pits are designed to accommodate routes for trucking, and are also flexible when changes in the operations are required due to factors such as Bench or Pit Failures, Maximising higher ore grade production etc. Within these operations, it is imperative to be able to conduct Production and Condition Monitoring on-board the equipment in order to improve Reliability and Productivity. Companies such as Komatsu, Caterpillar and Bell have been very successful in integrating Remote Monitoring Solutions to their Surface Operations. The CAT Minestar and Komatsu KOMATRAX systems are just a few that has been implemented within the Reliability Management Portals of Mine Production and Health Monitoring Services. Other Non-OEM players such as Micromine have also implemented systems (PitRAM, Geobank etc) in order to assist mine production management and maintenance personnel to plan and execute their strategies and improvements more effectively. The Concept of Continuous Mining in Surface Operations (IPCC) is not new, and although a number of systems have been implemented globally, the one area that needs improvement is within the Realtime Monitoring Space in order to improve the reliability of the systems, but also in order to capture Data to support future decisions of selecting IPCC over conventional methods. This is not just important for Mine Operators, but also for OEM’s such as Sandvik who need to be able to motivate and support their value proposition through data anylitics. Being able to monitor equipment performance have benefits to both mine operators and suppliers. Decisions can be made based on information that is real, information can be communicated that is reliable, because it can be measured, and once we can measure the performance of our equipment, it means that we can put strategies in place to Optimise the equipment performance and improve system reliability and productivity. There are many synergies between technologies and systems applied in mining for both the underground and surface, but the most challenging part is in order to change the way we do things, we monitor things, we report things, a Culture Change is required, and that only occurs when mines can see the value associated with improvement suggestions in operations management, productivity and maintenance. This paper will investigate IPCC and present methodologies that can be considered to be employed within the Sandvik IPCC Product environment to ensure Continuous Improvement on IPCC systems but also capture realtime reliable systems data for analysis to assists in Productivity, Reliability and also Sales Potential Improvements. Often information management on mines is associated with high cost of implementation, however once data integrity, or process integrity as a result of data SIMS IV Project Paper: IPCC After Commissioning – a Monitoring Methodology analysis is proven, mines will accept the technology or the changes if it reduces their overall operating and maintenance costs and improve their productivity. This Project will focus on the potential implementation and various aspects associated with Monitoring Systems and how they can be applied related to IPCC systems in operation. Monitoring provides various focal points that can be analysed for both Maintenance as well as Productivity improvement elements, however, there seem to be no single approach when different parameters are analysed, and the interpretation of these parameters. As maintenance practises are driven by data analysis, so there need to be a shift towards improvements to productivity that is driven by data. Further aspects that will be investigated in this paper relates to the application of New Potential Technology in areas such as Risk Management, Rehabilitati

M3 - Master's Thesis (University Course)

ER -