Using FPC to Size Truck and Loader Fleets ©2012 Dr. B. C. Paul Note – This presentation demonstrates fleet sizing using Caterpillar’s FPC program and.

Using FPC to Size Truck and Loader Fleets ©2012 Dr. B. C. Paul Note – This presentation demonstrates fleet sizing using Caterpillar’s FPC program and includes screen shots from the program. Credit is given to Caterpillar for the program and interfaces. Caterpillar has produced helps and directions for using the program which of course have common subject material with these slides. These slides also draw on earlier work done by the author.

What Is FPC? It is an easy to use tool for sizing truck and loader fleets for hauling ore over simple and consistent haulage routesIt is an easy to use tool for sizing truck and loader fleets for hauling ore over simple and consistent haulage routes

What Will We Do In This Demonstration? We will consider a fleet of trucks moving 16.5 million metric tonnes of rock every year out of a pit that is 500 meters deep.We will consider a fleet of trucks moving 16.5 million metric tonnes of rock every year out of a pit that is 500 meters deep. Similar to the final pit we developed in MineSight.Similar to the final pit we developed in MineSight.

When FPC Starts it Takes You to Its First Tabbed Screen Some Items Just Involve Labeling Your Project

You Also Make Your Unit Selection

You Need to Enter A Fuel Price Normally the fuel is “Red Dog” Diesel. Most Trucks run on Diesel Fuel Most Mining Trucks do not run On public highways. As a result Their diesel fuel is not subject To highway taxes. To keep untaxed diesel fuel from “getting into the highway truck Fleet” it is dyed red. Thus the Name “Red Dog”. If a highway Truck is cought with red fuel or Red fuel stains there will be big Trouble.

Working Time is Also Considered You enter the number of hours Per year of work And the so called shift efficiency

Hours Worked One Begins Considering How Many Hours to Schedule Mining Operations and trucks.One Begins Considering How Many Hours to Schedule Mining Operations and trucks. You could claim 24 hours a day and 365 days per yearYou could claim 24 hours a day and 365 days per year But that would imply Christmas, New Years, and other Holidays being workedBut that would imply Christmas, New Years, and other Holidays being worked That would also imply no weather delays or scheduled maintenance down-townThat would also imply no weather delays or scheduled maintenance down-town It would mean no weekends offIt would mean no weekends off It would mean if you ever got in trouble on production there would be no place to add time for catch-upIt would mean if you ever got in trouble on production there would be no place to add time for catch-up Not Surprisingly – 24 hours/day 365 days per year is not a usual choiceNot Surprisingly – 24 hours/day 365 days per year is not a usual choice

Some Possibilities 5 days per week5 days per week 52 weeks per year – about 260 days/year52 weeks per year – about 260 days/year A month off for Miners HolidayA month off for Miners Holiday Mines shut down and use crews for heavy maintenance and prep workMines shut down and use crews for heavy maintenance and prep work Leaves around 330 days with a few major holidaysLeaves around 330 days with a few major holidays 6 day work week – 52 weeks/year – about 3126 day work week – 52 weeks/year – about 312

Weather or Not You Like It Consider how many days you may loose for weather or catastrophic break-down eventsConsider how many days you may loose for weather or catastrophic break-down events For my example I selected 325 days/yearFor my example I selected 325 days/year I was going for a 7 day per week operation with reasonable holiday, maintenance, and weather or break-down days.I was going for a 7 day per week operation with reasonable holiday, maintenance, and weather or break-down days. Be consistent with existing or intended practice.Be consistent with existing or intended practice.

The Shifts/Day Issue In theory three 8 hour shifts make 24 hours per day.In theory three 8 hour shifts make 24 hours per day. In practice changing crews takes timeIn practice changing crews takes time Idea behind “hot seat change outs” start the next shift before previous endsIdea behind “hot seat change outs” start the next shift before previous ends Of course that will end the idea that three 8 hour shifts = 24 hoursOf course that will end the idea that three 8 hour shifts = 24 hours Some mines use 2 work shifts and a maintenance shiftSome mines use 2 work shifts and a maintenance shift If they are 8 hour shifts you might get 14 or 15 hours – not 16 with hot seat change outsIf they are 8 hour shifts you might get 14 or 15 hours – not 16 with hot seat change outs Some mines use 10 hour shiftsSome mines use 10 hour shifts Works with 4 days on and 3 off schedules – may not be accommodating to workers with fixed weekend needs (Saturday or Sunday Church for example)Works with 4 days on and 3 off schedules – may not be accommodating to workers with fixed weekend needs (Saturday or Sunday Church for example) Can probably get 18 or 19 hoursCan probably get 18 or 19 hours Often run two 10 hour work shifts with a 8 hour maintenanceOften run two 10 hour work shifts with a 8 hour maintenance

More Shift Issues Day-Light hoursDay-Light hours Lower 48 U.S. usually have around 10 or better of some type of daylightLower 48 U.S. usually have around 10 or better of some type of daylight Not an issue if you have an artificial light gridNot an issue if you have an artificial light grid Counting on running massive haul trucks off of “head-lights” is not likely or safeCounting on running massive haul trucks off of “head-lights” is not likely or safe Do you have an artificial light system?Do you have an artificial light system? If your planning the mine is that light system in your cost projections?If your planning the mine is that light system in your cost projections? Many quarries lack artificial light so 10 hour days is almost forced on themMany quarries lack artificial light so 10 hour days is almost forced on them If you are in the Arctic Circle you have whole months with no lightIf you are in the Arctic Circle you have whole months with no light

My Assumption 21 hours per day21 hours per day It’s a three 8 hour shift schedule without hot seat change outs and planned non-utilized time.It’s a three 8 hour shift schedule without hot seat change outs and planned non-utilized time. Often your days per year and hours per day decisions are not independent of each otherOften your days per year and hours per day decisions are not independent of each other

The Shift Efficiency Issue Reality is you never get 100% work time to match a scheduleReality is you never get 100% work time to match a schedule First factor is “Available”First factor is “Available” The fact that I planned on using something does not guarantee it will be runningThe fact that I planned on using something does not guarantee it will be running Second factor is “Utilized of Available”Second factor is “Utilized of Available” There are scheduling complexities – you seldom use something just because its runningThere are scheduling complexities – you seldom use something just because its running Third factor is “Shift Efficiency”Third factor is “Shift Efficiency” Workers are required by law and biology to have breaks in an 8 or 10 hour periodWorkers are required by law and biology to have breaks in an 8 or 10 hour period Typically you get about 50 minutes out of every hour – about 83- 84%Typically you get about 50 minutes out of every hour – about 83- 84%

Cat FPC Cat FPC has “shift efficiency”Cat FPC has “shift efficiency” I put in 83%I put in 83% The program builds “shift efficiency into every shift”The program builds “shift efficiency into every shift” Don’t use this to cover planning related non-utilization when equipment is available – non-use is seldom evenly spread across every shiftDon’t use this to cover planning related non-utilization when equipment is available – non-use is seldom evenly spread across every shift Legal and biological breaks are distributed across and shift which is what FPC assumesLegal and biological breaks are distributed across and shift which is what FPC assumes FPC will use shift efficiency to make sure your tires don’t overheatFPC will use shift efficiency to make sure your tires don’t overheat If you use “shift efficiency” to cover unevenly spaced scheduling difficulties you may blow-out tires in the field when you try to implement the planIf you use “shift efficiency” to cover unevenly spaced scheduling difficulties you may blow-out tires in the field when you try to implement the plan

More on FPC Although We Have not Seen it Yet FPC allows you to identify percentage availableAlthough We Have not Seen it Yet FPC allows you to identify percentage available Ie – allow for what % of the time the equipment is in running orderIe – allow for what % of the time the equipment is in running order Note FPC does not have “Utilized of Available”Note FPC does not have “Utilized of Available” You have to build that into your working hours per year entry (which I tried to do by scheduling 21 hours per day for three 8 hour shifts)You have to build that into your working hours per year entry (which I tried to do by scheduling 21 hours per day for three 8 hour shifts)

The Last Issues are Bunching and Operator Efficiency

What Is Bunching? If you have 5 trucks and one loader in theory the loader always has a truck available and when-ever a truck arrives the previous truck is just pulling away.If you have 5 trucks and one loader in theory the loader always has a truck available and when-ever a truck arrives the previous truck is just pulling away. But this requires perfect spacing between trucksBut this requires perfect spacing between trucks Drivers tend to congregate, three trucks may arrive to be loaded and have to waitDrivers tend to congregate, three trucks may arrive to be loaded and have to wait Then the loader has all the trucks away and nothing to load intoThen the loader has all the trucks away and nothing to load into This is called BunchingThis is called Bunching It reduces the theoretically possible productionIt reduces the theoretically possible production

FPC and Bunching Cat did extensive studies on production losses from bunchingCat did extensive studies on production losses from bunching It is one of the few programs to build bunching losses into predicted Production.It is one of the few programs to build bunching losses into predicted Production. I picked average (which means to use the Cat typical statistics)I picked average (which means to use the Cat typical statistics) I could pick “none” and not using bunching losses at all (but they will likely happen anyway)I could pick “none” and not using bunching losses at all (but they will likely happen anyway) I could pick “min”I could pick “min” I could pick “max” – more typical of what would happen if the road was congested and did not allow passingI could pick “max” – more typical of what would happen if the road was congested and did not allow passing

Operator Efficiency The Truck speed is limited by its own engine size and drive train limitsThe Truck speed is limited by its own engine size and drive train limits Or by road imposed speed limitsOr by road imposed speed limits Trucks usually don’t travel at the maximum possible speedTrucks usually don’t travel at the maximum possible speed Cat has compiled statistics on the ratio and found it to be a function of distance.Cat has compiled statistics on the ratio and found it to be a function of distance. I picked the button to use the Cat empirical studyI picked the button to use the Cat empirical study I could alternately choose a fixed percentage of the ratio of my average speed to the theoretical maximum speed.I could alternately choose a fixed percentage of the ratio of my average speed to the theoretical maximum speed.

Note! There are 4 quick to enter numbers on the first panel that have huge policy and practice implicationsThere are 4 quick to enter numbers on the first panel that have huge policy and practice implications Fill those numbers out with a full understanding of what you are planningFill those numbers out with a full understanding of what you are planning Don’t just blow them off and expect to get good results.Don’t just blow them off and expect to get good results.

FPC is Set Up By Moving Directly Across the Tabs at the Top Now we go to Fleet Input

You Can Try Different Fleets of Trucks Each fleet has a name you give it – and a description you or your team use to keep Straight what you are doing.

Now Start Building Your Fleet – Click Add Hauler

The Select Hauler Window Opens I wanted a Cat Standard Machine (others require user input) I wanted a Truck (When I select this the blue list Below opens) And obviously for my Cat 793 Fleet I wanted a Cat 793.

A Bunch of Truck Specific Default Data Comes Up Note that this is where I get access To the working availability time Of the truck unit.

Availability Considerations Newer trucks tend to have higher availabilityNewer trucks tend to have higher availability 90 to 95%90 to 95% Some people “rent fleets and simply pay a cost per ton – Cat maintains and usually guarantees around 95% availabilitySome people “rent fleets and simply pay a cost per ton – Cat maintains and usually guarantees around 95% availability Old highly worn trucks tend to drop down to about 60%Old highly worn trucks tend to drop down to about 60% 85% is usually regarded as an old middle of the road average standby85% is usually regarded as an old middle of the road average standby In a more complex run I could change the value as my fleet aged.In a more complex run I could change the value as my fleet aged.

I’m Using an old 85% Middle of the Road I will now move on And select my loader. Interesting note – I am Holding out on inputting My number of trucks And cost data till I get An idea of how many I need.

On the Select Loader Panel I will again pick Cat Standard Machines I’m going to try a Cable Shovel first It brings up the P+H line At this point we need a Discussion on matching Trucks and shovels.

The Loader and Truck Need to Be A Match The Loader Should be able to fill the truck in a reasonable number of passesThe Loader Should be able to fill the truck in a reasonable number of passes The Loader Should be able to lift the load up over the side of the truck and dump the material in.The Loader Should be able to lift the load up over the side of the truck and dump the material in. At this point we better have our Cat Handbook handy.At this point we better have our Cat Handbook handy.

Need to Fill in a Reasonable Number of Passes If you fill a truck with less than 3 passes you can’t get the load distributed – you’ll kill the suspension system in the truckIf you fill a truck with less than 3 passes you can’t get the load distributed – you’ll kill the suspension system in the truck If you take too many passes to fill the truck will spend a large part of its cycle time sitting to be loaded.If you take too many passes to fill the truck will spend a large part of its cycle time sitting to be loaded. Guidelines exist as to what tends to be workableGuidelines exist as to what tends to be workable Cable Shovels (3 to 4 passes)Cable Shovels (3 to 4 passes) Hydraulic Shovels (4 or 5 passes)Hydraulic Shovels (4 or 5 passes) FEL (4 to 6 passes)FEL (4 to 6 passes) Backhoes (often 5 to 7 passes)Backhoes (often 5 to 7 passes) Looks like we’ll be shooting around 3 or 4 passes.Looks like we’ll be shooting around 3 or 4 passes.

But How Much Will The Truck Hold? A Truck can be Weight or Volume LimitedA Truck can be Weight or Volume Limited Which depends on the materialWhich depends on the material Our Cat 793 holds 169 cubic yards just in the bed, but 230 cubic yards if you heap it and it can carry 250 tons.Our Cat 793 holds 169 cubic yards just in the bed, but 230 cubic yards if you heap it and it can carry 250 tons.

Material Weights Tables Exist in Many Handbooks This one is from the Caterpillar Performance Handbook Porphyry Copper ore is Granite- Like 2800 lbs/cubic yard loose 4600 lbs/cubic yard bank With a “load factor” of 0.61

A Material Caution In place rock is a solid with only internal air spaces and poresIn place rock is a solid with only internal air spaces and pores For loading and hauling rock tends to break into chunks that have air spaces between themFor loading and hauling rock tends to break into chunks that have air spaces between them If you’ve ever tried to put dirt back in a hole after digging it out you know what “Swell” meansIf you’ve ever tried to put dirt back in a hole after digging it out you know what “Swell” means

Always Distinguish Between Bank and Loose Volume The difference between bank and loose weight is huge Saw some students foul up homework by looking on the internet And grabbing a weight number with no idea what it was. Many Internet numbers are bank weights since loose weights are often Important only in mine planning.

In Our Case We Are Given the Loose Weight 2800 lbs per cubic yard2800 lbs per cubic yard 169 cubic yards * 2800 lbs/yd^3 / 2000 lbs/ton169 cubic yards * 2800 lbs/yd^3 / 2000 lbs/ton 237 tons237 tons Rated weight for truck is 250Rated weight for truck is 250 Because this truck hit the volume limit before the weight it is called Volume limitedBecause this truck hit the volume limit before the weight it is called Volume limited I bet you can guess what would happen if we were weight limitedI bet you can guess what would happen if we were weight limited We’ll we don’t have to – if we heap it a little we can get up to 230 cubic yardsWe’ll we don’t have to – if we heap it a little we can get up to 230 cubic yards

Continuing Our Calculation 230 * 2800 / 2000 = 322 tons > 250 tons230 * 2800 / 2000 = 322 tons > 250 tons Reality is that this truck is weight limitedReality is that this truck is weight limited We can slightly over or underfill a truckWe can slightly over or underfill a truck Less than 95% of rated weight usually wasting truck carrying capacityLess than 95% of rated weight usually wasting truck carrying capacity More than 105% of rated weight and you’ll tear up the suspensionMore than 105% of rated weight and you’ll tear up the suspension Usually a good idea to aim for the middle and allow the play for iregularities in loadingUsually a good idea to aim for the middle and allow the play for iregularities in loading

More Calculations on the Side 250 tons *2000 /2800 lbs/cubic yard250 tons *2000 /2800 lbs/cubic yard I need about 179 cubic yards to fillI need about 179 cubic yards to fill Now my loader needs to do this in an integer number of passesNow my loader needs to do this in an integer number of passes 3.5 passes is not a real number, I can only dump dippers of material in integer amounts3.5 passes is not a real number, I can only dump dippers of material in integer amounts

How Much Can a Bucket or Dipper Hold? That depends on the material its diggingThat depends on the material its digging And on the degree of control the operator has for the bucket through the dig pathAnd on the degree of control the operator has for the bucket through the dig path A Bucket or Dipper has a manufacture rated capacity based on the volume of the BucketA Bucket or Dipper has a manufacture rated capacity based on the volume of the Bucket But filling up all that space exactly is a trickBut filling up all that space exactly is a trick We have “Fill Factors” that give the percentage of the capacity that actually gets used.We have “Fill Factors” that give the percentage of the capacity that actually gets used.

By Material and Machine Type The Hydraulic shovel can pivot its bucket in most of the ways you can pivot your hand – helps get a good fillThe Hydraulic shovel can pivot its bucket in most of the ways you can pivot your hand – helps get a good fill It has the best fill factorsIt has the best fill factors Loose material out of stock-pile 100 to 110% (also written 1 to 1.1)Loose material out of stock-pile 100 to 110% (also written 1 to 1.1) You do need an unusual material stacking angle to get over 100% (the bucket is already rated heaped)You do need an unusual material stacking angle to get over 100% (the bucket is already rated heaped) Average well-blasted bank 0.95 to 1Average well-blasted bank 0.95 to 1 Hard digging 0.9 to.95Hard digging 0.9 to.95 Very hard digging – blocky and poorly blasted 0.85 to.9Very hard digging – blocky and poorly blasted 0.85 to.9

Moving Down the List Cable Shovels come in next – the dipper pushes through on the end of a rigid armCable Shovels come in next – the dipper pushes through on the end of a rigid arm But the Bucket is rated on struck capacity – not heaped.But the Bucket is rated on struck capacity – not heaped. Loose Stockpile Like MaterialsLoose Stockpile Like Materials Sand and Gravel 0.95 to 1Sand and Gravel 0.95 to 1 An unconsolidated face with a few boulders 0.9 to 0.95An unconsolidated face with a few boulders 0.9 to 0.95 Well Blasted Rock – called Hard digging for a Cable Shovel – 0.8 to 0.9Well Blasted Rock – called Hard digging for a Cable Shovel – 0.8 to 0.9 Poor Blasted with interlocking large blocks – called very hard digging 0.7 to 0.8Poor Blasted with interlocking large blocks – called very hard digging 0.7 to 0.8

Our Worst The Front End LoaderThe Front End Loader It has little pivot and a bucket as wide as the machineIt has little pivot and a bucket as wide as the machine It has to use its drive system to try and ram into what it digsIt has to use its drive system to try and ram into what it digs StockpilesStockpiles Uniform moist or sand-like 0.95 to 1Uniform moist or sand-like 0.95 to 1 ¼ inch uniform pee gravel 0.9 to 0.95¼ inch uniform pee gravel 0.9 to 0.95 Larger sizes 0.85 to 0.9Larger sizes 0.85 to 0.9 Well blasted face – easy to dig 0.8 to 0.95Well blasted face – easy to dig 0.8 to 0.95 Average blasted rock face – 0.75 to 0.9Average blasted rock face – 0.75 to 0.9 Poor blasting – 0.6 to 0.75Poor blasting – 0.6 to 0.75 Very hard digging - won’t go through at allVery hard digging - won’t go through at all Of course operator ability can play any of these numbers toward the top or bottom of the rangeOf course operator ability can play any of these numbers toward the top or bottom of the range

Consider a Cable Shovel Match for Our Truck A 4100 has a 56 yard bucketA 4100 has a 56 yard bucket Average blasted face about 0.85 fill (0.8 to 0.9)Average blasted face about 0.85 fill (0.8 to 0.9) Target is 179 cubic yardsTarget is 179 cubic yards 3 passes – 143 cubic yards3 passes – 143 cubic yards 4 passes – 190 cubic yards4 passes – 190 cubic yards We are betweenWe are between If we got 0.9 fill 3 passes would hit 151 cubic yardIf we got 0.9 fill 3 passes would hit 151 cubic yard It will be 4 passesIt will be 4 passes 179 / 4 = 44.75 cubic yards179 / 4 = 44.75 cubic yards 44.75 / 56 = 0.8 well within range for our expected digging44.75 / 56 = 0.8 well within range for our expected digging Note at the very end the fill factor must match a loaded truck with an integer number of dipper passesNote at the very end the fill factor must match a loaded truck with an integer number of dipper passes

Considering Other Shovel Sizes I had thought about a 2800XP but I’m already at 4 passes with a 56 cubic yard bucket so a 39 yard not a good candidateI had thought about a 2800XP but I’m already at 4 passes with a 56 cubic yard bucket so a 39 yard not a good candidate I had also thought of the really big 5700XP with a 70 yard bucketI had also thought of the really big 5700XP with a 70 yard bucket 70*3*.85 = 179 cubic yards70*3*.85 = 179 cubic yards I can do a 4100 with 4 passesI can do a 4100 with 4 passes Or a 5700 with 3 passesOr a 5700 with 3 passes

I Picked the Midsize 4100 If I wanted to try More than one Fleet I could Select Add New Fleet and then Pick my 793 Matched to a 5700

Now I Need to Deal with Availability Cable Shovels today use modular solid state electronicsCable Shovels today use modular solid state electronics Boards can be swapped out fast and sent for rebuildBoards can be swapped out fast and sent for rebuild Structural design of Cable Shovel is SimpleStructural design of Cable Shovel is Simple Does not have a lot of dirt sensitive highly stressed hydrualicsDoes not have a lot of dirt sensitive highly stressed hydrualics 90 to 95% availability should be fairly easy90 to 95% availability should be fairly easy (old units with motor generator sets more like 80 to 85%)(old units with motor generator sets more like 80 to 85%)

Remaining Panel Issues Does your haul Road allow trucks To pass? (This is highly Related to your Mines traffic Control plan) I could include support equipment for this fleet within FPC or deal with it somewhere else – don’t miss it in your plan I’m deliberately Bypassing the Exact number Of trucks or Loaders and Their cost.

Why am I bypassing? FPC is designed with the intent you put the cost of your equipment in nowFPC is designed with the intent you put the cost of your equipment in now It also is designed with the idea that you guess a number of unitsIt also is designed with the idea that you guess a number of units Personal StylePersonal Style I like to go quick and dirty and get routines to tell me about what number of units to tryI like to go quick and dirty and get routines to tell me about what number of units to try Then I’ll make a second pass with more detailThen I’ll make a second pass with more detail FPC will work for a first pass rough size – and that is what I like to do. (You may be different)FPC will work for a first pass rough size – and that is what I like to do. (You may be different)

What is This Support Equipment Issue? Trucks 250 ton and up are called Super TrucksTrucks 250 ton and up are called Super Trucks They are very productive and have longer lives than an average truckThey are very productive and have longer lives than an average truck They also depend on a solid haul-roadThey also depend on a solid haul-road That means you are doing sub-bases and almost designing the haul roads like highwaysThat means you are doing sub-bases and almost designing the haul roads like highways Means for road work I have dozers and road graders and probably a compactorMeans for road work I have dozers and road graders and probably a compactor Dirt roads probably mean I have water trucks both for environmental reasons and also to moisted road base for maximum compactionDirt roads probably mean I have water trucks both for environmental reasons and also to moisted road base for maximum compaction

Other Support Cable and Hydraulic Shovels are messy creaturesCable and Hydraulic Shovels are messy creatures They spill part of their rockThey spill part of their rock Some sort of front end loader or scoop is used to collect spillsSome sort of front end loader or scoop is used to collect spills If the loader is large enough it loads into trucksIf the loader is large enough it loads into trucks If you allow rock to build up in your loading area it will cut your truck tiresIf you allow rock to build up in your loading area it will cut your truck tires There are about 40,000 + good reasons to not want that to happen ($$$$)There are about 40,000 + good reasons to not want that to happen ($$$$)

Decisions about Support Equipment in FPC I generally do not do my support equipment in FPCI generally do not do my support equipment in FPC My road requirements are a function of my road length and how often I have to relocate roadsMy road requirements are a function of my road length and how often I have to relocate roads These functions are more associated with my mine plan than the number of trucks in my fleetThese functions are more associated with my mine plan than the number of trucks in my fleet My clean-up loader is sensitive to the position of my loading points and where else in the mine I may use them.My clean-up loader is sensitive to the position of my loading points and where else in the mine I may use them. I keep them out of FPC because I find their specifications tend not to correlate well with exactly what I’m doing with my trucks and loaders.I keep them out of FPC because I find their specifications tend not to correlate well with exactly what I’m doing with my trucks and loaders.

When I Try to Move On I Get a Hysterical Message My loader and truck Costs are zero. FPC really likes me to Enter now – but I’m A rough first pass Designer I’ll tell it Ok and move On.

What’s Under Those Subtabs It’s the rimpull and Retarder curves for The truck. (If I did not pick Cat standard I would Get to enter this stuff Myself)

On to the 3 rd Tab In this tab I will describe the road that my trucks must travel to deliver their ore or waste Loads.

Name the Course and the Amount of Material I’m going to consider the route For ore to the mill. I know from some things in the Next unit that I will be moving Around 9,000,000 tons of ore.

Input My Information If I already know my material loose And bulk density I can enter it Direct. Or I can click select material To use Caterpillar’s built in data Base.

On the Material Window I select broken Granite as most Similar to porphyry Copper ore. Once I have selected Granite Ok becomes Available to click.

Now I Need to Describe My Haulage Route I will need to identify the length of the segment, the grade resistance, A rolling resistance, a speed limit (if needed), and a description (which Comes in very handy during later review)

How do I Divide a Continuous Road into Segment? Road Segments Divide WhenRoad Segments Divide When There is a major change in grade (slope)There is a major change in grade (slope) There is a major change in underfoot conditionsThere is a major change in underfoot conditions There is a major change in vehicle operating considerationsThere is a major change in vehicle operating considerations StartingStarting StoppingStopping Major TurnsMajor Turns

What is Major? Depends in part on what you are doingDepends in part on what you are doing Computer Methods favor greater detailComputer Methods favor greater detail Hand methods favor more moderationHand methods favor more moderation Good intuitive Check is whether sustained enough to change vehicle speedGood intuitive Check is whether sustained enough to change vehicle speed

My Haulage Profile My loading bench is level and I will go 550 feet to the ramp to get out of the pit.My loading bench is level and I will go 550 feet to the ramp to get out of the pit. Issue #1 – part of that distance will be in a congested loading areaIssue #1 – part of that distance will be in a congested loading area I will probably want a speed limit on that area different than for the bench as a wholeI will probably want a speed limit on that area different than for the bench as a whole

My First 150 feet in a Congested Loading Area Another line appeared for more of the route. I entered 0% grade Because the bench itself is level. Now I need a speed limit

Congested Area Guidelines (From Surface Mining - First Edition) I’m going to consider my conditions average.

Enter the Data and a Description Now I need to deal with grade and rolling resistance

Roads Produce Forces that Influence Vehicle Movement Roads slope up hill and downRoads slope up hill and down This will cause gravity to work for or against the forward movement of the truckThis will cause gravity to work for or against the forward movement of the truck It is called grade resistanceIt is called grade resistance The common unit of Grade Resistance is %The common unit of Grade Resistance is % Example – if a road goes up 1 foot for every 10 feet of distance it is called 10% grade (note that 1 is 10% of 10)Example – if a road goes up 1 foot for every 10 feet of distance it is called 10% grade (note that 1 is 10% of 10) Note that we are not using slope anglesNote that we are not using slope angles

Other Forces Trucks are subject to wind or air resistanceTrucks are subject to wind or air resistance Air resistance increases dramatically with speedAir resistance increases dramatically with speed For a car going 70 mph wind resistance is one of the largest opposing forcesFor a car going 70 mph wind resistance is one of the largest opposing forces Haul trucks lumber along at slow paces and wind resistance is usually considered 0 for an engineering approximation.Haul trucks lumber along at slow paces and wind resistance is usually considered 0 for an engineering approximation.

Rolling Resistance Tires Sink into Ground - softer ground sink moreTires Sink into Ground - softer ground sink more Tires FlattenTires Flatten Driving uphill out of a rut on a flat tire spotDriving uphill out of a rut on a flat tire spot Need to Know Underfoot conditions and Type of Tire (Radial or Bias Ply)Need to Know Underfoot conditions and Type of Tire (Radial or Bias Ply)

Grade Resistance in % Number of feet up (or down) for every so many feet forward (or backward).Number of feet up (or down) for every so many feet forward (or backward). I’m on a level bench so I go up 0 feet for every 100 feet – thus my grade resistance is 0%I’m on a level bench so I go up 0 feet for every 100 feet – thus my grade resistance is 0% Rolling Resistance will depend on the road and the tires.Rolling Resistance will depend on the road and the tires.

Hard Smooth Stabilized Surface I like 1.7 for our established haul road with Radial tires

Enter the Information Next 400 more feet across the bench.

Enter the Data Now what about the grade resistance – what is positive and what is Negative?

Sign Conventions and Resistance Standard ConventionStandard Convention A positive resistance resists motionA positive resistance resists motion A negative resistance favors motionA negative resistance favors motion Note that rolling resistance will always be positive because it always resists motion no matter what the directionNote that rolling resistance will always be positive because it always resists motion no matter what the direction That 10% grade out of the pit is +10That 10% grade out of the pit is +10 That 5% grade down the canyon is -5That 5% grade down the canyon is -5

Now We Need to Do the Return Route I will click on The return Radio button If the haul road Back is unique I enter as before If I just reverse Directions I can Click Mirror Haul Road (and It reverses route)

The Forth Tab Lets you Match a Truck Fleet and Route for Study Since we have only entered one of each this is not to big a choice. If you’ve entered more Than one route or truck fleet you could have quite a few choices.

Tab 5 – Production and Costs has Large Number of Subtabs As before you generally work the subtabs left to right.

Oddity #1 – Double Select Buttons The select process is really two tear. The select tab lets you create a subset of cases to work With. Ultimately FPC can only do one case at a time – the second select picks one from the Sublist we created. (Again my one truck one road combo is boring).

One of the Most Critical Tabs The Cycle Time Tab is Where We Deal with Load Time, Dump Time, and any fixed Delay times on the route.

Before We Will Be Allowed to Do Anything We Must Disclose Our Unload Time FPC will start blocking your Other inputs on the page Until you cooperate.

Typical Unloading Arrangements Back the truck up – line it up with a dump point and dump into the pointBack the truck up – line it up with a dump point and dump into the point Such as back-up to a gyratory crusher and dump into it.Such as back-up to a gyratory crusher and dump into it. Requires precise placementRequires precise placement Depending on number of open gyratory dump points trucks may have to wait for a previous truck to get clear.Depending on number of open gyratory dump points trucks may have to wait for a previous truck to get clear. Back up to a general point and dumpBack up to a general point and dump Such as backing up to the edge of a leaching pile and then dumping material over the sideSuch as backing up to the edge of a leaching pile and then dumping material over the side Requires less – line upRequires less – line up Usually more open space and not forced to wait for a truck in front of themUsually more open space and not forced to wait for a truck in front of them

Unloading TailgateTailgate The truck dumps pulling forward and spreading load behind it.The truck dumps pulling forward and spreading load behind it. May or may not require a total stop of the truckMay or may not require a total stop of the truck Truck is moving forward and avoids backing manuverTruck is moving forward and avoids backing manuver Truck ends its unload cycle already in motionTruck ends its unload cycle already in motion Pull forward to dump pointPull forward to dump point Pull over a dump point and unloadPull over a dump point and unload Usually done with bottom dump trucksUsually done with bottom dump trucks

Size of Truck and Difficulty of Maneuver Control Time Typical Mining Truck can dump the bed in about 30 secondsTypical Mining Truck can dump the bed in about 30 seconds Big lumbering one might be closer to 40.Big lumbering one might be closer to 40. A general backing maneuver takes about 30 secondsA general backing maneuver takes about 30 seconds Make it more like 45 seconds if the dump target is small or the truck real bigMake it more like 45 seconds if the dump target is small or the truck real big Make it about 1 minute if I have to wait for another truck to clear out firstMake it about 1 minute if I have to wait for another truck to clear out first If you can just pull forward and stop on a point it can probably beat 10 secondsIf you can just pull forward and stop on a point it can probably beat 10 seconds

My Case I’ll assume I back up to one of two gyratory crushers and dump into the crusherI’ll assume I back up to one of two gyratory crushers and dump into the crusher I have 2 gyratories so I won’t have a wait time.I have 2 gyratories so I won’t have a wait time. I do have a big truck backing up to a small specific targetI do have a big truck backing up to a small specific target 45 seconds45 seconds I have a big truck bed so I’m about 40 seconds to dumpI have a big truck bed so I’m about 40 seconds to dump Total – about 1.5 minutesTotal – about 1.5 minutes

Input and Enter and I Get My First Truck Cycle Estimate Note that my dump strategy means I will make a full stop at the end Of my haul and will be starting my Return trip from a full stop Position (This would not be true of all Unloading arangements)

Now We Reconcile Loader Passes, Fill Factors and Truck Volumes We have discussed the Principles before but now We have to get it right.

I Remember I Needed 4 Passes at 80% Fill Note – this is a great place to Find or commit a screw-up. If my loader was a lousy Match for my truck I’m going To get a bad number of Passes. The program does not check To see if your fill factor is Realistic for your material. You can input garbage – but Guess what you’ll get! You must work this till you get an integer number of passes. The program will not check you.

Now I Need to Deal with My Load Time The times that come up on the list are for smaller loaders doing single truck Loading under ideal conditions.

The Loader Cycle Time How Long Does it Take a Loader to take a scoop – turn – dump it in a truck and return to a ready position for the next scoop.How Long Does it Take a Loader to take a scoop – turn – dump it in a truck and return to a ready position for the next scoop. Hydraulic Shovels have fastest movementHydraulic Shovels have fastest movement About 20 seconds for a little one with an easy digAbout 20 seconds for a little one with an easy dig About 35 for a big oneAbout 35 for a big one Front End Loaders are worst – they have to back, maneuver and scoop.Front End Loaders are worst – they have to back, maneuver and scoop. About 40 seconds for a small oneAbout 40 seconds for a small one About 50 seconds for a big oneAbout 50 seconds for a big one

For A Cable Shovel Graph of Dipper Size and Digging Conditions for Impact on one Loader Cycle.

But Wait – There is More Most manufactures cheat on published dataMost manufactures cheat on published data (This does not impact front end loaders)(This does not impact front end loaders) They assume the angle between the digging face and dump point is 90°They assume the angle between the digging face and dump point is 90° For the most common configurations the angle is 120° so the swing time is longerFor the most common configurations the angle is 120° so the swing time is longer To adjust for 120° swing the published cycle needs to be multiplied by 1.1 to 1.2To adjust for 120° swing the published cycle needs to be multiplied by 1.1 to 1.2

Getting My Number I Have a Cable Shovel with a 56 yard dipperI Have a Cable Shovel with a 56 yard dipper I’m assuming an average blasted face which is “Hard Digging” for a Cable ShovelI’m assuming an average blasted face which is “Hard Digging” for a Cable Shovel I’ll be about 32 seconds * 1.15 About 37 seconds

Now Lets Consider the Hauler Exchange This is the time it takes one truck to pull away and then another to move in and Spot and be ready to load. For larger trucks this is more like 1 minute rather than 0.7 This leads to what is the First Bucket Dump?

First Bucket Dump It is assumed that during the lag time when one truck is pulling out and another Pulling in that the loader is getting a scoop of material ready. When the truck is Positioned only the short time to dump the dipper is involved.

Actual Times Depend on Field Loading Configurations Depends on the type of equipment usedDepends on the type of equipment used On the space availableOn the space available Shovels and Hydraulic Excavators tend to load in one set of waysShovels and Hydraulic Excavators tend to load in one set of ways Backhoes have some variationsBackhoes have some variations FEL have some unique onesFEL have some unique ones

Single Truck Loading Loader near the face Truck backs up next to the loader on the drivers side (Gives the loader operator a better view Loader working into cut in the face Loader swings about 120 degrees to dump

Advantages of Single Truck Loading SimpleSimple Truck doesn’t have to back tires into the rockiest areasTruck doesn’t have to back tires into the rockiest areas The shovel faces armor of the tracks into the dig faceThe shovel faces armor of the tracks into the dig face Shovel operator has optimized view of truck bed targetShovel operator has optimized view of truck bed target

Disadvantages of Single Truck Loading Backing into place can take around 1 minute and may require a spotterBacking into place can take around 1 minute and may require a spotter Loaders expensive and idleLoaders expensive and idle Back time is an unproductive bottleneckBack time is an unproductive bottleneck Can form large ques because trucks tend to bunchCan form large ques because trucks tend to bunch 120 degree swing angle can be slow120 degree swing angle can be slow Manufactures often rate on 90 degreeManufactures often rate on 90 degree

More Disadvantages Limited Space Available for Oversize MaterialLimited Space Available for Oversize Material Can set to sideCan set to side Do a bowling ball drop into truckDo a bowling ball drop into truck Hydraulic shovels can set - but cable shovels drop bucket bottom openHydraulic shovels can set - but cable shovels drop bucket bottom open Extension cord problems with electric equipmentExtension cord problems with electric equipment Cord has to cut across truck pathCord has to cut across truck path Putting on poles can cost timePutting on poles can cost time

Using Single Truck Loading in FPC It’s easy – the screen layout assumes single truck loadingIt’s easy – the screen layout assumes single truck loading Do it just like we just finished doing.Do it just like we just finished doing.

Double Truck Loading Same Arrangement as single truck loading only the trucks pull up on both sides

Advantages of Double Truck Loading Second Loading Spot Allows a second truck to spot during loading operationsSecond Loading Spot Allows a second truck to spot during loading operations Avoids dead time on the loaderAvoids dead time on the loader Doesn’t help the truck cycle time other than eliminating some queingDoesn’t help the truck cycle time other than eliminating some queing

Disadvantages of Double Truck Loading Still have extension cord problems on electric unitsStill have extension cord problems on electric units Oversize boulder problem is now even more severeOversize boulder problem is now even more severe Forces Loader operator to load on the blind side (most big loaders put the cab to one side of equipment)Forces Loader operator to load on the blind side (most big loaders put the cab to one side of equipment)

Doing Double Truck Loading in FPC Loader cycle timeLoader cycle time On one side of the truck the loader operator will not actually be able to see the truck bed till he/she is on top of itOn one side of the truck the loader operator will not actually be able to see the truck bed till he/she is on top of it Shovel Cab Truck Note how late the operator will Be in actually seeing his dump Target. You’ll need to slow the cycle down About 5 to 10%

Double Truck Loading in FPC Hauler Exchange timeHauler Exchange time By having a second load point the loaders wait for another truck drops to 0By having a second load point the loaders wait for another truck drops to 0 Hauler Exchange time goes to 0Hauler Exchange time goes to 0 Side EffectSide Effect First Bucket Dump now takes the full cycle time since the loader did not have a time break while trucks backed in.First Bucket Dump now takes the full cycle time since the loader did not have a time break while trucks backed in.

Another Impact The Loader has no truck wait timeThe Loader has no truck wait time The truck may not wait for another truck to pull out but backing into place still puts about 30 to 45 seconds onto a truck cycleThe truck may not wait for another truck to pull out but backing into place still puts about 30 to 45 seconds onto a truck cycle For single truck loading FPC automatically adds the loader exchange time to both the truck and the loader.For single truck loading FPC automatically adds the loader exchange time to both the truck and the loader. By zeroing that time for the loader – I have lost the back time for the truckBy zeroing that time for the loader – I have lost the back time for the truck

I Need to Add This Time Back for My Truck I would add about 0.75 minutes Into my dump and maneuver time (even though the extra Maneuver is actually at the load Point).

If You Get The Feeling I’m Forcing FPC to do Something it was not Designed For Your RightYour Right FPC was designed assuming all trucks use single truck loadingFPC was designed assuming all trucks use single truck loading They left a loop-hole large enough to allow it to do something else.They left a loop-hole large enough to allow it to do something else.

Drive By Truck Loading Shovel Lines up Along the face Trucks pull forward and stop beside the loader Shovel Swings 90 to 180 degrees to dump

Advantages to Truck Drive-By Greatly Reduced Spotting Time - no backing cycleGreatly Reduced Spotting Time - no backing cycle Cable doesn’t cross the Trucks PathCable doesn’t cross the Trucks Path Can Set Oversize Beside and out of the wayCan Set Oversize Beside and out of the way Machine marches on a steady forward advanceMachine marches on a steady forward advance Can do in a narrower space – your working benches don’t have to be as wide.Can do in a narrower space – your working benches don’t have to be as wide.

Disadvantages of Drive -By Often have problems with dipper swinging over the top of the drivers cabOften have problems with dipper swinging over the top of the drivers cab Loader gets revenge for the truck running over its extension cordLoader gets revenge for the truck running over its extension cord If the dipper comes open your truck driver can get deadIf the dipper comes open your truck driver can get dead Trucks get to drive those expensive tires through spillsTrucks get to drive those expensive tires through spills

More Disadvantages Lack of spotting makes it a one shot that can lead to long swingsLack of spotting makes it a one shot that can lead to long swings Tracks are broadside to long face areaTracks are broadside to long face area

Doing Drive-By in FPC If the truck drivers stop well this will get a 90° swing – will speed up the loader cycleIf the truck drivers stop well this will get a 90° swing – will speed up the loader cycle Lower your loader cycle time about 10%Lower your loader cycle time about 10% One truck still has to pull forward and another follow inOne truck still has to pull forward and another follow in This is about a 10 to 15 second ordeal instead of a 45 second to 1 minute ordealThis is about a 10 to 15 second ordeal instead of a 45 second to 1 minute ordeal Put in a smaller timePut in a smaller time Since this affects truck and loader alike there is no need to add extra time to the truck dump and manueverSince this affects truck and loader alike there is no need to add extra time to the truck dump and manuever

FPC and Drive-By The Truck change-out time does indeed reduce the first pass time for the loaderThe Truck change-out time does indeed reduce the first pass time for the loader First Bucket Dump = Loader Cycle – Exchange TimeFirst Bucket Dump = Loader Cycle – Exchange Time Since Drive-By is often used in strip pits, Cat’s FPC accommodates it without really forcing things.Since Drive-By is often used in strip pits, Cat’s FPC accommodates it without really forcing things.

Modified Drive-By (Or Getting Fancy) Shovel in Drive-By PositionShovel in Drive-By Position Truck Drives up to Shovel as if it was a drive-byTruck Drives up to Shovel as if it was a drive-by Loading drops onto a moving targetLoading drops onto a moving target While the Loading goes for the next bite the truck backs into a single load like positionWhile the Loading goes for the next bite the truck backs into a single load like position Shortens swing distanceShortens swing distance

Advantages Get most of the positioning advantages of single truck load without the idle spot timeGet most of the positioning advantages of single truck load without the idle spot time

Disadvantages Dump onto a Moving TargetDump onto a Moving Target With swinging over cab can be a real adventurous feeling for driverWith swinging over cab can be a real adventurous feeling for driver Gets the tires into some real rocky conditionsGets the tires into some real rocky conditions

Modified Drive-By in FPC Loader cycle time – usually no changeLoader cycle time – usually no change Loader exchange time – drop to 0Loader exchange time – drop to 0 No need to add time to truck dump cycle – he spots while the loader scoopsNo need to add time to truck dump cycle – he spots while the loader scoops Loader First Bucket Time IncreasesLoader First Bucket Time Increases The loader is trying to dump onto a moving truckThe loader is trying to dump onto a moving truck

Backhoe Loading Methods Backhoe works below gradeBackhoe works below grade Can allow work to be kept off wet pit floorCan allow work to be kept off wet pit floor can also provide multi-level loadingcan also provide multi-level loading Backhoes generally need good size machine relative to bucket. Doesn’t wear as well - generally used for special conditionsBackhoes generally need good size machine relative to bucket. Doesn’t wear as well - generally used for special conditions

Can Work Double and Single Truck Loads

Can also Load on Multiple Levels

Multilevel Loading Double Loading configurationDouble Loading configuration has extra room for oversize and still two truckshas extra room for oversize and still two trucks Because truck has to come in on right level does require some additional advance data to send truck to right spotBecause truck has to come in on right level does require some additional advance data to send truck to right spot Can also get 3 position loadingCan also get 3 position loading often a bit of overkilloften a bit of overkill

FPC Handling Like Single or Double Truck LoadingLike Single or Double Truck Loading Remember to use loader cycle time suitable for backhoeRemember to use loader cycle time suitable for backhoe Since backhoe buckets tend to be small you are more likely to have 5 to 7 passes to load.Since backhoe buckets tend to be small you are more likely to have 5 to 7 passes to load.

Front End Loader Configurations FELs are less expensive than the trucks and are mobileFELs are less expensive than the trucks and are mobile Makes practical to consider more than one loader providing loading serviceMakes practical to consider more than one loader providing loading service Limited lift heights make truck match more criticalLimited lift heights make truck match more critical Tires can tear up bad underfootTires can tear up bad underfoot

Single Truck Loading

Common Loading Arrangements Drive By LoadingDrive By Loading

Arrangements Putting More Than One Loader at a Loading Point

How to Chain Load in FPC FPC assumes the number of loaders is equal to the number of load pointsFPC assumes the number of loaders is equal to the number of load points If I need 5 loaders to Chain Load a TruckIf I need 5 loaders to Chain Load a Truck Lie – tell FPC you have a loader with a load cycle time of 0.05 minutesLie – tell FPC you have a loader with a load cycle time of 0.05 minutes Tell it your loaders first bucket is also 0.05Tell it your loaders first bucket is also 0.05 (When you do enter cost tell FPC your one loader that is as fast as 5 loaders also costs as much as 5 loaders)(When you do enter cost tell FPC your one loader that is as fast as 5 loaders also costs as much as 5 loaders) When you count your loaders at the end of the computer run multiply the number of loaders by 5When you count your loaders at the end of the computer run multiply the number of loaders by 5 This gets the truck loaded in the right timeThis gets the truck loaded in the right time The problem is if the program sends another truck to be loaded 0.25 minutes later the loaders will not be ready to chain load (it takes each loader about 0.75 minutes to really scoop material and load it).The problem is if the program sends another truck to be loaded 0.25 minutes later the loaders will not be ready to chain load (it takes each loader about 0.75 minutes to really scoop material and load it).

Building in loader lag time Of the 0.75 minutes a real cycle takes about 0.05 is the dumpOf the 0.75 minutes a real cycle takes about 0.05 is the dump This I did account for so I have 0.7 minutes left outThis I did account for so I have 0.7 minutes left out While other loaders are loading the first has time to start its cycleWhile other loaders are loading the first has time to start its cycle In this example I used 5 loaders to chain loadIn this example I used 5 loaders to chain load There was 4*0.05 minutes while other loaders workedThere was 4*0.05 minutes while other loaders worked Now my unaccounted time is 0.5 minuteNow my unaccounted time is 0.5 minute

Entering the Loader Lag Time Look at the Hauler exchange timeLook at the Hauler exchange time What really happens is the truck just pulls through the chain and is loaded on the flyWhat really happens is the truck just pulls through the chain and is loaded on the fly Thus there is no real hauler exchange timeThus there is no real hauler exchange time To Cope with Loader Lag TimeTo Cope with Loader Lag Time Lie – in this case say there is a hauler spot time of 0.5 minutesLie – in this case say there is a hauler spot time of 0.5 minutes This will keep FPC from sending the load point more trucks than it can really handle.This will keep FPC from sending the load point more trucks than it can really handle.

Now We Have Problems With Truck Cycle Time The truck now has 0.5 minutes added to it’s cycle that does not existThe truck now has 0.5 minutes added to it’s cycle that does not exist Lie – cut the dump time by 0.5 minutesLie – cut the dump time by 0.5 minutes Now the truck cycle time is rightNow the truck cycle time is right One more truck adjustmentOne more truck adjustment The haul end speed is about 3 to 5 Mph – not 0. The same is true of The start speed.

Tandom Loading This time I put two loaders on one truckThis time I put two loaders on one truck The truck backs between two loaders that then load it from both sidesThe truck backs between two loaders that then load it from both sides

Using Tandom Loading in FPC Tell FPC you have one loaderTell FPC you have one loader But this loaders’ cycle time is twice as fast as a normal loaderBut this loaders’ cycle time is twice as fast as a normal loader Its cost is also twice as much as a single loaderIts cost is also twice as much as a single loader When you count up the number of Loaders at the end of the run – remember to double the number of loaders you buyWhen you count up the number of Loaders at the end of the run – remember to double the number of loaders you buy The money for this was already handled when you created “one” loader that cost as much to buy and operate as 2The money for this was already handled when you created “one” loader that cost as much to buy and operate as 2

The First Bucket Load Time Problem While the truck spotted the loaders got ready to dump – thus they only need 0.05 minutes for the first bucket.While the truck spotted the loaders got ready to dump – thus they only need 0.05 minutes for the first bucket. The FPC problem – it allows one bucket to take only 0.05 minute – in reality two buckets go in at the same timeThe FPC problem – it allows one bucket to take only 0.05 minute – in reality two buckets go in at the same time Solution – LieSolution – Lie It takes about 0.7 to 1 minute to spot the truckIt takes about 0.7 to 1 minute to spot the truck Cut the time savings from the zero time second bucket off of the spotting time.Cut the time savings from the zero time second bucket off of the spotting time.

Staggered Tandom Loading As the truck comes in the first Loader hits it on the fly like it Was chain loading. The truck then spots During that time the two loaders Were filling their buckets and Are ready to go in dump time Only.

Illustrative Case Suppose the truck will take 4 passes to loadSuppose the truck will take 4 passes to load It will take the truck about 1 minute to spotIt will take the truck about 1 minute to spot During that 1 minute loader #1 has dumped the first bucket inDuring that 1 minute loader #1 has dumped the first bucket in Loaders #1 and #2 have loaded buckets and are ready to dump in 0.05 minutesLoaders #1 and #2 have loaded buckets and are ready to dump in 0.05 minutes At the end of 1.05 minutes the truck has 3 buckets in placeAt the end of 1.05 minutes the truck has 3 buckets in place

My Motion Timing Continued Now Loaders #1 and #2 go for another bucketNow Loaders #1 and #2 go for another bucket Loader #1 takes its bucket and positions for the next truckLoader #1 takes its bucket and positions for the next truck Loader #2 dumps its bucket into the truckLoader #2 dumps its bucket into the truck This takes 0.75 minutesThis takes 0.75 minutes 1.8 minutes after the truck comes in to fill – it is out the door and loader fleet is ready for the next truck1.8 minutes after the truck comes in to fill – it is out the door and loader fleet is ready for the next truck

Now Lets Try to Get That One into FPC We report the truck exchange time as 1 minuteWe report the truck exchange time as 1 minute We now have 0.8 minutes to put in 4 buckets of materialWe now have 0.8 minutes to put in 4 buckets of material Tell FPC the loader cycle time is 0.2 minutesTell FPC the loader cycle time is 0.2 minutes Tell FPC the first bucket time is 0.2 minutesTell FPC the first bucket time is 0.2 minutes Done.Done.

Front End Loaders We are not using Front End Loaders in this example – but front end loaders are a trickier match to trucksWe are not using Front End Loaders in this example – but front end loaders are a trickier match to trucks You need to check loading heightYou need to check loading height How high must the loader lift the material to get it over the side of the truck and then nicely centered in the truck bed.How high must the loader lift the material to get it over the side of the truck and then nicely centered in the truck bed.

Loading Height 21’ 5” to get over the side of a Cat 793

Check Out a 980 A 980 can only get up to about 11 feet – no go on 21.

In Fact a 994 (The Big One) Cannot Dump Above the Edge of a 793 Truck Be Careful of loading height limits for Front End Loaders

Commentary on Loading We have spent tremendous amounts of time analyzing miniscule details of such things as how a truck loads or dumps – WhyWe have spent tremendous amounts of time analyzing miniscule details of such things as how a truck loads or dumps – Why Suppose we lower the cost per ton for loading and hauling ore by 1cSuppose we lower the cost per ton for loading and hauling ore by 1c 9 million tons is $90,000 – your salary for the whole year9 million tons is $90,000 – your salary for the whole year Little parts of a cycle done millions of time each year become big differencesLittle parts of a cycle done millions of time each year become big differences

Penny Pinching In Perspective If a mine comes out non-economic the first impulse is to begin nit-picking every dimeIf a mine comes out non-economic the first impulse is to begin nit-picking every dime The decisions that shift NPVs by hundreds of millions of dollars deal with mine size, mine method, cut-off grade, and financial structureThe decisions that shift NPVs by hundreds of millions of dollars deal with mine size, mine method, cut-off grade, and financial structure If the “Air-Craft Carrier” sized decisions have been made wrong – penny pinching will usually not save the day.If the “Air-Craft Carrier” sized decisions have been made wrong – penny pinching will usually not save the day. Don’t rely on Penny Pinching to decide whether you get to “play the game”Don’t rely on Penny Pinching to decide whether you get to “play the game” Penny Pinching deals with how you play the game – after you get into the game.Penny Pinching deals with how you play the game – after you get into the game.

Understanding How Loading Relates to Other Mine Plan Issues Loading Configurations change the width of the space needed for loadingLoading Configurations change the width of the space needed for loading Drive-by is usually chosen because it works in narrower spacesDrive-by is usually chosen because it works in narrower spaces Your working bench width influences your working slope which greatly alters your stripping ratio – a major effect on economics.Your working bench width influences your working slope which greatly alters your stripping ratio – a major effect on economics. Your working bench width also controls the size of a practical mining “push-back” in an open pit mineYour working bench width also controls the size of a practical mining “push-back” in an open pit mine Sketch out your loading plan considering vehicle sizes – berm widths, prudent clearances and turning radiusesSketch out your loading plan considering vehicle sizes – berm widths, prudent clearances and turning radiuses Then pick your loading configuration.Then pick your loading configuration.

Loading Configuration and Mill Operation Some of the Loading configurations discussed can greatly alter the truck loading time.Some of the Loading configurations discussed can greatly alter the truck loading time. For an open pit where 30 minutes is a common truck cycle, saving 1 minute off of loading time will probably not revolutionize costFor an open pit where 30 minutes is a common truck cycle, saving 1 minute off of loading time will probably not revolutionize cost It can greatly alter the number of trucks that one loading point can handleIt can greatly alter the number of trucks that one loading point can handle This in turn can change the number of loading pointsThis in turn can change the number of loading points Smaller numbers of loading points or loading points close together usually cause feed quality to the mill to swing more wildly.Smaller numbers of loading points or loading points close together usually cause feed quality to the mill to swing more wildly. Mills hate unstable ore conditions and usually protest by sending recoveries to – well you know where.Mills hate unstable ore conditions and usually protest by sending recoveries to – well you know where.

Point Understand that just a few numbers going into FPC represent major decisions in how you will run the mineUnderstand that just a few numbers going into FPC represent major decisions in how you will run the mine Make wise decisions about how to run the mine and then make your FPC entries match those decisions.Make wise decisions about how to run the mine and then make your FPC entries match those decisions. Don’t just blow numbers into FPC and expect good results.Don’t just blow numbers into FPC and expect good results.

Now I Will Close In On That Rough Design I Talked About I’ll use the Fleet Size Sub-Tab what it does is Show me what I can do With a variable number Of trucks and 1 loader (Remember I wanted to Avoid committing to A number of trucks or Loaders until I had an Idea of cycle time)

Tip on a Frustration The default number Of trucks FPC tries Is 1 to 4. I wanted 1 to 10. I typed in the 10 And nothing Happened. I had to click in Another field to make The change take.

Look at Results Things I see #1 – I can reach 9 million tpy with just one loader #2 – I need 4 of 5 trucks #3 – My production per truck keeps going up fairly linearly – suggests that I am not really “over-trucking my loader”

Jump Back to My Cycle Times Tab It takes about 38 minutes for a truck To make a trip but only 3 minutes To load 38/3 = 12.67 I would need 13 trucks to over-truck My loader. (Over-truck means I have so many Trucks that the loader is the Production limit). This is under-trucked – availability of Trucks controls production.

What Did I Do? I just got the program to help me ratio my trucks and loaders without me doing any guessing or hand calculation.I just got the program to help me ratio my trucks and loaders without me doing any guessing or hand calculation. Now I’ll go back and change # of trucks to 5.Now I’ll go back and change # of trucks to 5.

Check My Fleet Production Yup – I need 87% of my scheduled Time to do 9,000,000 tons of ore With 5 trucks and one cable shovel.

Issues that Remain I need to check my Ton-Mile-Per-Hour RatingsI need to check my Ton-Mile-Per-Hour Ratings (make sure I’m not running my trucks around so fast that I overheat and blow-out the tires)(make sure I’m not running my trucks around so fast that I overheat and blow-out the tires) I need to enter my cost data and see the costI need to enter my cost data and see the cost I need to consult with my mill and ore reserve modeling people.I need to consult with my mill and ore reserve modeling people.

Why the Consult I am feeding the mill from one load point onlyI am feeding the mill from one load point only My ore reserve people can estimate the typical changes in ore grade going to the millMy ore reserve people can estimate the typical changes in ore grade going to the mill My mill people can tell me whether this will upset my recovery rates at the mill (financially upsetting the mill will cost more at most metal mines than optimizing my truck and loader fleet can save)My mill people can tell me whether this will upset my recovery rates at the mill (financially upsetting the mill will cost more at most metal mines than optimizing my truck and loader fleet can save) It is very possible we will be told that our trucks and loaders are too darn big for practical grade control at a mine this size.It is very possible we will be told that our trucks and loaders are too darn big for practical grade control at a mine this size.

Lets Put the Tire Heating Issue to Rest A Cat 793 needs 46/90R57 Tires The tire is rated at 630 ton miles per hour (ie a load of 1 ton on 1 tire traveling at 1 Mile per hour is 1 ton mile per hour) (The tables are from the Cat Handbook)

Enter This Into FPC I am going to the fleet input tab and using the Tmph Limit field.

Now For Results Go for the Production and Cost Tab and the Tire Temp Subtab.

We See the Average Number of Tons Load on Each Tire Interesting to note that it’s the front tires that take the worst load (these tires are Not double like those in back)

We Check Tire Heating at the Technical Maximum Speeds for the Truck As we can see we are just barely over-rating on the front tires.

Then We Adjust A real operator never operates the truck and mechanical theoretical maximum and A real operator does not work an 8 hour shift with no breaks (remember the 84% Shift efficiency). Assume this allows some tire cooling and we are at 82% of Tire capacity. We won’t blow out the tires. (if the temperature is 120 or 140 for long periods of time we would have to reduce The tire rating. If we ran a driverless truck we might also have an issue).

Time for the Cost Issue For this I will simply illustrate putting in information for another truck. (not our 793) but it gets the point across.For this I will simply illustrate putting in information for another truck. (not our 793) but it gets the point across.

Truck Production Costs Divided into Ownership and Operating CostsDivided into Ownership and Operating Costs Ownership includesOwnership includes Annualized Investment CostsAnnualized Investment Costs Taxes and InsuranceTaxes and Insurance Tax advantagesTax advantages Operating Costs are Incurred as Vehicle performs serviceOperating Costs are Incurred as Vehicle performs service

Operating Costs FuelFuel TiresTires LubricantsLubricants RepairRepair OperatorsOperators

Setting Costs In FPC Use the Hourly Cost Button On Fleet Input Tab

Sub Menu Divides Owning and Operating Cost

Using Menu Requires a lot of side calculations Latest Editions of Cat Handbook Has removed cost estimating Sections. Have to revert to Earlier issues (which we have Online) Lets Go for Fuel First

Getting Fuel Consumption Rates Info from 29 th Ed Cat Handbook Our Conditions are Medium Our truck is A 777 We get About 17 gallons/hr We assumed $2.0/gal. 17*$2= $34/hr

Input Our Fuel Cost Lets go for the Lube Filter, Oil and Grease (Ok – you would not buy $1/gallon really)

Enter the Lube/Filter/Grease Terex rule of thumb was High and 10% of fuel Undercarriage is a dozer Or tracked machine Thing – 0 here Repair Reserve Next

Vehicle Life Impacts Repair Costs Cat 777 will last 40,000 to 60,000 hours Under Average Conditions About 50,000 Table from Cat Handbook 29 th Edition (online)

Repair Reserve Tables Cat 777 has a base Repair reserve cost Of $10/hour

Actual cost Varies with Life of Machine If we go for A 50,000 hour Life we will Pay about 1.5 times what Is in the table Or $15/hour

Enter Our Data Lets do Tires Next

Need to Get Tire Life Where most tires wear out But some cut is zone B An average is 3,000 hours If retread cost is about 1.5 Times normal tire and Life is about 1.75 Cat Handbook does not Give a cost.

Western Mine Cost Service Has Books of Costs Including Tires in the Supply section This resource is Available online for Students or by Subscription fee for Commercial users.

Find Our 100 Ton Cat 777 Lists about $8,881

A Calculation of Tire Cost 6 tires * $8,900 each is $53,4006 tires * $8,900 each is $53,400 Because of heating considerations I’m not retreadingBecause of heating considerations I’m not retreading $53,400 / 3,000 hours = 17.8/hour$53,400 / 3,000 hours = 17.8/hour

Adding into FPC Now Lets Go for Operator

Western Mine Cost Service Has Labor Surveys Production Truck Drivers getting About $15.6

Another Source Is the US Bureau of Labor Statistics Note that I can pull Pay and Benefit by Area and Occupation

Industries Are Listed By NAICS Code Numbers

Find the Best Match Looks like mine Machine operators In quarries average $15.9 /hr

Comment on Estimating In addition to books, manuals and internet sourcesIn addition to books, manuals and internet sources Remember the Buddy NetworkRemember the Buddy Network Excerpts from Trade JournalsExcerpts from Trade Journals Your Companies Own Historical Cost RecordsYour Companies Own Historical Cost Records Local Union Contracts or State Wage ScalesLocal Union Contracts or State Wage Scales Vendor QuotesVendor Quotes

Cooking Our Estimate Normally there are other costsNormally there are other costs Unemployment, workers comp, social security, vacation, health etc.Unemployment, workers comp, social security, vacation, health etc. You can calculate specifically or use rule of thumb estimatingYou can calculate specifically or use rule of thumb estimating 40-60% burden40-60% burden I’ll go at low end for quarryI’ll go at low end for quarry 1.4 * $15.75 = $22.051.4 * $15.75 = $22.05

Input and Switch to Ownership Hmm – Looks like It costs about $70.2/hr to run.

One of My First Issues in How Long it Will Last

Input My Knowns I already scheduled 2772 hrs per year With 80% availability In my example I also know the truck should last about 50,000 hours At 2,218 hours per year that about 22.5 years

Getting My Truck Cost Looks like I’ll be About $1,062,000 For my Cat 777 Using Western Mine Cost Service

Price and Tires Most Prices are Quoted at the Factory – Your have freight And assembly (I added a little Extra as you saw) Tires are a wear item so often They are deducted from the price To avoid double counting Truck weighs 161,000 lbs or 1,610 units of 100 lbs – use $4/100 Weight rule to estimate freight about $7,000 double for assembly

The Issue of Taxes and Insurance Rule of thumb is that Tax and Insurance Are about 5% (2.5% each) of Average Annual Investment (I wish they would call it average annual value) As vehicles values go down so does tax on insurance Average value of calculation is (N+1)/2N * Cost where N is life Substitute and crank 33/64*$1,600,000 = $825,000 * 0.025 = $20,625

Griping About FPC FPC does not handle time value of moneyFPC does not handle time value of money Taxes and Insurance are high in the early years and low in the late yearsTaxes and Insurance are high in the early years and low in the late years A mathematical average does not show what this can do when investors are looking for a return on moneyA mathematical average does not show what this can do when investors are looking for a return on money

The Interest Problem If money is borrowed most of the interest comes earlyIf money is borrowed most of the interest comes early I’ll show a method for getting time value of money into it even if FPC tries to ignore it.I’ll show a method for getting time value of money into it even if FPC tries to ignore it.

From Engineering Economics Get the Interest Rate Comparison Spreadsheet Put in that I borrow Money at 9% over 10 years to pay for The Truck

The Spreadsheet Gives a Yearly History of Interest Payments Use Excels Copy function And copy the interest Column and paste it into Class Assistant (Another Engineering Economics Spreadsheet)

Paste My Interest Cash Flow Into the Cash Flow Analyzer in Class Assistant

Get the Total Life Cycle Cost of the Interest A typical mine looks For 15% rate of return The truck goes into Almost immediate Service – time zero Lasts for 32 years An equivalent stream Of interest over 32 Years is $79,378

Plug it Into FPC I could have done The total life Cycle cost trick to The Insurance And Property Tax Too At this point I know it costs me $107.85/hr to own the truck

When I Click Ok on the Subscreen I Know Have Total Hourly Cost for My Truck See! There it is!

This Still Needs to Be Done for My Loader Much will be the same as we just did for our truckMuch will be the same as we just did for our truck A Couple tid-bits for cable shovelsA Couple tid-bits for cable shovels The repair cost is a function of digging conditions and tonnage movedThe repair cost is a function of digging conditions and tonnage moved Very Hard 5 cents/tonVery Hard 5 cents/ton Hard 4 centsHard 4 cents Medium 3 centsMedium 3 cents Easy 2 centsEasy 2 cents Cable Shovels use about 0.6 KWH of electricity per cubic yard of loose rock moved.Cable Shovels use about 0.6 KWH of electricity per cubic yard of loose rock moved.

FPC Strengths and Weaknesses It goes into truck and loader fleets in a very complete way.It goes into truck and loader fleets in a very complete way. Weakness – It calculates a specific load of material over a specific road with a specific truck fleetWeakness – It calculates a specific load of material over a specific road with a specific truck fleet May be more than one road to move the load to the destinationMay be more than one road to move the load to the destination FPC has no selection capacity beyond what you selectFPC has no selection capacity beyond what you select MineSight has a built in haulage routineMineSight has a built in haulage routine If there is more than one route it just picks the shortestIf there is more than one route it just picks the shortest In practice roads may have different capacities and you regulate traffic flow on the flyIn practice roads may have different capacities and you regulate traffic flow on the fly No standard package can optimize thisNo standard package can optimize this

FPCs Catastrophic Weakness Probability of AvailableProbability of Available It treats the entire truck and loader fleet as one entity each.It treats the entire truck and loader fleet as one entity each. Ie – if the trucks are 90% available then the entire truck fleet is available 90% of the time and the entire fleet is down 10% of the time.Ie – if the trucks are 90% available then the entire truck fleet is available 90% of the time and the entire fleet is down 10% of the time. If loaders are 90% available then all loaders work 90% of the time and all loaders are down 10% of the timeIf loaders are 90% available then all loaders work 90% of the time and all loaders are down 10% of the time Over-all production available 0.9*0.9 = 0.81Over-all production available 0.9*0.9 = 0.81 81% of the time81% of the time

The Impact FPC is right if you have 1 truck and 1 loaderFPC is right if you have 1 truck and 1 loader Reality of 5 trucks is thatReality of 5 trucks is that You can have 5 trucks runningYou can have 5 trucks running 4 trucks running4 trucks running 3 trucks running3 trucks running 2 trucks running2 trucks running 1 truck running1 truck running The whole darn fleet downThe whole darn fleet down No it does not all average out – you bunching and fleet match veryNo it does not all average out – you bunching and fleet match very FPC under-predicts your fleet capacityFPC under-predicts your fleet capacity (some suggested cycle times are optimistic so they get some cancelation by luck – but for millions of dollars luck is rather lame)(some suggested cycle times are optimistic so they get some cancelation by luck – but for millions of dollars luck is rather lame)

Using FPC to Size Truck and Loader Fleets ©2012 Dr. B. C. Paul Note – This presentation demonstrates fleet sizing using Caterpillar’s FPC program and.

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Using FPC to Size Truck and Loader Fleets ©2012 Dr. B. C. Paul Note – This presentation demonstrates fleet sizing using Caterpillar’s FPC program and.

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Presentation on theme: "Using FPC to Size Truck and Loader Fleets ©2012 Dr. B. C. Paul Note – This presentation demonstrates fleet sizing using Caterpillar’s FPC program and."— Presentation transcript:

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