2. OverviewOverview
• System - overview of proposalSystem - overview of proposal
½ level layout½ level layout
CPS (central pump station) layoutCPS (central pump station) layout
Working area layoutWorking area layout
Equipment overviewEquipment overview
Water qualityWater quality
Water usage and recirculationWater usage and recirculation
3. OverviewOverview
• ImplementationImplementation
Key actionsKey actions
Phased rollout & trainingPhased rollout & training
InfrastructureInfrastructure
• Maintenance and Operation costs
Hydropower equipmentHydropower equipment
HP pumpsHP pumps
OperationOperation
14. Equipment overview – JET PUMPSEquipment overview – JET PUMPS
– RETURN WATER JET PUMPSRETURN WATER JET PUMPS
– WASTE WATER JET PUMPSWASTE WATER JET PUMPS
15. Water qualityWater quality
• COMRO WHP 70 SPEC, 30°C MAX TEMP
– Ph 6 to 8.5
– SUSPENDED SOLIDS 5 mg/l MAX
– TDS 1500 mg/l MAX
– CHLORIDES 250 mg/l MAX
– PARTICLE SIZE to ISO 4406 CLASS 19/15
• PRACTICALLY
– GENERAL GOOD WATER TREATMENT
– FILTER/SETTLE to 25 OR 50 microns
• BETTER WATER = LOWER COST & MORE RELIABLE
• EQUIPMENT STORAGE, HOSE FLUSHING IS NB
16. Water usage and recirculationWater usage and recirculation
• NO RECIRCULATION OF OTHER WATER – SAWS,
JETTING, WASHING DOWN, ETC
• 75% RECIRC OF DRILL EXHAUST WATER
• REQUIRES
– WATER TANK AND BOOSTER PUMPS AT CPS
– RETURN WATER HOSE & PIPE
– JET PUMP MANIFOLD IN STRIKES
– DISCIPLINE TO MAINTAIN WATER CLEANLINESS
– DISCIPLINE TO NOT USE WATER FOR COOLING
– LESS MAKE-UP WATER
– MAKE UP FLOW TO CATER FOR WATER JETTING FLOW
17. • ImplementationImplementation
Key actionsKey actions
– ACHIEVE MINE ‘OWNERSHIP’ACHIEVE MINE ‘OWNERSHIP’
– RESPONSIBLE MINE PROJECT MGRRESPONSIBLE MINE PROJECT MGR
– CLEAR OBJECTIVES & MEASURESCLEAR OBJECTIVES & MEASURES
– ENGAGEMENT WITH UNIONSENGAGEMENT WITH UNIONS
– MINE TRAINING DEPT ON BOARDMINE TRAINING DEPT ON BOARD
– INFRASTRUCTURE IN PLACEINFRASTRUCTURE IN PLACE
18. • ImplementationImplementation
trainingtraining
– NOVATEK TRAIN MINE TRAINERSNOVATEK TRAIN MINE TRAINERS
– NOVATEK OVERSEE TRAINING BYNOVATEK OVERSEE TRAINING BY
MINEMINE
• CLASSROOM TRAININGCLASSROOM TRAINING
• TRAINING STOPE FOR NEW CREWSTRAINING STOPE FOR NEW CREWS
19. • ImplementationImplementation
InfrastructureInfrastructure
• HYDROPOWER ENGINEERINGHYDROPOWER ENGINEERING
• WATER SUPPLY & TREATMENTWATER SUPPLY & TREATMENT
• CPS CONSTRUCTIONCPS CONSTRUCTION
• MAINTENANCE & TEST FACILITIESMAINTENANCE & TEST FACILITIES
• MINE STORESMINE STORES
• MINE TRAININGMINE TRAINING
• SUPPLIER PARTNERSHIPSSUPPLIER PARTNERSHIPS
20. • Capital costs - HP pumpsHP pumps
• PREV QUOTE – VSD DRIVES.
– VSD ALLOWS CONTROL FROM 50 - 100% FLOW – ON
1 PUMP ONLY
– R50k+ PREMIUM PER PUMP
• PREFERRED TO USE PLC SYSTEM
– SIMPLER, EASIER TO DAISY-CHAIN EXTRA PUMPS
– PLC OPERATES MORE/FEWER PUMPS DEPENDING ON
DEMAND – BY MONITORING PRESSURE.
• BOOSTER PUMPS IF SUCTION P<300 kPa
21. • Maintenance and Operation costs
Pneumatic
system
Hydropower
system
Maintenance cost 2 x higher
Operator cost 2 x higher
Energy cost 10 x higher
Overall cost higher lower
If productivity
advantage is used
22. • Maintenance and Operation costs
HP pumpsHP pumps
• PREFERRED MAINTENANCE BY PUMP
SPECIALIST
• TYPICALLY R 8000 / PUMP/ MONTH (EXCLUDES
MAJOR MAINTENANCE & DAMAGE)
• COST APPROX 1/3 OF OVERALL MAINT COSTCOST APPROX 1/3 OF OVERALL MAINT COST
23. • Maintenance and Operation costs
RockdrillsRockdrills
• DRILLS ON TIERED SYSTEMDRILLS ON TIERED SYSTEM
– 5 RATES DEPENDING ON SCOPE & COST5 RATES DEPENDING ON SCOPE & COST
– EXCLUDES LOSS & DAMAGEEXCLUDES LOSS & DAMAGE
• LEGS AT 1 RATELEGS AT 1 RATE
• NOVATEK EQUIP, STAFF ANDNOVATEK EQUIP, STAFF AND
SUPERVISEWORKSHOPSUPERVISEWORKSHOP
• COST APPROX 1/3 OF OVERALL MAINT COSTCOST APPROX 1/3 OF OVERALL MAINT COST
24. • Maintenance and Operation costs
Rockdrills - Robustness of the machineRockdrills - Robustness of the machine
• Susceptibility to sabotage – good, but … dirt, drop down
orepass, off-collar drilling, abuse, will work.
• Service interval – when operated to specifications, over
600 m is achievable, even better using rigs. Highly
dependent on operator, water, drillsteels, etc.
• Breakdown frequency and causes
– General wear 90% – rotation, piston, valve, seals.
– Breakage – chuck & rotation, pistons – worn drillsteel, abuse
– Dirt – premature wear – no flushing of hoses, poor water
– NFF – low pressure, fuse problems, too many drills per pump
• Ratio of machines that reach service interval and expected
life span – life is indefinite; all parts are replaced under the
maintenance contract.
25. • Maintenance and Operation costs
Other equipmentOther equipment
• MOST MAINTENANCE IN NOVATEK WORKSHOPMOST MAINTENANCE IN NOVATEK WORKSHOP
• SPECIALISED MAINTENANCE & REPAIR –SPECIALISED MAINTENANCE & REPAIR –
OFFSITE (eg SAFETY VALVES)OFFSITE (eg SAFETY VALVES)
• ITEMISED COSTINGITEMISED COSTING
• COST APPROX 1/3 OF OVERALL MAINT COSTCOST APPROX 1/3 OF OVERALL MAINT COST
26. • Noise – target <110 dbA in area
RockdrillsRockdrills
– 105 dbA each105 dbA each
– 108 dbA in working area108 dbA in working area
– 4-5 hours exposure/shift4-5 hours exposure/shift
CPSCPS
– 95 dbA per pump95 dbA per pump
– 98 dbA for 6 pumps98 dbA for 6 pumps
– 5 hours exposure/shift5 hours exposure/shift
27. • Noise – operator exposure
RockdrillsRockdrills
– Source is drillsteel noiseSource is drillsteel noise
– Hearing protection = 85 dbA at earHearing protection = 85 dbA at ear
Use of drill rigsUse of drill rigs
– Drilling faster & more efficientDrilling faster & more efficient
– Operator further from noise sourceOperator further from noise source
28. Risk assessment - hydropower
– HIGH PRESSURE WATER
• FUSES, SSVs,
• FIX LEAKS, CARE OF HOSES, PRE-USE CHECKS
• SECURE & MAINTAIN PIPING
• WORK TO STANDARD ENGINEERED LAYOUTS
– MOVING PARTS & HIGH FORCES
• DRILL THRUST, DRILLSTEEL, SAWS, ETC
• WATER JETTING
– WATER MANAGEMENT
• THIXOTROPIC ORE
• DRAINAGE
29. Use of simple rigsUse of simple rigs
– FASTER, MORE ACCURATEFASTER, MORE ACCURATE
• BETTER ADVANCE/BLASTBETTER ADVANCE/BLAST
• BETTER HANGINGWALL CONTROLBETTER HANGINGWALL CONTROL
– HEALTH & SAFETYHEALTH & SAFETY
• LOWER ROCKFALL & GENERAL RISK EXPOSURELOWER ROCKFALL & GENERAL RISK EXPOSURE
• LOWER NOISE EXPOSURELOWER NOISE EXPOSURE
• LOWER HAVS EXPOSURELOWER HAVS EXPOSURE
30. Why Novatek?Why Novatek?
34 YRS34 YRS
WE ENGINEERWE ENGINEER
WE MANUFACTUREWE MANUFACTURE
ISO 9000, BBBEEISO 9000, BBBEE
PARTNERSHIPPARTNERSHIP
