An empirical approach to optimize the shovel-dumper fleet productivity

An empirical approach to optimize the shovel-dumper fleet productivityA case study of Moher & Moher Amlohri Extension Coal Mine

Submitted byUmesh Khandelwal(2010JE0511)

Reliance Summer Internship Program 2014(26th May 5th July 2014)

An empirical approach to optimize the shovel-dumper fleet productivity: A case study of Moher & Moher Amlohri Extension coal mine

Project Mentors: Mr. Shankar Agrawal Asst. Manager-Planning Sasan Power Ltd., Waidhan-486886 Madhya Pradesh, India Email id: shankar.agrawal@relianceada.com &Mr. Ravi Hatadia Sasan Power Ltd., Waidhan-486886 Madhya Pradesh, IndiaEmail id:ravi.hatadia@relianceada.com Submitted By:Mr. Umesh KhandelwalMining Engineering DepartmentIndian School of Mines,Dhanbad-826004, Jharkhand India Email id:umeshkhandelwal26@gmail.com

ACKNOWLEDGEMENT

The study for this project was conducted in Moher & Moher Amlohri Extension Opencast Coal Project of Sasan Power Ltd., A subsidiary of Reliance Power Ltd. We would like to extend our gratitude to Mr. Bimal Baral, Mine Manager; for allowing us to conduct study in the mines for the above period. Secondly, we would like to thanks Mr. Umesh Mahato, Head, technical services for his immense help and guidance.We gratefully acknowledge the help provided for my field study by the officials of Sasan mines. We are especially thankful to Mr. Ravi Hatadia, Mr. Satyam Baranwal, Mr.Shankar Agrawal, Mr. Kapilmohan Sharma, Mr. Ankit anil Gupta, Mr. Rahul kumar for their valuable guidance and suggestions.Lastly we would like to express our heartily thanks to all those who were associated with the project.

(Umesh Khandelwal)

Index

Chapter No.TitlePage No.

1.Introduction1.1 Background1.2 Fleet Productivity & Factors Affecting it3

2.Background Of Reliance Power and Details of Sasan Coal Mines2.1 Bird Eye View Of Project2.2 Coal Block Location2.3Geological Details2.4 seam depiction with thickness details2.6 Net geological Reserves2.6 Surface Master Plan2.7 Mine Parameters2.8 Proposed Mining Method2.9 Bench Geometry2.10 HEMM used and Their Specifications6

3.Different Departments Visited and Studies Conducted3.1 Drilling and Blasting System3.2 Results of Cycle Time Study Conducted3.3 Mine Information System3.4 SAP system3.5 Advantages of SAP and MIS system3.6 Truck dispatch System3.7 Minecare System3.8 Provision System21

4.Calculation OF Number of Dumpers Per Shovel And Matching Factor Ratio27

5.Empirical Model For Shovel Dumper Fleet Productivity30

6.Conclusion And Inferences34

7.References35

List of Figures Sr. No.TitlePage No.

1.Fig. No.111

2.Fig. No.211

3.Fig. No. 312

4.Fig. No. 413

5.Fig. No. 514

6.Fig. No. 619

7.Fig. No. 720

8.Fig. No. 820

9Fig. No. 925

List of TablesSr. No.TitlePg. No.

1.Table No.19

2.Table No. 213

3.Table. No.315

4.Table No.416-17

5.Table No.518

6.Table No.629

7.Table No.731-32

8.Table No.833

SYNOPSISIn the present global scenario of decreasing commodity prices, low thermal coal prices and high capital investment, mining companies can only increase their profits by either operational excellence or process excellence. Reliance has deployed some of the largest mining machineries in the world. This has involved high capital cost and also operational cost of these machineries is also quite high. So, its very crucial for the organization to utilize these machines efficiently and effectively. Shovel-Dumper operation is crucial operating system for all those opencast projects which uses this combination for working operation. Reliance has 42 m3 rope shovels in combination with 240 te dumpers. Organization was in a need to identify the crucial factors affecting this system so that it can be improved which will in turn improvise the economy of mine. Hence, during this project efforts were being made to identify different factors affecting the working of this shovel dumper combination. After analyzing the past records of production an empirical relation between fleet productivity and different factors affecting it was obtained. Using this empirical relation cost sensitivity analysis was done to identify the critical parameter.Hence, study aimed to scientifically suggest methods to improve the shovel dumper fleet productivity.

CHAPTER1 INTRODUCTION1.1 Background:Fleet management and its production optimization is one of the most critical tasks from operational point of view in open pit mining. Truck haulages correspond to almost 50% of total operational cost incurred in opencast mining. Any marginal improvement in their performance would save a significant amount of money in modern open-pit mining operations. Accurate assessment of the system performance is not so easy because of the complexity of the system and interdependency of loading and hauling units. Productivity improvement involves attention on two: first to have a proper fleet management so as to have best possible allotment of trucks to shovel. In most of the modern large open pit mines, this is done through fully automated systems. This automated system helps in real time monitoring of shovel and dumpers so that idle time of shovels is reduced and there is minimum queuing of dumpers. Moher & Moher Amlohri Extension Mines have adopted Modulars DISPATCH module to have proper monitoring of the fleet. Second important section on which fleet productivity depends is role of different operational factors which affect the productivity of shovel and dumper combination. These factors proved to be more decisive on field to change the actual productivity and are major reasons behind difference between actual and theoretical productivity. The study mainly concentrates on effect of these factors. Hence, efforts are made to find a relationship between productivity of shovel and these different parameters.

1.2 Fleet Productivity & Factors affecting it Productivity in case of open cast mines is expressed as production (in bank cubic meters or tonne ) per operating hours. Shovel productivity is primarily a function of the number of trips in operating hours and quantity of material in each trip i.e. payload. Number of trips depends on cycle time and efficiency of both shovel and dumper. The different operational parameters affecting the productivity of shovel are:1. Shovel cycle time.2. Lead distance.3. Payload per trip.4. Load travel speed.5. Empty travel speed.6. Dumper spotting time.7. Dumper waiting time.8. Unloading time.

1. Shovel cycle timeIt is the total time (involving digging time, forward swing time, unloading time, backward swing time and lowering time) required for a shovel in its one pass of the bucket.It basically depends up on swing angle involved in loading dumper. Higher the swing angle, higher will be the shovel cycle time and hence lower will be the productivity. On field it is also affected by the condition of face and operational efficiency of operator.

2. Lead DistanceLead distance plays a vital role in fleet productivity. Shovel productivity decreases significantly if lead is higher. Therefore, selection of proper dumping sites is very important. If possible, input dumping can be adopted so as to minimize the lead distance for the dumpers. Proper planning is much significant in order to reduce lead of fleets.

3. Payload per tripFleet productivity depends on average loading capacity of dumper. Efforts should be made to utilize maximum capacity of dumpers .For this bucket should be filled optimally so that in specified number of buckets, dumper is filled close to its specified capacity. Thus bucket fill factor is another parameter identified that affects productivity. Bucket fill factor is affected by condition of material to be filled. Also as discussed earlier, operational efficiency of shovel operator will also affect loading done in dumpers.

4. Load travel speed and empty travel speedTime taken by dumper to cover the lead distance, depends on dumper speed. Although very high speed of dumpers is not desirable because as dumpers are of huge size safety is major concern, but an optimal speed within the safety limit can be achieved. Load travel speed and empty travel speed is directly affected by gradient of haul roads. Proper planning for haul road designing has to be done to ensure that the loaded dumpers will go down the gradient for major part of their travel. Maintenance of haul road by proper grading from graders and dust suppression at haul roads will also help in increasing average speed of dumpers.

5. Dumper spotting timeSpotting time taken by dumpers will depend on type of cut approach adopted by shovel, normally front cut approach is used. Efforts should be made to minimize spotting time so that fleet productivity improves by decreasing swing angle to minimum and shovel operator should have a proper view of dumper so that loading can be done efficiently.

6. Dumper waiting timeThis is a very crucial component with regard to fleet productivity. Efforts should be made to minimize dumper waiting time as much as possible. Dumper waiting time gives rise to improper matching ratio i.e. improper number of dumper allotted in a fleet. Matching ratio should be as close to 1 as possible so that fleet productivity is optimum. For this computer aided real time monitoring of fleet should be done and dispatching should be done efficiently so that dumpers are utilized according to need of hour. Waiting time in a fleet may arise due some field problem faced by shovel or some technical defect in shovel. Hence, proper maintenance of shovels is important.

7. Unloading TimeAlthough this is a very small component of fleet cycle, so quiet often it is neglected but it is found that it can also affect the dumper cycle time significantly if proper unloading preparations are not done. Queuing can take place at dumper site if dumping sites are not available at dump yards or jamming of dumpers is taking place. Dump material should be dozed by dozers to maintain proper condition of dump yard for unloading.

Chapter -2 BACKGROUND OF RELIANCE POWER AND DETAILS OF SASAN COAL MINESPower or electricity is one of the most critical components of infrastructure affecting economic growth and wellbeing of nations. The existence and development of adequate infrastructure is essential for sustained growth of the Indian economy. Infrastructure Power or electricity is one of the most critical components of infrastructure affecting economic growth and prosperity of nations. The existence and development of adequate infrastructure is essential for sustained growth of the Indian economy. Infrastructure investment in India is on the rise, but growth may be constrained without further improvements. To cater this need of power generation, reliance being one of the most trusted organization of the country, has entered this crucial sector. Power projects of reliance power are mainly of three types- coal projects, gas projects and hydroelectricity projects. Power generated by reliance is then handed over to central transmission utilities, state transmission utilities and other agencies for effective transmission and distribution.Under coal projects, captive mines have been allotted to reliance power by government of India through competitive bidding. These mines are supplying fuel for four ultra-mega power projects of Reliance power which has capacity of 3960 Mw at full operational condition which are located in Madhya Pradesh, Jharkhand and Andhra Pradesh. Besides them there are also three small 600 Mw projects.Sasan UMPP is one of the major coal projects of reliance power. It is Indias first domestic private UMPP project and aims to be Indias largest coal power project. Project has been allotted one to biggest coal reserve to a private player consisting of three blocs- Moher, Moher Amlohri extension and Chatrasaal which accounts for 750 million tonnes of coal reserve. Moher and Moher Amlohri extension mines has obtained mine approval for 20 million tonne opencast mining from ministry of mines, government of India. At present 4 of its unit are operational and it is supplying power to 14 states in India at a very cheap rate of Rs.1.19 /unit. 2.1 BIRD EYE VIEW OF THE PROJECTTable No. 1

1.Target Project20 MTPA

2.Estimated Life of mine29 years

3.Net geological reserves575 Mt

4.Mineable reserve473.70 Mt

5.Stripping ratio4.03

6.Total volume of overburden to be handled1893.73 Mm3

7.Grade of coal

D to F

8.Percentage of extraction81.18 %

9.Total area15.39 Km2 [Moher (10.70 Km2) + Moher-Amlhori (4.69 Km2)]

10.

11.Gradient Of Seam

End use of coal 2 to 3 degreesProposed Sasan ultra mega power plant (3960 MW) and other proposed power plants under RPL group

2.2 COAL BLOCK LOCATION: South western part of Moher sub basin, Singrauli Coalfield Area

Moher BlockMoher-Amlohri extn. Block

Fig. No.2Fig no.1

Total Area (as per GR): 15.39 sq km Moher: 10.70 sq km Moher-Amlohri extn: 4.69 sq km

2.3 GEOLOGICAL DETAILSGeological formations: Deposit is occupied by exposures of Barakar formation with recent soil or alluvium cover at places. Predominant rock type is sandstone followed by shale and lensoid clay horizons.Geological Structure: Moher block: Coal seams exhibit E-W strike in southern part which swings gradually to almost N-S in northern part. Moher-Amlohri extension block: Coal seams exhibit NW-SE Strike. Dip: Moher block: 2-3 in the northern part and 3-6 in the southern part. Moher-Amlohri Extension block: 2-3 in general, with slightly 5 in the north-east corner.

Faults: Moher block: 11 faults with throw from 0 51 m. Moher- Amlohri extension block: free from faults in general.2.4 Seam Depiction with Thickness Details: Fig. No.3

2.5 Net Geological reserves:Table No.2Cross-sectional View Of Borehole

Coal SeamsNet Proved Coal Reserves (Mt.)

Moher BlockMoher-Amlohri Extn BlockTotal

Turra186.56107.90294.46

Purewa130.10150.44280.54

Total316.66258.34575.00

Fig. No. 4Parting51m to 68 mTurra Seam12m to 19 mPurewa Seam19m to 26 mTop OB Range12 m to 198 m

Source: Geological Report

2.6 SURFACE MASTER PLAN

Fig. No.5Pit Top & CHP

2.7 MINE PARAMETERS:Table No. 3

SL No.ParametersUnitValue

1 Maximum Depthm290

2 Average Face Length: North Pit South Pitkm2.3 2.9 to 4.4

3 Maximum Dip Rise Length: Moher Block Moher-Amlohri Ext.kmkm3.2 1.9

4 Area: On the Mine Floor On the Mine Surface Haha10631440

2.8 PROPOSED MINING METHOD Mining technology: Open-Cast method of working with shovel-dumper and dragline combination for overburden removal is proposed to be used. FEL Loader -Dumper combination for coal extraction will be deployed.

Method of Working: Shovel dumper combination with Inclined slicing in top over burden benches above Dragline sitting level is being proposed. The width and gradient of the haul road are to be maintained as per permissible limits. The draglines will be used to remove inter parting between Turra and Purewa seam for side casting into the de-coaled area.

Drilling and Blasting Operation: Drilling and blasting will be required both in overburden and coal benches before excavation. Inclined Drilling is proposed for Dragline benches and vertical drilling for Shovel Benches.

Coal transportation: Coal transportation occurs in three steps. Initial coal transportation from face to receiving pit is being done through dumper trucks. Then coal is transported to bunker or crusher through conveyors. Coal is finally transported from crusher to power plant through high angle belt conveyors.

2.9 BENCH GEOMETRYTable No. 4

LocationBench Height (m)Bench Width (m)High Wall Angle HEMM

Top OB15-1840-6070042m3 Rope shovel

Parting between Purewa & Turra15-1840-6070042m3 Rope shovel

Parting between Turra & Purewa38-6155-6070062m3 Dragline with operational reach of about 90m.

Purewa SeamIn two benches4080028-32 m3 FE loader & 13-15 m3 Hyd. Backhoe

Turra SeamIn two benches 4080028-32m3 FE loader & 13-15 m3 Hyd. Backhoe

2.10 HEMM USED AND THEIR SPECIFICATIONS:Moher and Moher amlohri extension has deployed some of the biggest mining equipments in the world. The mine operates with shovel dumper combination of 42 m3 shovel and 240 te dumper. Dragline of size 62m3 X 100 m is being commissioned. These equipments provide larger production capacity to mine so that it can suffice the fuel requirement of UMPP project.

HEMM STATEMENT:Table No. 5

Equipment NosCapacityExpected Delivery Date

OB RemovalOf 1st equipment of same category

Dragline262 m3May 2012

Rope Shovel642 m3Jan 2011

RBH Drill4311 mm 1 April 2012

RBH Drill10250 mm 1 Nov.2010

Rear Dumper 42240 T Jan,2011

Dozer6850 HPOct 2010

Coal Production

FE Loaders428-32 m3March 2012

Hydraulic Backhoe113-15 m3N/A

RBH Drill4160 mmN/A

Rear Dumper Coal Body13240 TMarch,2012

Dozer With Ripper 2850 HPSep,2012

Dozer2560 HPN/A

42 CuM Shovel with 240 Ton DumpersFig. No.6

42 CuM Le Tourneau Loader - Front View

Fig. No,762 cubic metre dragline during assembling phase

Fig. No.8

Chapter-3DIFFERENT DEPARMENTS VISITED AND STUDIES CONDUCTED Mine as whole operate through different subsystems which when synchronize together leads to effective and efficient production. Each subsystem has different components and all these subsystems are important for mining operation. The main subsystems present in moher and moher amlohri extension opencast project are: Drilling and blasting system. Shovel dumper system. FEL And dumper system. Mine information system (MIS) and SAP. TDS system. Minecare and provision system.All this departments where visited to properly understand and study their operation and identify existing flaws in the system.

3.1 Drilling and blasting system:As specified earlier, three different drills are available for drilling. Larger drills(259mm and 311mm) are used for overburden drilling and smaller drills (159 mm) are used in coal drilling. This drills are either electrically powered or diesel operated drills. The other parameters regarding drilling and Blasting identified are given below:Drilling blasting specification for O/BDrilling: Drilling dia. (in OB): 259 mm. Drilling Rate : 1.2 m/min. Burden and Spacing: 11m. and 9 m. Rod length: 18m. Max. depth drilled by one rod 16.6 m. Depth of hole : 24 m.

Blasting:Explosive used: SME (Site mixed emulsion provided by Special Blasting Ltd.)Accessories : Electric detonator, detonating fuse (10 gm. PETN/m., 10mm.), cord relay(1 gm PETN)exploder.Powder factor: 5.5 T/kg (for coal) 2.15 m3/kg (for OB)No. of boosters used per hole: 6Cord Relay used between two holes : 6 (each provide delay of 17 ms.)Explosive used in each hole: 700 kg (65 kg/m.)

3.2 Results of cycle study time conducted for Shovel dumper combination: For Dumper: Spotting time: 36 sec. Loading time:138 sec. Unloading time: 43 sec. Load and empty travel time: 305 sec. Waiting time: 93 sec. For Shovel: Total time to load one dumper: 138 sec. And one cycle time: 46 sec

Results of cycle study time conducted for FEL dumper combination: For Dumper: Spotting time 56 sec. Loading time 300 sec. (4 buckets) Load and empty travel time 315 sec. Unloading time 43 sec. Waiting time 48 sec. For FEL: Total time to load ondumper is 300 sec. (approx.) And one cycle time is 75 sec.3.3 MINE INFORMATION SYSYEM: MIS is an advanced system for collecting, storing and reporting mine production and equipment working data. MIS mainly involves use of Microsoft Excel for providing input to the system. Some predetermined parameters for each of machines related to their operation are decided and we record this parameters in excel. Different parameters such as Hour meter reading, operational time/production hours, delay time , stand by time, breakdown time , meal break time, check time, Shift change time etc. are being recorded by the operator and we transfer this data into the system manually. Using the recorded parameter we calculate different other parameters related to all machines. Important calculated parameters using MIS are: Availability time of machine. Breakdown time of machine. Utilization time of machines. Operational efficiency of machine etc. Total material (OB or Coal) excavate by excavators like shovel or FELS, total no. of trips by dumpers are also recorded. Using this data, MIS provides us compressed and systematic data pertaining to production or performance of machine. This data are recorded for each of the shift on daily basis.

3.4 SAP SYSTEM: SAP stands for system application process. SAP has different modules like MIS, FICO, PO, WO, PR but here we are using MIS only. The application of SAP is same as that of MIS but difference is that inputs can be obtained directly from TDS system and no manual data feeding is required. Also SAP Provides reports according to need of the user between any two days as required. 3.5 Advantages of MIS AND SAP System: Proper storing of data for different activities conducted in mines. Obtaining reports for production, productivity, performance measurement, consumption, inventory positions and cost parameters in reportable format. When SAP and TDS system will be installed in full capacity, the manual recording of the different data will not be required and accuracy of data will be more prcised. As reports obtained are more precise this will help to increase the efficiency and productivity of different machines by identifying the prominent problem related to particular machine and thus increases overall efficiency.3.6 TRUCK DISPATCH SYSTEM Computer aided system used in opencast mines to improve the productivity of equipments by reducing the idle time of equipments. Based on Global positioning system. Provides real time monitoring of equipments (involving ready, standby, breakdown and idle conditions), which enhance efficiency of equipments. It decreases fuel consumed by machine and hence increase productivity. Help in locating ramps and haul roads. Decreases the communication gap between the operators and other members.

Fig. NO.9

3.7 MINECARE SYSTEM: Monitor health of the equipment in real time, fully integrated with Dispatch system. Enables the maintenance crew through remote condition monitoring of mobile equipment to reduce the incidence and severity of breakdowns. Provides minimum and maximum range of all the parameters available in the equipment diagnostic. Remote condition monitoring, maintenance history, and operational data is integrated to provide the end user with sufficient information to make optimal maintenance decisions. On line monitoring of equipment health show graphic trending pattern of selected parameters together with OEM specified limits. When the specified upper or lower limits are breached, system creates an alarm. Criticality of the different parameters can be defined based on the importance of the parameter. A multi-tiered alarm classification scheme coupled with an alarm handling methodology to ensure that only safety related or critical alarms are sent to personnel in real-time. However, the system creates the entire logs of the alarms generated. The system allows maintenance personnel to perform remote diagnostics from their computer on the network without stopping the equipment.3.8 PROVISION SYSTEM It is mainly used in Dozer, shovel and drill. Main functions of Pro-Vision are ore control, productivity tracking, surface guidance and safety features. It helps in making keyed surface, keep inclination surface and ramp. Keyed surface means flat surface Keep inclination surface means only inclination is given. Ramp means two points(x,y,z) are given and software joins both of them and form an inclined way. The module provides a proper guideline to operator on its screen so that planned results are obtained.

CHAPTER 4Calculation of Number of Dumpers per Shovel & Matching Factor

In this, we have conducted the cycle time study of dumper and shovel. Therefore, calculation for number of dumpers will be done as:Let the dumper capacity= Dc Tonnage per shovel bucket=Bc* Bf* SF*, where Bc is bucket capacity of shovel, Bf is bucket fill factor Sf is swell factor and is insitu density of material.Number of buckets needed to fill a dumpers= Int. (Dc /(Bc * Bf* SF*))Loading time for a dumper= No. of buckets * Shovel cycle timeLoad travel time = Lead distance /Load travel speedEmpty travel speed = Lead distance / Empty travel speedUnloading time is approximately 1 to 1.5 minutes.Waiting time and Spotting time is also included in dumper cycle time.Hence, Dumper cycle time= Spotting time+ Loading time+ Load travel time+ Unloading Time+ Empty Travel time + Waiting TimeNow, required number of dumpers per shovel is,{Dumper cycle time/ (loading time + spotting time)}Field Study Results:For the mine condition, the average data obtained is as: shovel bucket capacity (Bc) as 42 m3, bucket fill factor (Bf) as 0.8, swell factor (Sf) as 0.8, overburden density as 2.1te/m3, lead distance as 3.5 m., shovel cycle time as 48 sec., number of buckets required to fill a dumper as 3, load travel speed as 25 kmph, empty travel speed as 30 kmph, spotting time as 33 sec., loading time as 150 sec, unloading time as 47 sec., waiting time as 377 sec.Therefore, Tonnage per shovel bucket = 42*0.8*1.0 = 33.6 m3No. of passes required to fill a dumper = 218/2.1*33.6 = 3.089 = 3 (round off)Therefore, theoretical time required to fill the dumper= shovel cycle time * No. of passes = 48*3 = 144 sec.Loading travel time = 3.5*3600/25 = 504 sec.Empty travel time = 3.5*3600/30 = 420 sec.Dumper cycle time = 33+95+504+47+420+377 = 1476 sec.No. of Dumpers required per shovel = 1476/ (33+144) = 8.33 = 8 (lesser integer)Hence for this mine, at least 8 dumpers should be allotted for obtaining optimum shovel productivity.On an average 9 dumpers were allotted in Moher & Moher - Amlohri Extension Mines for lead of 3.5 k.m. Matching factor ratio = No. of trucks * Loader cycle time/ no. of loader * dumper cycle time = Actual no. of dumpers allotted/ Theoretical no. of dumpers required = 9/ 8 = 1.125.

Lead DistanceLoad Travel TimeEmpty Travel TimeDumper Cycle TimeNo. of Dumpers Req.Actual No. of Dumpers req.

228824010806.106

2.536030012126.856

343236013447.597

3.550442014768.348

457648016089.089

4.564854017409.839

5720600187210.5810

5.5792660200411.3211

6864720213612.0712

6.5936780226812.8112

71008840240013.5613

7.51080900253214.3114

81152960266415.0515

In the Table No. 6, number of dumpers required per shovel for varying lead distance can be shown as:Table No.6

31

CHAPTER 5Empirical Model for Shovel Dumper Fleet ProductivityIn this, on the basis of data obtained from field study and the data analysis of mine information system, the regression equation has been produced with the help of MS Excel. In this equation we have defined productivity on the basis of dumper payload, shovel cycle time, lead distance and reduced dumper cycle time (where reduced dumper cycle time is equal to dumper cycle time minus dumper loading time). The new term defined as Reduced Dumper Speed which is calculated from dividing lead distance by reduced dumper cycle time. It signifies the average speed of a dumper in one cycle calculated from reduced dumper cycle time (which includes spotting time, load travel time, empty travel time and waiting time required by the dumper). The data analysis (of month april 2014 and may 2014 for shovel no. 4) done for deriving the equation is shown in Table No.6:PLTsTrX

2,180 196540.3061035338.006213

2,656 207480.2685653857.21927

2115200570.2966541677.826875

2,483199480.3650335388.915129

3347201360.4041269.37183

2,406205510.3326312968.455224

2334205420.2949154427.792624

2,371202510.3028321877.945393

2165202560.3665006958.934029

2493198480.341258.586081

2,259221590.3155521678.174797

2138203570.3629493338.888017

2157207550.3413062228.586913

2042204570.264098757.11074

2187209550.2790770837.460976

2557210470.285547.60075

2152194520.2703073337.260624

1,996200570.2685517.218927

2333202500.2750071117.369584

2048207580.2737657.34115

2278208520.2654343337.143575

2464207480.3882612289.197576

2478208480.3396974298.562999

2404203480.2815016677.514165

2,565206450.27049587.265067

2533209500.2528833336.821327

2346201520.2511966676.775568

2561209490.2481166676.690401

2661218490.3328533338.45868

2548211500.2499133336.740337

2122205580.2087366675.379984

1798210700.2260176676.011256

3229202380.2255666675.99601

2011211630.2673666677.1905

2274211480.2786966677.452547

2260217580.302757.943848

2067211610.369968.977998

2246204550.3459811468.655141

2004203610.351048.726926

1666203730.3682733338.956663

2381196490.3340633338.477434

2586207480.335098.493241

2540205480.2882666677.65784

2389205520.2626366677.074412

2566209490.2522233336.803494

2621214490.2561833336.909115

2082210470.2538733336.847903

2512201480.2529566676.823303

2458208510.2628933337.080819

2669219490.2755066677.380947

2569214500.276467.402518

2264208550.2665966677.171883

2334257660.2902527787.698749

Legends

ProductivityP (BCM/Hr)

PayloadL(MT)

Shovel Cycle TimeTs (Sec.)

Reduced Dumper TimeTr (Hr.)

Reduced Dumper SpeedX (KM/Hr.)

Table No. 7

From the regression analysis of above data, the empirical relationship between shovel productivity, dumper payload, shovel cycle time and reduced dumper speed was obtained as:Condition: This time is calculated for a particular Lead Distance (3.5 km)

Regression Statistics

Multiple R0.883433113

R Square0.780454066

Adjusted R Square0.767012478

Standard Error141.549657

Observations53

With the help of regression equation, we have analyzed productivity by varying the inputs of the equation and that can be given as:PLTsXPP %

2366.250618207527.6669

On increasing L by 3%

2425.293631213527.666959.043012.495213826

On Reducing Ts by 10%

2563.818712207477.6669197.56818.349415386

On Reducing Td by 10% (by keeping D constant and decreasing St and Wt)

2380.063486207528.662913.812870.583744925

Table No. 8

In the Table No.2, first row consists of average values of different parameters for two months. Here we can easily see that; by varying shovel time by just 10% productivity varies by approximately 8.34%. Hence from the economic point of view, if cost is 150 INR per BCM, then total cost saved per shovel hour comes out to be 29,500 INR and considering shovel utilization factor as 60 % then total cost saved for all the six shovels per day will come out to be:Cost Saved per day = 150*197*24*6*0.6 = 25.5 lacs INR

CHAPTER 6Conclusion & inferencesConclusion: Out of all operational factors, Shovel cycle time is major factor affecting the productivity as per the empirical relation and results obtained. It has been observed that condition of face which depends on fragmentation plays crucial role in reducing cycle time of shovel. Double spotting of dumper can be adopted to reduce shovel cycle time and operator efficiency is also a significant with respect to shovel cycle time. Besides this, achieving higher average payload per trip is other way of improving productivity. Productivity can be marginally improved by reducing dumper waiting time and queuing by proper fleet allocation and fleet management.

CHAPTER-7 References1. S Nel, M S KiziL and P knights; 24-30 September 2011; Improving truck shovel-matching; 35th APCOM Symposium/ Wollongong, NSW.2. Necmettin etin; September 2004; Open-Pit Truck/Shovel Haulage System Simulation; The graduate school of natural and applied sciences of middle east technical university.

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