Sandvik Mining & Construction (Tomago) Pty Ltd

Sandvik Mining & Construction (Tomago) Pty Ltd

ACARP Roadway Development – Operators’ Workshop

Sandvik Development Systems

Sandvik Mining and Construction

Sandvik – global leaderThree business areas

Sandvik Tooling

SandvikMining and Construction

SandvikMaterials Technology

Invoiced sales, M

Employees

SEK 22,500 (AUD 3989)

SEK 25,000 (AUD 4432) SEK 19,300 (AUD 3422)

15,100 12,200 8,60031 Dec. 2006



1998

Toro

Our history

Driltech

EIMCO

EJC

Secoma

Rammer

Roxon

Voest-Alpine

Tamrock

Sandvik Rock Tools

Drillmaster

Mission

MGT

Hagby-Asahi

SDS

UDR

BPISvedala

BrøytBeltreco

Toyo

New strategy

Applications & solutions

2006

Shark

2007

Hydramatic

Implemin

Prok


Sandvik Development Systems

Introduction – Sandvik

Where we have come from

Where we are now (and what has driven the changes)

Where is our future ~ 2012 (5 years)

New Products


Where We Have Come From

•1st simultaneous cut and bolt machine (commercially available)

•Capable of achieving high “one off” performance results, not been sustainable – over longer term

Why?

•Ergonomics

•Complex engineering & maintenance

•Not able to measure development system/process constraints (pillar design, matched equipment, service support etc)


Where Are We Now - Ergonomics Platforms are larger, level,clear and open

Bolter station positions and push button controls

Operator screen locations Non slip and anti vibration floor mats (reduce

fatigue/vibration)

Adjustable height platforms (reduced repetitive strain)

Access / egress (fold up rear steps, 3 point contact)

Machine lighting – (to illuminate walkways, ladders, controls, work areas)

North / South roof rigs (reduces twisting during bolting)


Where Are We Now - Ergonomics

•Integrated mesh carrier (reduduces manual handling)

•Housekeeping (materials/consumables stored to suit ergonomic & open work area philosophy)

•+100% increase in ventilation duct area

•“Outrigger” design supports flexible duct and minimises twisting (maintains vent duct area)

•Hydraulic driven air fans provide evaporative cooling in a humid environment (prevents safety glasses from fogging up and assists with dust control)

•Flexible ducting “connect/reconnect” designed for single man operation (for changing material pods if required)


Where Are We Now – Engineering/Maintenance

Hose and cable management (manifolds, exterior routing)

Recirculating oil filtration (eliminates high pressure filters)

24V flameproof solenoids Simplified hydraulics/reduced complexity -

fully load sensing and single in line pumps 2 speed drill motors – lower pump flow

requirements 6 rig simultaneous operation Fully load sensed hydraulics (including

bolters) = lower operating temperatures (from 60 deg - < 40 deg)


Where Are We Now – Measuring the Process


ABM 20 OPERATING AVAILABILITY SUMMARY

11% 11% 10% 10% 9% 8% 6% 5% 4% 4% 4% 2%

54% 58%

40%

59% 62%69%

60% 56%56% 58% 60% 55%

75%

39%

77%

33% 30%

49%

28%21%

30% 36%36% 36% 35% 41%

21%

57%

21%

7%1%12% 12% 2%3%6%10% 7%7% 6% 6% 6%

60%

51%66%

51%50%51%64%

49% 49%59%

33%48%

32%44%

30%42%

29%

51% 44%35%

48%

0%

10%20%

30%

40%50%

60%

70%

80%90%

100%

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

MACHINE NUMBER

ABM 20 DOWNTIME POSSIBLE CUTTING TIME PANEL DOWNTIME

Source: Colliery Shift Reports 1991 - 1997

AVG.

But what happens in the ‘uptime’….

Uptime versus Downtime


ABM 20 CYCLE TIMES - OPERATING PERFORMANCE

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0W

K8

WK

11

WK

14

WK

17

WK

20

WK

23

WK

26

WK

29

WK

32

WK

35

WK

38

WK

41

WK

44

WK

47

WK

50

WK

1

WK

4

WK

7

WK

10

WK

13

WK

16

WK

19

WK

22

WK

25

WK

28

WK

31

WK

34

WK

37

WK

40

WK

43

WK

46

WEEK OF YEAR

Average Cycle Time Minimum Cycle Time

There is the need to compare these results with what can be realistically achieved….


SIMULTANEOUS CUT & BOLT DEVELOPMENT RATES AS A FUNCTION OF DISTANCE

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

6.5

7.0

7.5

8.0

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

Wheeling Distance from Shunt 1 (m)

Ra

te (

m/h

r)

Real Data Points (102 Panel A & B Heading Combined) Mathematical Model

Theory vs reality, but how is it monitored?....


Cyclereport from 2003/05/07 Shift 3:

[min] 30 24 20 16 12 8 4 0 0h 1 h 2 h 3 h 4 h 5 h 6 h 7 h 8 h

Cycle Time Cutting Activity Bolter Activity Conveyor Activity

ABM 20_010

Average

Cycles longer than the planned 11 minute cycle time. These cycles require a more detailed investigation from a process control perspective. The remaining cycles have achieved 11 minutes or less.

•Manage by exceptions


0h 1 h 2 h 3 h 4 h 5 h 6 h 7 h 8 h

Cyclereport from 2004/06/17 Shift 2:

[min] 30 24 20 16 12 8 4 0

ABM 25_015

Average

Cycle Time

Cutting Activity

Bolter Activity

Conveyor Activity At this point, if it was a 2 shuttle car cycle, the cycle time achieved would

have been 10 minutes or less. Due to requirement for 3rd shuttle car, cycle times of 16 minutes achieved.

• ~ 50% increase in cycle time from a 2 car cycle to a 3 car cycle



Sequential roof and rib bolting

Rib bolting (generally) takes longer


MINING SYSTEM PERFORMANCE MORANBAH NORTH

0.00

1.00

2.00

3.00

4.00

5.00

6.00

10 30 50 70 90 110 130

DISTANCE FROM SHUNT S1 (m)

ME

TR

ES

pe

r O

PE

RA

TIN

G H

OU

R

Place Change Wide Head CM ABM-25

A B M- 20

S h utt le C a r

S h un t (S 1 )

B oo t-e nd

Le

ng

th o

f Pilla

r

Dis

tan

ce

Sh

un

t - Fa

ce

D is ta nc e S hunt to B oot

A B M- 20

B oo t-e nd

O ve rd riv e

S h utt le C a r

S h un t (S 1 )

TW O HEA D IN G PA NEL LA YOU T

W id th o f P i lle r

6 roof bolt, 4 rib bolt, mesh, 2 S/C, 5m cut out, 2 Car cycleMINING SYSTEM PERFORMANCE MORANBAH NORTH

0.00

1.00

2.00

3.00

4.00

5.00

6.00

10 30 50 70 90 110 130


ME

TR

ES

pe

r O

PE

RA

TIN

G H

OU

R


AB M- 20

Sh utt le C ar

Sh unt (S 1)

Boo t-e nd

Le

ng

th o

f Pilla

r

Dis

tan

ce

Sh

un

t - Fa

ce

D is ta nc e S hunt to Boot

AB M- 20

Boo t-e nd

O ve rdriv e

Sh utt le C ar

Sh unt (S 1)

TW O HEA D IN G PA NEL LA Y OU T

W idth of P i ller

6 roof bolt, 4 rib bolt, mesh, 2 S/C, 5m cut out, 2 Car cycle

MINING SYSTEM PERFORMANCE MORANBAH NORTH

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

10 30 50 70 90 110 130


ME

TR

ES

pe

r O

PE

RA

TIN

G H

OU

R


AB M- 20

Sh utt le C ar

Sh unt (S 1)

Boo t-e nd

Le

ng

th o

f Pilla

r

Dis

tan

ce

Sh

un

t - Fa

ce

D is ta nc e S hunt to Boot

AB M- 20

Boo t-e nd

O ve rdriv e

Sh utt le C ar

Sh unt (S 1)

TW O HEA D IN G PA NEL LA YOU T

W idth of Pi ller

4 roof bolt, 4 rib bolt, mesh, 2 S/C, 2m cut out, 2 Car cycle

Macro View

-Performance expectations should be variable and based on conditions, position in pillar cycle etc, not averaged over an entire gate road

- Performance expectations can be based on actual history


Where is our Future ~ 2012

Focus on development system solutions

Ergonomics – improved ergonomics leads to safer and more productive

development (continue drive towards zero harm)

Engineering/Maintenance (continue drive towards 100% reliability)

Measuring the development system/process performance

Towards Automation

New Products


Measuring the development system/process performance

Live production reports (on machine & surface) (maintain a

consistent “sense of urgency”)

Roof mapping (real time and panel duration)

Longer term trending of operational data (weekly, monthly, pillar

etc)

Longer term trending of predictive maintenance data

Playback in 3D (all functions monitored)

Equipment monitoring /reporting => management tool

to improve development performance

It wont change anything by itself – it does enable the

right questions to be asked (and provides interested people with a more

accurate understanding of the development process)


Towards Automation Electronic Push Button Drill Rig Control

greater control and flexibility over the drilling and bolting process,

software controlled (not reliant on hydraulic logic)

Consistent bolt set times and guaranteed minimum bolt torque

Easily adaptable for any self drilling bolts

Future technology developments will make units smaller

Horizon control /Auto Cut

possible interface with new & existing (coal seam/rock, in-seam stone bands etc) technologies

(gamma, CID, infra red etc)

Auto Cut – simple/easy to use/flexible (get the basics right first)

Interface with materials/services systems

Material pod changeout systems (including continuous haulage systems)

Monorail systems (ventilation, complete)

Integration with other Sandvik product line technologies

Drilling / bolting / systems

Cable bolt feed systems etc

Potential interface with other development process management systems

Self drilling bolt (Steve Weaver)


New Products – EBS 120 Punch Mining System

Continuous Haulage System

•Utlises an ABM10 with mobile hopper car and LTU system (~200m punches)

•Currently in operation in USA

•Designed capacity > 10 metres/operational hour


Panels develop from Return Side

Sub-Main Advances as needed.

Extraction Sequence


New Products – CHS 500 – SICON Conveyor

Continuous Haulage System

•~ 220m length (500m3/hr)

•Currently being built in USA


MINING SYSTEM PERFORMANCE

0.00

2.00

4.00

6.00

8.00

10.00

12.00

10 30 50 70 90 110 130


MET

RES

per

OPE

RA

TIN

G H

OU

R

ABM-25

AB M- 20

Sh uttle Car

Shunt (S 1)

Boo t-end

Length of Pillar

Distance S

hunt - Face

D ista nce S hunt to Boot

AB M- 20

Boo t-e nd

O ve rdrive

Sh uttle Car

Sh unt (S 1)

TW O HEAD IN G PANEL LAYOUT

Width of Pi ller

4 roof bolt, 2 rib bolt, mesh, 2 S/C only, 8t cars, 3m cut-out

Continuous Haulage

Self Drilling Bolt

Documents

Sandvik Mining & Construction (Tomago) Pty Ltd