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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
Sandvik Mining and Construction
Sandvik Mining and Construction
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 Mining and Construction
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
Sandvik Mining and Construction
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)
Sandvik Mining and Construction
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)
Sandvik Mining and Construction
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)
Sandvik Mining and Construction
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)
Sandvik Mining and Construction
Where Are We Now – Measuring the Process
Sandvik Mining and Construction
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
Sandvik Mining and Construction
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….
Sandvik Mining and Construction
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?....
Sandvik Mining and Construction
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
Sandvik Mining and Construction
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
Sandvik Mining and Construction
Sandvik Mining and Construction
Sequential roof and rib bolting
Rib bolting (generally) takes longer
Sandvik Mining and Construction
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
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
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
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
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
Sandvik Mining and Construction
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
Sandvik Mining and Construction
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)
Sandvik Mining and Construction
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)
Sandvik Mining and Construction
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
Sandvik Mining and Construction
Panels develop from Return Side
Sub-Main Advances as needed.
Extraction Sequence
Sandvik Mining and Construction
New Products – CHS 500 – SICON Conveyor
Continuous Haulage System
•~ 220m length (500m3/hr)
•Currently being built in USA
Sandvik Mining and Construction
MINING SYSTEM PERFORMANCE
0.00
2.00
4.00
6.00
8.00
10.00
12.00
10 30 50 70 90 110 130
DISTANCE FROM SHUNT S1 (m)
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
Recommended