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Implementation of autonomous haulage at Maules Creek Mine
Autonomous haulage has been widely adopted in the open cut iron ore mines of Western Australia where there is a decade or more of experience in application and a code of practice has been published. For a variety of reasons in NSW there has been minimal operational implementation, and as such, the guidance material and industry experience in deployment in open cut coal mines is relatively limited.
Implementation of autonomous haulage at Maules Creek Mine
- 1. Learnings from Implementation of Autonomous Haulageat Maules Creek Chris Bedggood December 2019
- 2. Content Whitehaven Coal Maules CreekMine AHS Evaluation Project Key Implementation Considerations Next steps
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- 4. The largest producer ofhigh quality coal in the Gunnedah Basin
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- 6. Maules Creek Mine •Commercial production began in July 2015 after two years of construction and capex of ~$720 million • Produces metallurgical (SSCC) and high CV thermal coal • Approaching current approved limit of 13Mtpa • Can be expanded to 16Mtpa ROM coal in the future following lodgement of required documentation and subsequent approval Our newest, largest, high quality coal mine 0 2 4 6 8 10 12 14 FY2015 FY2016 FY2017 FY2018 FY2019 Mt Maules Creek ROM Production
- 7. Maules Creek Fleet HitachiFleet with scope for autonomous haulage Excavators 5 – EX8000 (880t) 4 – EX3600 (360t) Trucks 45 – EH5000 (304t) 5 – EH3500 (190t) Other fleet 13 Haul Trucks 17 Dozers 9 Water Carts 3 Service Carts 2 Loaders 3 Graders 6 Drills Ultra class, ready for autonomy
- 8. Wenco Fleet ManagementSystem • Wenco FMS deployed in July 2015 • We have moved beyond measuring results to driving asset performance • A key toolset in enabling mine expansion through effective utilisation of existing assets • Wenco FMS is the foundation for the autonomous haulage control system interface Visibility, control & command
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- 10. What is anAutonomous Haulage System (AHS)? • Haul trucks are driverless for load, haul and dump activities • Haul trucks are coordinated from a central control room with field support • Haul trucks equipped with on-board control systems, GPS, obstacle detection and working within a wireless mesh network • Mission based operation – not remote control • Excavator, dozer, grader and watercart remain manned and are also equipped with GPS, wireless network and user interface to allow interaction with autonomous trucks 10 // Basic introduction
- 11. © Hitachi, Ltd.2018. All rights reserved. 11 Autonomous Haulage System (AHS) - Simplified
- 12. © Hitachi, Ltd.2018. All rights reserved. 12 Autonomous Haulage System (AHS) - Simplified
- 13. Expected Benefits • AHSis already proven at a number of open cut ore mines in WA • Hitachi has successfully established 3 autonomous EH5000 trucks at its Qld demonstration site • Expected benefits in a mature AHS operation include: • Improved safety • Increase in truck utilisation • Decrease in fuel, tyre and maintenance costs • Reduce pressure on tight labour resources • Opportunities to upskill workforce 13 // Why have we considered AHS?
- 14. AHS Evaluation Project •Collaborating with Hitachi to automate a start-up fleet of EH5000-AC3 trucks • AHS control facility equipped • AHS hardware and software installation on EH5000-AC3 trucks • AHS Wi-Fi network established • Trial operations area constructed • Hitachi resources onsite 14 // Partnering with Hitachi
- 15. AHS Evaluation Project •Two Hitachi excavators upgraded • Ancillary fleet also equipped • Evaluation phase is focussed on both system functionality and operational useability • Autonomous operational trials of loaded trucks • No interaction with manned fleet at this stage • Operational readiness activities well underway 15 // Partnering with Hitachi
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- 18. Rules and Regulations •Minimal directly applicable requirements in NSW • Some associated NSW guidelines do exist (MDG2007 & MDG15) • Some WA and international guidelines have been published • Whitehaven is working closely with NSW Resources Regulator to manage our activities, including; • Face to face discussions • Site inspections at Maules Creek • Physical AHS demonstration at Hitachi Proof of Concept site 18 // What is applicable to AHS?
- 19. Rules and Regulations •Published in 2015 by WA Department of Mines & Petroleum • Application in WA • Sets out guidelines for; • Risk management approach • General hazard controls • Emergency preparedness • WA Requirement for submission of a Project Management Plan (PMP) to gain approval • Whitehaven has drafted an equivalent PMP to assist our operational readiness 19 // CoP – Safe mobile autonomous mining in WA
- 20. Rules and Regulations Appendix4 – Project Management Plan contents; 1. Introduction 2. Project overview 3. Functionality of the system 4. Equipment control system 5. Autonomous mine & operations plan 6. Commissioning, maintenance & inspections’ 7. General safety plan 8. Training & competence assessment 9. Means of investigating failures 20 // CoP – Safe mobile autonomous mining in WA
- 21. AHS Introduction for Maules Creek MiningChanges Mining Areas Commissioning Area #1 Operational Area #1 AHS Access Systems AHS Procedures New AHS Roles Training Requirements Network & System Establishment Hardware Installation Frequency Changes Survey Drones Remote Control Equipment Software Updates Major Version Minor Version #1 Minor Version #2 Fleet Installations Autonomous Truck Conversions Remote Fire System Manned Fleet Conversions Excavator Dozer Watercart Change Management • We have applied the existing Whitehaven Management of Change (MoC) processes • In overview our activities to date can be portrayed graphically • Each green box is effectively a new MoC event • Not all MoC effort is shown here 21 // As expected, a fundamental activity
- 22. Site Readiness Assessment 22// Assess impact of introduction of AHS on existing roles and mining processes A structured, formal review of the introduction of AHS on existing business functions at Maules Creek Functions assessed include; • Executive Management • Production • Maintenance • Technical Services • Dispatch • Mine Services • Drill & Blast • Training Capture • Prepare framework • Verify current processes • Undertake workshops Analyse • Define impacts • Score • Rank Action • Gap analysis • Scope required changes • Plan implementation
- 23. Site Readiness Assessment 23// Classify and rank the impacts of AHS implementation Working with Hitachi, we have categorised the impacts in terms of; People, Process, Systems or Data Impact was then ranked based on a variety of factors. For example the level of AHS involvement could be; • High – the role or process may have been newly created due to AHS • Medium – significant involvement in empowering and supporting AHS • Low - no direct involvement with AHS People Process Systems Data Executive Management IS&T Commercial AHS Project Maintenance Drill and Blast Coal Handling and Processing Technical Services Electrical Engineering Mining Dispatch Mining Production Mine Services Environmental External Relations Mine Management Health and Safety Training
- 24. Site Readiness Assessment 24// Develop action plans to close the gap • Grouped by business function & process • Categorise the impact and type of change • Provide details of the scope of the change • Ultimately resource and execute Business Function Business Process Category Change Type Change Management Plan Information Systems & Technology Manage Communication Trailers Data New Specs Define as ‘critical ‘ in asset management systems People New Role Provide 24/7 coverage Process Optimise Expedite pit license approval to remove escort limitations Manage Cyber Security Process New Procedures Perform regular security audits Systems New Functionality Physical security for control facility
- 25. Controlling the AutonomousOperating Zone (AOZ) 25 // Arrangements during commissioning & testing • Physical separation from manned operation • Provided alternate LV access to lookout & office • Management of change review • Risk assessment • Development of AHS specific procedures • Workforce notification of arrangements
- 26. HV ACCESS CHAIN GATE Controllingthe Autonomous Operating Zone (AOZ) 26 // Specific access controls during initial system commissioning • AHS Working Area established • AOZ boundary via windrows • Tight chicane used to ensure a uncontrolled truck cannot escape • Area specific radio channel provided • Access register in use • AOZ status communicated via multi-use signage with three states; 1. Autonomy ACTIVE 2. AHS tasks without autonomy 3. No AHS tasks or autonomy
- 27. Training Requirements 27 // IntegrateAHS training requirements A variety of inputs are required to deliver a comprehensive outcome; 1. Existing operator competencies 2. OEM training in the use of AHS 3. Site procedures for the application of AHS at the mine Preparing further updates to the Mine SMS to fully integrate AHS operations, for example; • PHMP - Roads & Other Vehicle Operating Areas
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- 29. • Maules Creektransition to operations in second half of FY20 • One operational fleet with six EH5000s • Autonomous zone segregated within the mine • Expansion towards 45 autonomous trucks in coming years • Vickery fleet consideration - exploring autonomy opportunities • Winchester South also on the horizon 29 // Moving Forward With AHS Implementation plans
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Editor's Notes
- #5 Narrabri Underground Maules Creek, Tarrawonga & Werris Creek Sunnyside & Rocglen in rehab Vickery approved but seeking increase to 10mtpa Winchester South Asian customers quality metallurgical & thermal via Newcastle Terminals
- #8 Large fleet of Hitachi excavators and trucks Other fleet will be equipped to work with autonomous trucks
- #9 Recent upgrade to Wenco V6 is further improving our preparations The interface in the AHS Control room will be familiar to our staff
- #11 AHS provides control of basic truck inputs; steering, accelerator and brakes Equipped haul trucks can only be used in a defined autonomous operating zone
- #12 Control centre Wireless network Truck installation Manned fleet installations for any machines working in the AOZ
- #13 Once assigned a mission Autonomous truck travels to loading area via fixed paths and permission logic Loading point created by manned excavator Truck calculates a unique path within the dynamic area and presents to spot point After loading the excavator operator kicks the truck out Travel to dump area again via fixed paths Dumping bays created by dozer or control A variety of dumping options; crusher; paddock and over the edge
- #17 Drone footage of initial activities Spotting to excavator, manned EX3600 equipped to work with EH5000s GPS antenna poles, flashing blue light Truck kicked out and hauling to dump Hauling via fixed haul roads, multiple truck trials Where paths overlap trucks wait for permission Trial area is established on our OOP dump Reversing to OTE dump using LiDAR Stats: 6 x EH5000s, 865km, 559 haul cycles, 187 loads, 55,000t
- #18 With limited time available we can only touch on a few of the areas for consideration
- #19 MDG2007 Guideline for the selection and implementation of collision management systems in mining MDG15 Mobile & transportable plant for use on mines ISO17757 Autonomous and semi-autonomous machine safety GMG Guideline for the Implementation of Autonomous Systems in Mining WA COP Safe mobile autonomous mining All of these are valuable reference materials that should be researched
- #21 The introduction - context for pursuing AHS Project overview - phases of implementation & org structure Sections 3 & 4 to detail how the AHS system will work and integrate Mine plans, survey and drill & blast arrangements in section 5 Commissioning methods, ITS and maintenance requirements General safety section discusses the integration with the site SMS Training arrangements are then specified The processes for dealing with any failures is determined A series of appendices provides further detail
- #22 Top level MoC as decision to proceed with AHS Simple classification into areas of focus Further detail at the next level where some of the specific MoC activity occurs E.g Fleet Installations – AHT conversion – Remote fire system AHS area arrangements & training
- #24 Impacts are classified into People, Process, Systems or Data And the scored to generate a heat map to determine focus areas High, medium & low
- #25 Simple extract of much larger action plan here showing the increase in focus required with respect to IT and comms to support 24/7 AHS operations
- #26 Aerial view of AHS commissioning area 1 Isolated location on OOP dump AOZ boundary defined Alternate access to lookout & office Procedures developed through RA processes Arrangements communicated to workforce
- #27 Conservative approach has been taken to initial commissioning AHS working area Radio channel AOZ inside – chain gate and chicane on single access Register for controlling entry Status via signage & chain Has worked very well to ensure safe separation for all activities to date Learnings will be carried over into arrangements for Operational Area 1
- #28 Training in AHS is a significant task Existing competencies for operations OEM training for AHS – see example matrix, roles vs modules MCC AHS procedures – detailing application of the AHS at this mine Capture & merge with mine exiting training systems Further SMS integration & updates Primary Hazard Management Plan
- #30 Overview of Maules Creek showing the main pit, the initial autonomous dig area, the haul roads and the targeted dump locations Segregated loading hauling and dump on the mine boundary to minimise interference with other mining operations Plans for significant expansion as experience and performance increases