101025 Excellence in Exc Planning Presentation E Heiland
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EXCELLENCE IN
EXCAVATOR PLANNING
AT DRAYTON MINE
FROM THE DESIGN TO THE IMPLEMENTATION IN THE FIELD
Erik Heiland
Anglo American Metallurgical Coal
Australia
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LOCALITY
• Hunter Valley/ New South Wales
• One of AAMC’s most challenging
operations
• Operation began in 1983
• Scheduled production in 2010:
5Mt of thermal coal
– 4Mt for export market
– 1Mt for domestic market (Liddell
and Bayswater power stations)
Map of Region
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MINING EQUIPMENT
• Major Mining Equipment
– One BE1370 dragline
– Two Hitachi EX5500 excavators
– One Hitachi EX3500 excavator
– Two front end loaders
(Le Tourneau L1100 and L1400)
– 24 Caterpillar 789B and C trucks
• 67% of Drayton’s prime overburden
is planned to be moved by Hitachi
EX5500 excavators
• Aim: Uncover coal in the safest and
most efficient way in accordance
with the business plan schedule
BE1370 Dragline
Excavator 305
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COMPLEX GEOLOGY
• Deposit consists of five major seam
groups with up to 40 splits
• Major geological features are:
– 45 to 60 degree steep dipping coal
seams
– Up to 40m faults
– 100m thrust plane
– Dykes
– Intrusions
• Geology creates tough working
environment for the machinery
Drayton Mine Seam Split Diagram
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COMPLEX GEOLOGY CONT.
• Thrusting and Faulting create a major challenge for the mining operation
• Drayton has a 100m thrust plane running through the deposit
Diagrammatic Representation of Normal Faulting and Thrust Faulting
Balmorals
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• An Example: South Pit East
• Thrust plane, 10 faults, seam splitting, fill, spon com…
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COMPLEX GEOLOGY CONT.
Diagrammatic Representation of Normal Faulting and Thrust Faulting
Representative Cross-Section Through South Pit East, October 2010
Thrust plane
SectionAB
A B
Faults
shown
in black
Faults
These are the same Grasstrees seams
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BENCHMARK PERFORMANCE
• Drayton’s excavator fleet delivers benchmark performance within AAMC
• EXC306 and 307 are ranked No. 1 and 2 in its category
• Major Key Performance Indicator: Operational Equipment Efficiency
AAMC Operational Efficiency Ranking, Above 500t Excavator Category, August 2010
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THE EXCAVATOR PLANNING PROCESS
• Process includes eight process steps
• Bullet point 2
• Bullet point 3
• Bullet point 4
• Bullet point 5
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MINE ACTIVITY DESIGN (MAD)
• Compliance with
AAMC Operations
Management System
• Focus on the long
term, medium term
and short term
planning, actual
production and
reconciliation
• MAD document
focuses on the
18-month planning
process The AAMC Mine Planning Process
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16 WEEK SCHEDULE
• Visual representation of equipment path for the Dragline and two
EX5500 Excavators
• Purpose of schedule
– Identification equipment interactions
– Input data for the 16 week drill and blast schedule
– Determination of coal uncovered dates for the coal and partings schedule
– Identification of short term truck shortages or excess
The 306 Excavator Path in the 16 Week Schedule
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MONTHLY OPERATING PLAN (MOP) DESIGN REVIEW
• Review of excavator designs for
the following month
• Determination of average
monthly dig rate per excavator
for input in schedule
• Optimisation of dig plans
• Presentation of plans by the
excavator engineer
One of Tony’s pics
Visualisation of the EN03 Broughams dig area
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MOP DELIVERY PLAN MEETING
• Identification of critical issues
• Ensure the monthly Key Performance Indicators are achieved
• Assign actions and agree on due dates
Key Performance Indicator: Prime, Monthly Delivery Plan, September 2010
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EXCAVATOR PLAN SIGN OFF PROCESS
• E = Q x A [Effectiveness = Quality x Acceptance]
• Ensure that final design
plans contain the most up to
date information
• Import of actual drilling data
to deliver most accurate coal
surface
• Sign off to be completed one
week before an excavator
enters the work area
Sign off for SPW09-10P and SPW08G dig
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WEEKLY PLAN PROCESS AND PACK
• Weekly Plan Process includes a pre-planning meeting and a planning
meeting
• Agree on the weekly equipment path, blast and mining sequence,
equipment interaction
• Weekly plan pack is a comprehensive package which is sent via E-mail
to all relevant mine personnel
Weekly Plan Excavator Path, Plan commencing 7 October 2010
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DAILY PIT COMMUNICATION
• Pit inspections are
conducted a minimum of
three times a week
• Communication of the plan
to front line personnel
• Inspection of current and
future dig and dump areas
during the tour
• Supervisor’s light vehicle
and four bull dozers are
equipped with a GPS
• Video GPS in Supervisors light vehicle – SPW09P12 dig area
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DAILY PIT COMMUNICATION
• Minimum three times a week
• Communication of the plan
to front line personnel
• Inspection of Current and
future dig and dump areas
are inspected during the
tour
• Supervisor’s light vehicle
and four bull dozers are
equipped with a GPS
• Video
NN10 East - Excavator
N
Shot to be fired Fired
on 26/06
Vol remaining: 735kBCM
Trucks: 7
Target seam: RL
Dig Sequence
1) Continue 4.5m BSL pass from East to West to form Ramp on Northern side
2) Come off the Ramp and BSL 4.5m passes uncover unshot material from West to East
USE MATERIAL TO COVER FIRES IN SS WHEN TRUCKING AVAILABLE
BLOCKY MATERIAL IN THE SOUTH OF THE DIG AREA
GPS FILE: NN10-190
Dump
Level 7-RL295, GPS-File: LV7REH
1
2
Unshot material to
be uncovered
70Deg PS wall
45Deg Softwall
Haul route
to
East
Ramp
Application of 3D Dig Software in the NN Pit
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DIG AREA REVIEWS
• Dig reviews are carried out within one month after completion of the dig
• Reconciliation of planned vs. actual performance
• Key learning outcomes are identified and actions assigned
• Learning outcomes are included into the next MAD document
Excavator Dig Reconciliation
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CONCLUSION
Excavator Planning at Drayton is very
comprehensive process
Key reasons for success:
– Customer focus and having good
working relationships
– Input from experienced Production
personnel in the planning process
– Use of direct communication
– Accurate tracking of Key Performance
Indicators
– Compliance with Operations
Management System
