An empirical approach to optimize the shovel-dumper fleet

productivity
A case study of Moher & Moher Amlohri Extension Coal Mine

Submitted by
Umesh Khandelwal
(2010JE0511)






1


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

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

















Submitted By:
Mr. Umesh Khandelwal
Mining Engineering Department
Indian School of Mines,
Dhanbad-826004, Jharkhand India
Email id:
umeshkhandelwal26@gmail.com

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, India
Email id:
ravi.hatadia@relianceada.com

2


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)











3




Index

Chapter
No.
Title Page No.
1. Introduction
1.1 Background
1.2 Fleet Productivity & Factors Affecting it
3
2. Background Of Reliance Power and Details of Sasan Coal
Mines
2.1 Bird Eye View Of Project
2.2 Coal Block Location
2.3Geological Details
2.4 seam depiction with thickness details
2.6 Net geological Reserves
2.6 Surface Master Plan
2.7 Mine Parameters
2.8 Proposed Mining Method
2.9 Bench Geometry
2.10 HEMM used and Their Specifications
6
3. Different Departments Visited and Studies Conducted
3.1 Drilling and Blasting System
3.2 Results of Cycle Time Study Conducted
3.3 Mine Information System
3.4 SAP system
3.5 Advantages of SAP and MIS system
3.6 Truck dispatch System
3.7 Minecare System
3.8 Provision System
21
4. Calculation OF Number of Dumpers Per Shovel And 27
4


Matching Factor Ratio
5. Empirical Model For Shovel Dumper Fleet Productivity 30
6. Conclusion And Inferences 34
7. References 35


List of Figures
Sr. No. Title Page No.
1. Fig. No.1 11
2. Fig. No.2 11
3. Fig. No. 3 12
4. Fig. No. 4 13
5. Fig. No. 5 14
6. Fig. No. 6 19
7. Fig. No. 7 20
8. Fig. No. 8 20
9 Fig. No. 9 25

List of Tables
Sr. No. Title Pg. No.
1. Table No.1 9
2. Table No. 2 13
3. Table. No.3 15
4. Table No.4 16-17
5. Table No.5 18
6. Table No.6 29
7. Table No.7 31-32
8. Table No.8 33


5


SYNOPSIS
In 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 m
3
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.


6





CHAPTER1
INTRODUCTION
1.1 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
7


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 time
It 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 Distance
Lead 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 trip
Fleet 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
8


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 speed
Time 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 time
Spotting 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 time
This 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.

9


7. Unloading Time
Although 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.
10


Chapter -2
BACKGROUND OF RELIANCE POWER AND DETAILS OF SASAN COAL MINES
Power 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.
11


2.1 BIRD EYE VIEW OF THE PROJECT


1.

Target Project

20 MTPA

2.

Estimated Life of mine

29 years

3.

Net geological reserves

575 Mt

4.

Mineable reserve

473.70 Mt

5.

Stripping ratio

4.03

6.

Total volume of overburden to
be handled

1893.73 Mm
3


7.

Grade of coal


D to F

8.

Percentage of extraction

81.18 %

9.

Total area

15.39 Km
2

[Moher (10.70 Km
2
) + Moher-
Amlhori (4.69 Km
2
)]


10.

Gradient Of Seam

2 to 3 degrees
Table No. 1
12



11.

End use of coal
Proposed Sasan ultra mega
power plant (3960 MW) and other
proposed power plants under
RPL group
13


2.2 COAL BLOCK LOCATION:



















2.3 GEOLOGICAL DETAILS

South western part of Moher sub
basin, Singrauli Coalfield Area
Total Area (as per GR): 15.39 sq km
Moher: 10.70 sq km
Moher-Amlohri extn: 4.69 sq km
Fig no.1
Fig. No.2
14


Geological 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
15



2.5 Net Geological reserves:




Coal
Seams
Net Proved Coal Reserves (Mt.)
Moher Block
Moher-Amlohri
Extn Block
Total
Turra 186.56 107.90 294.46
Purewa 130.10 150.44 280.54
Total 316.66 258.34 575.00
Parting
51m to 68 m
Source:
Geological Report
Turra Seam
12m to 19 m
Purewa Seam
19m to 26 m

Cross-sectional View
Of Borehole
Top OB
Range
12 m to
198 m

Table No.2
Fig. No. 4
16


2.6 SURFACE MASTER PLAN

Pit Top & CHP

Fig. No.5
17



2.7 MINE PARAMETERS:
SL No. Parameters Unit Value
1 Maximum Depth m 290
2
Average Face Length:
North Pit
South Pit
km
2.3
2.9 to 4.4
3
Maximum Dip Rise Length:
Moher Block
Moher-Amlohri Ext.
km
km
3.2
1.9
4
Area:
On the Mine Floor
On the Mine Surface
Ha
ha
1063
1440
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
Table No. 3
18


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 GEOMETRY

Location
Bench Height
(m)
Bench
Width
(m)
High Wall
Angle
HEMM
Top OB 15-18 40-60 70
0
42m
3
Rope shovel
Table No. 4
19


Parting between Purewa
& Turra
15-18 40-60 70
0
42m
3
Rope shovel
Parting between Turra &
Purewa
38-61 55-60 70
0

62m
3
Dragline with
operational reach of about
90m.
Purewa Seam
In two
benches
40 80
0

28-32 m
3
FE loader & 13-
15 m
3
Hyd. Backhoe
Turra Seam
In two
benches
40 80
0

28-32m
3
FE loader & 13-15
m
3
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 m
3

shovel and 240 te dumper. Dragline of size 62m
3
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.

20


HEMM STATEMENT:

Equipment Nos Capacity
Expected Delivery Date
OB Removal

Of 1
st
equipment of same
category
Dragline 2 62 m
3

May 2012
Rope Shovel 6 42 m
3

Jan 2011
RBH Drill 4 311 mm
1 April 2012
RBH Drill 10 250 mm
1 Nov.2010
Rear Dumper 42 240 T
Jan,2011
Dozer 6 850 HP
Oct 2010
Coal Production

FE Loaders 4 28-32 m
3

March 2012
Hydraulic Backhoe 1 13-15 m
3

N/A
RBH Drill 4 160 mm
N/A
Rear Dumper Coal Body 13 240 T
March,2012
Dozer With Ripper 2 850 HP
Sep,2012
Dozer 2 560 HP
N/A
Table No. 5
21


42 CuM Shovel with 240 Ton Dumpers



Fig. No.6
22


42 CuM Le Tourneau Loader - Front View



62 cubic metre dragline during assembling phase
Fig. No,7
Fig. No.8
23


Chapter-3
DIFFERENT 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/B
Drilling:
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.

24


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: 6
Cord 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.
25


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.

26


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.
27


Decreases the communication gap between the operators and other members.



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.
Fig. NO.9
28


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.









29


CHAPTER 4
Calculation 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= D
c

Tonnage per shovel bucket=B
c
* B
f
* S
F
*, where B
c is
bucket capacity of shovel, B
f
is
bucket fill factor S
f
is swell factor and is insitu density of material.
Number of buckets needed to fill a dumpers= Int. (D
c
/(B
c
* B
f
* S
F
*))
Loading time for a dumper= No. of buckets * Shovel cycle time
Load travel time = Lead distance /Load travel speed
Empty travel speed = Lead distance / Empty travel speed
Unloading 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 Time
Now, 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 m
3
, bucket fill factor (Bf) as 0.8, swell factor (Sf) as
0.8, overburden density as 2.1te/m
3
, lead distance as 3.5 m., shovel cycle time as 48
30


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 m
3

No. 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.




31


In the Table No. 6, number of dumpers required per shovel for varying lead distance can be shown as:
Lead
Distance
Load Travel
Time
Empty Travel
Time
Dumper Cycle
Time
No. of Dumpers
Req.
Actual No. of
Dumpers req.
2 288 240 1080 6.10 6
2.5 360 300 1212 6.85 6
3 432 360 1344 7.59 7
3.5 504 420 1476 8.34 8
4 576 480 1608 9.08 9
4.5 648 540 1740 9.83 9
5 720 600 1872 10.58 10
5.5 792 660 2004 11.32 11
6 864 720 2136 12.07 12
6.5 936 780 2268 12.81 12
7 1008 840 2400 13.56 13
7.5 1080 900 2532 14.31 14
8 1152 960 2664 15.05 15
Table No.6
CHAPTER 5
Empirical Model for Shovel Dumper Fleet Productivity
In 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:
P L Ts Tr X
2,180 196 54 0.306103533 8.006213
2,656 207 48 0.268565385 7.21927
2115 200 57 0.296654167 7.826875
2,483 199 48 0.365033538 8.915129
3347 201 36 0.404126 9.37183
2,406 205 51 0.332631296 8.455224
2334 205 42 0.294915442 7.792624
2,371 202 51 0.302832187 7.945393
2165 202 56 0.366500695 8.934029
2493 198 48 0.34125 8.586081
2,259 221 59 0.315552167 8.174797
2138 203 57 0.362949333 8.888017
2157 207 55 0.341306222 8.586913
2042 204 57 0.26409875 7.11074
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2187 209 55 0.279077083 7.460976
2557 210 47 0.28554 7.60075
2152 194 52 0.270307333 7.260624
1,996 200 57 0.268551 7.218927
2333 202 50 0.275007111 7.369584
2048 207 58 0.273765 7.34115
2278 208 52 0.265434333 7.143575
2464 207 48 0.388261228 9.197576
2478 208 48 0.339697429 8.562999
2404 203 48 0.281501667 7.514165
2,565 206 45 0.2704958 7.265067
2533 209 50 0.252883333 6.821327
2346 201 52 0.251196667 6.775568
2561 209 49 0.248116667 6.690401
2661 218 49 0.332853333 8.45868
2548 211 50 0.249913333 6.740337
2122 205 58 0.208736667 5.379984
1798 210 70 0.226017667 6.011256
3229 202 38 0.225566667 5.99601
2011 211 63 0.267366667 7.1905
2274 211 48 0.278696667 7.452547
2260 217 58 0.30275 7.943848
2067 211 61 0.36996 8.977998
2246 204 55 0.345981146 8.655141
2004 203 61 0.35104 8.726926
1666 203 73 0.368273333 8.956663
2381 196 49 0.334063333 8.477434
2586 207 48 0.33509 8.493241
2540 205 48 0.288266667 7.65784
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2389 205 52 0.262636667 7.074412
2566 209 49 0.252223333 6.803494
2621 214 49 0.256183333 6.909115
2082 210 47 0.253873333 6.847903
2512 201 48 0.252956667 6.823303
2458 208 51 0.262893333 7.080819
2669 219 49 0.275506667 7.380947
2569 214 50 0.27646 7.402518
2264 208 55 0.266596667 7.171883
2334 257 66 0.290252778 7.698749

Legends
Productivity
P
(BCM/Hr)
Payload L(MT)
Shovel Cycle Time Ts (Sec.)
Reduced Dumper Time Tr (Hr.)
Reduced Dumper
Speed
X
(KM/Hr.)

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:


Regression Statistics
Condition: This time is calculated for a particular Lead
Distance (3.5 km)
Table No. 7
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Multiple R 0.883433113
R Square 0.780454066
Adjusted R
Square 0.767012478
Standard Error 141.549657
Observations 53
With the help of regression equation, we have analyzed productivity by varying the
inputs of the equation and that can be given as:
P L Ts X P P %
2366.250618 207 52 7.6669
On increasing L by 3%
2425.293631 213 52 7.6669
59.0430
1 2.495213826
On Reducing Ts by 10%
2563.818712 207 47 7.6669
197.568
1 8.349415386
On Reducing Td by 10% (by keeping D constant and decreasing St and Wt)
2380.063486 207 52 8.6629
13.8128
7 0.583744925

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
Table No. 8
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CHAPTER 6
Conclusion & inferences
Conclusion:
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.








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CHAPTER-7
References
1. S Nel, M S KiziL and P knights; 24-30 September 2011; Improving truck shovel-
matching; 35
th
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.