A Reference Guide to Mining Machine Applications

Purpose of Mine Evaluation

• Confirm that mine is getting maximum value from its investment

in Cat equipment.

• Help mine set and achieve new benchmarks for safety, efficiency

and profitability.

Key Factors to Review

• Machine/system sizing and selection.

• Job set-up.

• Operating techniques.

• General site conditions.

• Haul road design and maintenance.

TrucksPerformance Benchmark

• Exchange time

− Target. . . . . . . . . . . . .42 seconds

− Acceptable. . . . . . . . .54 seconds

TrucksLoad Placement

• Center load above hoist cylinders and along body centerline.

• Minimize material on headboard.

• Minimize spillage from sides, corner, rear.

• Always target 66% - 33% load split on front/rear axles.

Correct Loading

Incorrect

Loading

Correct LoadingIncorrect Loading

TrucksPositioning

• Loader operator spots truck.

• Position for fastest cycle times.

− Wheel loaders - 45°

− Other loading tools - angle varies

• Keep rear tires off pile.

• Minimize wait time.

TrucksOther Tips

• Safety

− Apply parking brake

• Body

− Check liner plate wear and

body pad alignment

• Tires

− Inspect tire condition

− Check TKPH/TMPH ratings

Loading Tool SelectionRope Shovel Front Shovel Mass Excavator Wheel Loader

Cycle time(seconds)

28-32 27-30 24-28 30-40

Fill factor (%) 100-105 90-100 90-110 90-110

Pass match 3-4 4-6 4-6 4-6

Favorableconditions

Single faceStable level floorWide benchesWell-shot material

Selective diggingTight area &materialPoor floor

Truck below HEXTight area &materialShort swing

Level, dry floorWell-fragmentedmaterialLower face profileMulti-face loading

Unfavorableconditions

Poor underfoot ExcessivetrammingLow benches

High/unstablebenchesExcessivetrammingLow angle ofrepose material

Poor/wet underfootTight load areas

Rope Shovels Performance Benchmarks

• Cycle time

− 28-32 seconds (31-second average)

• Bucket fill factor - well shot rock

− 100-105%

• Pass match

− 3-4 passes

Rope ShovelsSite Conditions

• Optimum bench height

− Top of boom sheeves

• Best applications

− Single face, correct height

− Wide benches

− Well-shot material

• Unfavorable conditions

− Poor underfoot

Rope ShovelsTips

• Maintain maximum swing - 70-90°.

• Keep floor clean.

• Monitor power cable maintenance.

• Never operate a bare edge.

Hydraulic Front ShovelsPerformance Benchmarks

• Cycle time

− 27-30 seconds (28-second average)

• Bucket fill factor - well shot rock

• 90-100%

• Pass match

− 4-6 passes

Hydraulic Front ShovelsSite Conditions

• Optimum bench height

− Just above boom/stick pivot

• Best applications

− Selective digging, multiple targets

− Tight load area and materials

− Poor underfoot

• Unfavorable conditions

− Excessive tramming

− Low benches

Hydraulic Front ShovelsTips

• Strip top, load from center.

• Keep tight digging zone.

• Avoid digging too far into face.

• Watch for high, unstable benches.

• Load from left.

• Avoid excessive prying.

• Maximize tip contact.

• Always have defined dig

pattern R to L or L to R and

maintain pattern.

Hydraulic Backhoes (Mass Excavation)Performance Benchmarks

• Cycle time

− 24-28 seconds (26-second average)

• Bucket fill factor - well shot rock

− 90-110%

• Pass match

− 4-6 passes

Hydraulic Backhoes (Mass Excavation)Site Conditions

• Optimum bench height

− Length of stick or distance between truck siderail and ducktail

• Best applications

− Truck below excavator

− Tight load area, tight material

− Short swing - 60°

• Unfavorable conditions

− High benches

− Excessive tramming

− Low angle of repose material

Hydraulic Backhoes (Mass Excavation)Tips

• Watch for excess bench height.

• Keep tight digging zone and swing angle.

• Remove farthest pass during truck exchange and maintain

“Key Cut” (pass in front of inside track) to establish straight

wall for next cut.

• Avoid digging too far into face.

• Keep cut in line with inside

track, no more than 45° over

outside track.

• Watch for poorly blasted toe.

Wheel LoadersPerformance Benchmarks

• Cycle time

− 30-40 seconds (38-second average)

• Bucket fill factor - well shot rock

− 90-110%

• Pass match

− 4-6 passes

Wheel LoadersSite Conditions

• Optimum bench height

− Bucket hinge pin height at maximum lift

• Best applications

− Level, dry, smooth, firm floors

− Good drainage

− Well-fragmented material

− Lower face profile

− Multi-face loading

• Unfavorable conditions

− Poor or wet underfoot

− Tight load areas

Wheel LoadersTips

• Enter pile straight on.

• Keep frame straight when digging.

• Lift bucket before crowding.

• Horizontal lift arms when bucket

is full.

• Keep time in face below 12 seconds.

• Position loader 1.5 wheel turns

from face to truck.

• Never operate a bare edge.

Motor GradersBlade Position

• Keep top of moldboard 50 mm ahead of cutting edge.

• Keep edge at 90° angle to surface.

• Maintain constant tip angle.

Motor GradersBlade Angle

• Use widest pass width.

• Increase blade angle if material flows around leading edge.

• Use 10° blade angle for Grader Bit System or serrated edge.

Motor GradersOther Tips

• Grade in 2nd or 3rd gear.

• Rip in 1st gear with all machines.

• Always keep edges sharp

for better penetration.

• Change edges prior to

moldboard damage.

Track-type TractorsRipping Tips

• Rip downhill.

• Rip in same direction scrapers will load.

• Watch speed.

− 1.5-2.5 km per hour

• Position tip properly.

− Begin with tip rearward

− Pull forward after penetration

− Shank lies backward while ripping

Track-type TractorsDozing Tips

• Use slot dozing.

• Use slopes.

• Steer with blade.

• Minimize corner loading,

prying, impact.

• Maintain steady pressure.

• Position blade properly.

− Tilt forward

− Lay blade back when half full

− Continue racking blade back as it fills

Track-type TractorsOther Tips

• Reinforcing ribs on penetration ripper tip must face up.

• Ensure proper installation of GET.

• Never operate bare shank.

• Avoid excessive tramming.

• Watch for missing or loose track hardware.

ScrapersPerformance Benchmarks

• Load time - open bowl/push-loaded WTS.

− Target . . . . . . . . . . . . . . 24-30 seconds

− Average . . . . . . . . . . . . 36-43 seconds

• Shorter time for tandem.

• Longer time for single powered.

DrillsPerformance Benchmarks(25,000-40,000 lb/111.25-178 kN pulldown)

• Depths

− Multi-pass . . . . . . . . .up to 40 m/43 yd

− Single-pass . . . . . . . 10-12 m/11-13 yd

• Hole sizes

− 100-200 mm/3.9-7.8 in

• Rotation speeds

− Coal . . . . . . . . . . . . 120-150 rpm

− Hard rock . . . . . . . .100-120 rpm

• Penetration

− Coal . . . . . . . . . . . . 40-60 m/hr/43.7-65.6 yd/hr

− Hard rock . . . . . . . .10-30 m/hr/10.9-32.8 yd/hr

DrillsPerformance Benchmarks (40,000-60,000 lb/178-267 kN pulldown)

• Depths

− Multi-pass . . . . . . . . . up to 60 m/65.6 yd

− Single-pass . . . . . . . .12-16 m/13-17 yd

• Hole sizes

− 150-250 mm/5.9-9.8 in

• Rotation speeds

− Coal . . . . . . . . . . . . . 100-130 rpm

− Hard rock . . . . . . . . . 80-110 rpm

• Penetration

− Coal . . . . . . . . . . . . . 40-80 m/hr/43.7-87.4 yd/hr

− Hard rock . . . . . . . . .10-40 m/hr/10.9-43.7 yd/hr

DrillsPerformance Benchmarks(60,000-110,000 lb/267-489.5 kN pulldown)

• Depths− Multi-pass . . . . . . . up to 100 m/109 yd

− Single-pass . . . . . .14-18 m/15-19 yd

• Hole sizes− 200-350 mm/7.8-13.7 in

• Rotation speeds− Coal . . . . . . . . . . . .80-110 rpm

− Hard rock . . . . . . . 70-90 rpm

• Penetration− Coal . . . . . . . . . . . 40-100 m/hr/43.7-109.4 yd/hr

− Hard rock . . . . . . . 10-50 m/hr/10.9-54.6 yd/hr

DrillsPerformance Benchmarks(Track drills)

• Depths

− Multi-pass . . . . . . . . . up to 50 m/54 yd

− Single pass . . . . . . . . 8-10 m/8.75-10.9 yd

• Hole sizes

− up to 150 mm/5.9 in

• Rotation speeds

− Coal . . . . . . . . . . . . . 80-120 rotary

− Hard rock . . . . . . . . . up to 40 rpm hammer

• Penetration

− Coal . . . . . . . . . . . . . 30-50 m/hr/32.8-54.6 yd/hr

− Hard rock . . . . . . . . . 10-30 m/hr/10.9-32.8 yd/hr

DrillsFavorable Site Conditions

• Level floor.

• Unbroken ground.

• Minimal water ingress.

• Regular pattern spacing.

• Limited tramming.

• Adequate maneuvering space.

DrillsOperating Tips

• Watch for excessive vibration.

• Avoid drill plunging.

• Avoid excessive pulldown pressures.

• Avoid excessive rotation speeds.

• Set bailing velocity correctly.

• Monitor chip size.

• Level drill correctly.

• Maintain flat floor.

Haul Road DesignHorizontal and Vertical Alignment

• Design corners and crests that allow excellent visibility at normal

travel speeds.

• Use worst-case scenarios.

10

1

Haul Road DesignCross-slope

• Flats

− Apply minimum slope to maintain drainage

− Use constant crossfall when possible

• Grades

− Minimal cross-slope required

2° constant crossfall

Haul Road DesignGrade

• Maintain smooth grade.

• Maintain consistent percentage.

Correct Incorrect

Haul Road DesignCorners

• Use maximum practical radii.

• Employ super elevation for

higher speed operations.

• Use super elevation >10%

with caution.

Haul Road DesignRoad Width

• One way - 3 truck widths.

• Two-way straights - 3.5 truck widths.

• Two way corners - 4 truck widths.

One-way (Straights/corners)

Two-way (In Straights)

Two-way (In Corners)

Haul Road Design Bench Width

• Truck must clear loader under full acceleration.

• Minimum width = machine turning radius + width of safety berm.

Bench Width

Haul Road Design Drainage & Safety Berms

• Drainage system - sized to accommodate maximum rainfall.

• Berm size - at least one-half wheel height.

Drainage

1/2 wheel height

Haul Road Design Rolling Resistance

• Hard, well-maintained road . . . . . . . 1.5%

• Well-maintained road with flex . . . . . . 3%

• 25 mm/1 in tire penetration . . . . . . . . .4%

• 50 mm/2 in tire penetration . . . . . . . . .5%

• 100 mm/4 in tire penetration . . . . . . . .8%

• 200 mm/8 in tire penetration . . . . . . .14%

Tire penetration

Haul Road MaintenanceRules of Thumb

• Begin at face; end at dump.

• Pick-up truck travels

comfortably at

60 km/hr (37 mph).

• OHT travels at reasonable speed.

• Remove and repair wet/soft spots.

• Consider checkerboard

or spot watering on slopes.

Haul Road Maintenance Analysis Tools

• Application Severity Analysis (ASA).

• Vital Information Management System (VIMS).

• Fleet Production and Cost (FPC).

Haul Road Visual InspectionLoad Zone

• Floor is smooth.

• Water removal is adequate.

• Debris is cleared away.

• Trucks don’t drive over rocks.

• Trucks leave under full,

continuous acceleration.

• Trucks return without making

tight, high-speed turns.Loading Zone

Haul Road Visual InspectionMain Haul Road

• Road is free of puddles, potholes, ruts, gullies.

• Passing room is adequate.

• Corner radius allows safe operation at high speed.

• Spillage is removed quickly.

• No rubber deposits on tight, rocky turns.

• High braking forces not necessary on corners.

• Expected road speeds are achieved.

Haul Road Visual InspectionDump Zone

• Floor is smooth.

• Trucks enter at high speed, parallel to edge.

• Trucks brake in straight line, then turn and stop to

reverse to dump.

• Safety berms are regulation height.

• Is dump stable enough to

dump over safely or

should you dump short

and push off.

Discussion Topics for Mine ManagersBucket Fill Factors

• Higher fill factors improve productivity and reduce cost per ton.

• Achieve higher fill factors through:

− Better fragmentation

− Correct bucket selection

− Correct GET selection and maintenance

− Correct bench heights

− Correct loader orientation to face

Discussion Topics for Mine ManagersLoader Cycle Times

• Faster cycle times improve productivity and reduce cost per ton.

• Achieve faster cycle times through:

− Correct orientation to face

− Improved floor conditions

− Correct truck placement

− Improved material condition

Discussion Topics for Mine ManagersOHT Road Speeds

• Higher OHT road speeds improve productivity and reduce cost

per ton.

• Achieve faster speeds through:

− Smooth roads - load to dump

− Reduced rolling resistance

− Better road design

− Better payload control

Discussion Topics for Mine ManagersCat Software Tools

• Compare actual and theoretical:

− Grade speeds

− Cycle times

− Total productivity

• Analyze impact of changes:

− Haul road speeds

− Bucket fill factors

− Truck exchange time

− Fuel consumption

− Component life

− Tire life

Dozers: 0 to 100 m (0 to 350 ft)

*Load and Carry: 50 to 120 m (150 to 400 ft)

*Scrapers: 120 to 1200 m (400 to 4000 ft)

*Articulated Trucks: 120 to 1200 m (400 to 4000 ft)

*Rear Dump Truck: 120 to 1500 m (400 to 5000 ft)

*Wagon/Hauler: 1200 to 10 000 m (4000 to 35,000 ft)

Discussion Topics for Mine ManagersHauling System Application Zones

*Underfoot, material type, production rate & operator skill also affect system selection

Discussion Topics for Mine ManagersSupport Equipment

• Correct use of support machines can:

− Enhance safety

− Improve productivity & extend life of production equipment

− Extend tire life

− Maximize haul road life

Reference MaterialPrint

• Cat Performance Handbook

• A Reference Guide for Mining Machine Applications (AEDK0391)

• Handbook of Ripping (AEDK0752)

• 5130/5230 Applications Guide (AEDK0128)

• H-Series Motor Grader Application Guide (AEGQ0945)

• 994 Bucket Selection Guide (AEDK0268)

• Making the Most of Scraper Potential (AEGQ2380)

• Optimum Scraper Load Time (AEGC0195)

• GET Inspection & Maintenance Guide (PEXT8033)

• GET Service Guide (PEGP7030)

Reference MaterialVideo

• 24H Motor Grader Introduction (TEVN3797))

• 24H Operating Techniques (AEVN4741/AEVP4741)

• 5130B/5230 Front Shovel Application Techniques

(AEVN4380/AEVP4380)

• 5130B/5230 ME Application Techniques (AEVN4381/AEVP4381)

• 994 Operating Tips (AEVN2947)

• GET Operating Tips (PEVN4009/PEVP4009)