The ‘Big Data’ evolution

In the future, people will look back at the last decade of the 20th century and the first decade of the 21st as being the genesis of ‘big data’. With the birth of the Internet, wireless networking, and the ever-decreasing cost of digital storage, capturing and storing huge amounts of data has become the rule rather than the exception. Along with the development of the Internet, IP networking has made even more data possible as devices never even dreamt of years ago can now be easily connected.

Who would have thought 20 years ago there would be a time where we could go for a run and instantly know how far we’ve gone, where we’ve gone on a map, the calories burnt and altitude gained, all read from a crystal clear screen on a mobile phone not much bigger than your average wallet.

There has been a similar explosion of ‘big data’ in mining, albeit slightly behind that of the Internet revolution, but nonetheless, the amount of data now available from mining equipment is staggering. In fact, there is so much data available people often don’t know which way to turn.

Information overload is not a new term, but its use in the past decade has increased dramatically as the amount of data that fills digital storage grows. Collecting data is one thing; displaying it meaningfully is another. Several large mining companies have attempted to quell the information overload problem through the use of remote operationscentres (ROC) where relevant information from operations thousands of kilometres away is displayed for management review. For other companies where an ROC is not on the agenda, the challenge of disseminating and displaying vital information remains.

In order to show the challenge of ‘big data’, let’s take a specific example and break it down. In open pit mining, seconds are paramount. Whilst seconds may not play a large part in drill and blast (its generally all about metres), in the load and haul cycle a matter of seconds can make or break a production target. 

Before my current role I was more familiar with underground mining where metres were king. ‘Metres advanced’ is the metric used in underground development. I never really gave much thought to how much emphasis is given to seconds above the ground but it soon becomes obvious when you break it down. Haul cycles are made up of simple segments: travelling, spotting, loading and hauling (there are other segments like waiting and tipping that can be added but we’ll keep it simple for now).

One haul cycle is the total of these activities in minutes and seconds. Each of these activities can be timed individually using a variety of methods. For most operations, a fleet management system that can detect when each of these activities ends and the next starts can provide this information. For example, when a haul truck is moving along a haul road without a load, it is travelling. When full on the same road, it is hauling. The system knows this based on the GPS position of the truck and if it has a load or not. For spotting, the GPS position is used but it also correlates this with the proximity of a load unit and the selection of reverse gear. If all these are true, then the truck must be spotting. Now that we have a way of breaking the activities down, we also have a way of determining the total cycle time. Likewise, as the activities can be captured individually, we can now also display these individually in a variety of formats such as static reports or dynamic dashboards.

So where do the seconds count? Let’s say a haul cycle is 20 minutes in total and consists of the following breakdown:

  • Travelling – 5 mins
  • Spotting – 30 seconds
  • Loading – 2 minutes
  • Hauling – 12.5 minutes

Now we have a baseline that we can compare all other data in order to answer questions such as:

  • Is 20 minutes good?
  • Can it be improved?
  • How does this operator compare to the others?
  • What happens if the haul route changes?

There are many answers to these questions, but they all have one thing in common: only data can provide objective answers. Let’s tackle the first and third questions – by measuring all operators it will soon become apparent whether 20 minutes is good and where the operator sits in the scale of things. Once you have the answer to those questions you can then answer question number two. If the average is in fact 18 minutes, this operator is well below. Why? Again data can provide the answer, or at least point you in the right direction.

And this is where data can also lead you on a wild goose chase. 

Having only one source of data may not tell you the full story. What if the reason this haul was 20 minutes was because a shower of rain caused a portion of the haul road to become slippery. 

This would only be apparent on one or two hauls as the road would soon drain and dry out, creating a temporary increase in the overall total time. The moral of this example is don’t get too wrapped up in the data you fail to see the ‘truth’.

Let’s go back to question two, as this is where we can really show the power of data. Once the data has been verified, we can focus on the cost savings to be had from reducing the cycle time.

This is where engineering and technology can come together to show the potential benefits of ‘big data’. Let’s target a one minute improvement on the cycle time to keep things simple. As the current cycle time is 20 minutes, three cycles are possible in one hour, therefore there is a three minute saving every hour. In a 12-hour shift there is usually 10 effective hours on average, so therefore with one truck across one shift there is 30 minutes extra – more than enough time for an extra load. Now lets extrapolate that across a fleet of 50 trucks for the year – 1 extra load x 50 trucks x 2 shifts x 365 days = 36,500 extra loads for the year.

Now let’s work out the potential value of these extra loads. We’ll use best case, round figures to make it easy, but you’ll soon see what a one minute saving each load can add up to.

We’ll use a CAT 793F haul truck with a gold grade of 1 gramtonne. A CAT 793F averages 220 tonnes per load, therefore there is potentially 220 grams of gold in each load. 220 x 36,500 = 8.03 million grams which is just over 258,000 troy ounces. At a gold price of Aus$1350ounce that equals Aus$348.3 million. At Aus$200 per ounce profit, that’s a tidy Aus$51.6 million extra profit, all from reducing cycle times by one minute

I did say this was best case – this certainly wouldn’t be the case in the real world as each load isn’t always a premium grade load as there is waste that needs to be moved. There’s a whole host of other factors that would affect the above equation, but it shows the potential of what can be achieved by using ‘big data’.

Now that we’ve seen what ‘big data’ can do for us, the challenge is sharing this information with those decision makers that value the data. 

For a production engineer, giving him an extra load per hour is like having another truck in the fleet – something that can’t be physically achieved with spending many millions of dollars. But give it to him for free and he’ll be your next best friend. 

And this precisely is the future challenge facing many – how to capture, interpret and display big data in this age of information overload. That sounds like a great topic for another article.

Jason Nitz is a fleet management and dispatch superintendent at Newmont Mining.

This article originally appeared in full at Austmine.

Honeywell Users Group 2014 wraps up

More than 200 people attended the event, held on the Gold Coast, with the majority of attendees made up of users of Honeywell technology from across Australia.

Today was used by customers to hold sessions demonstrating their use of Honeywell technology on their sites, and how they implemented it.

Productivity and efficiency gains were the main focus for the presentations.

The company itself used the event as a launchpad for a number of new releases, such as the oil and gas productivity and safety software suites and the Experion Orion console released on the first day of the event, officially launching its universal cabinets for its universal input/output (I/O) modules today.

According to the company the “universal I/O modules allow operators to quickly and remotely configure channels as analog or digital I/O using Honeywell’s proprietary Universal Channel Technology software”.

“The Universal Cabinets incorporate Universal I/O modules and make the entire cabinet a standard part which can play a key role in on-time start-ups by removing I/O from the critical path. This can help project managers to reduce the impact of changes on automation project schedules, especially late in a project cycle.”

Honeywell’s Lean Execution of Automation Projects (LEAP) processes were also highlighted during the show.

LEAP is “a new methodology and philosophy in project execution,” the company stated.

It uses cloud engineering and virtualisation methods to aid companies in implementing process solutions into their projects.

By using a cloud approach to engineering design “it decouples the software and the hardware, so they can be produced in parallel with one another, as opposed to sequentially, shifting formerly backend processes to the frontend,” Honeywell said today.

In spite of the current market conditions in mining, the mood was overall positive at the event.

“Despite the market being down, people have all been very positive here,” Honeywell director sales – Pacific, Neil Wold, told Australian Mining.

“In fact the turn out was even better than last year,” he said.

Regarding the customer sessions held earlier in the day, Wold stated that it was one of his favourite parts of HUG, as “it’s always exciting to see how our technology is being used”.

HUG will be held in Perth next year

PACE attended HUG as a guest of Honeywell.

ABB wins massive truckless mine automation contract

ABB has won a contract to make the world’s largest iron truckless.

The $103 million contract will see it install electrical and automation systems at Vale’s S11D iron ore mine in Brazil.

This latest contract follows on from an earlier $140 million contract to complete the first phase of the mine’s automation project which saw it begin to install shiftable conveyor belts instead of off-highway dump trucks to move the ore from the mine to the processing plant.

“This is the first time a ‘truckless’ solution will be used on a large scale at an iron ore mine,” according to the company.

It stated that using “a truckless system significantly reduces operating costs and produces lower carbon emissions.

“If the S11D mine were to be operated using trucks it would need around 100 trucks and consume 77% more diesel per year.”

This new contract will see ABB supply a 230 kilovolt in-feed substation to connect the mine to the grid, as well as 42 secondary substations.

These secondary substations will be self-contained in ABB’s e-houses, prefabricated, walk-in, modular, outdoor enclosures.

ABB will also supply the motors driving the mine’s conveyor belts.

According to ABB’s head of process automation division, Velo-Matti Reinikkala “this project will also allow Vale to increase production by approximately 90 million tonnes, while reducing emissions and improving operational efficiency and process safety”.

Industry professionals convene in Texas for Automation Fair

Houston, in Texas, became the hub of the automation world recently when more than 9,700 manufacturing and industrial professionals gathered for the Automation Fair event, hosted by Rockwell Automation and its PartnerNetwork members. 

The two-day event has attracted manufacturing and process business leaders, industry analysts, and technology and service providers from the industrial sector who are eager to capitalise on the most promising trends in automation and process control. 

This year’s 22nd annual event also marks the 110th anniversary of the founding of Allen-Bradley, the flagship brand of automation equipment from Rockwell Automation. 

“By showing how attendees can converge automation and information into one connected enterprise, the event enables customers to improve their business profitability, help optimise their plants, and make their operations cleaner, safer, more secure and more energy-efficient,” said Keith Nosbusch, chairman and CEO, Rockwell Automation.

Automation Fair featured hands-on labs, demonstration workshops, technical sessions, industry forums and more than 100 exhibitors showcasing cutting-edge products and solutions. 

Attendees of the Process Solutions User Group meeting heard about best practices and discovered solutions to improve their processes and create new revenue. 

Rick Esker, senior director, Industry Solutions Group at Cisco, shared how companies can balance big data and industrial security. Industry experts from Endress+Hauser, Acuite and Rockwell Automation shared the latest technology trends affecting the connected enterprise for instrumentation, human-machine interface, and production information, and how they can help drive performance.

Process professionals were invited to hear more than 16 educational sessions and to offer input on the prioritisation of future developments to the PlantPAx process automation system from Rockwell Automation. 

Attendees from 31 customer companies – in industries ranging from life sciences to oil and gas – discussed their experiences using the PlantPAx system and other process solutions. 

Industry analysts and journalists joined Rockwell Automation for the half-day global media forum Automation Perspectives, focusing on the theme of “Leveraging Technology to Transcend Industrial Business Barriers.”

Keith Nosbusch of Rockwell Automation gave the keynote address. He discussed how the adoption of standard IP-based Ethernet is revolutionising industry and enabling truly connected enterprises – leading to sustainable competitive differentiation with optimised plants and supply networks.

Following Nosbusch, industry leaders discussed the risks and rewards of this connectivity. Attendees learned about the importance of protecting industrial control and SCADA systems, and key elements in implementing an effective security strategy. 

A second group of speakers then discussed the unprecedented transformation of the global energy landscape, and how innovations in automation, intelligent motor control, remote services and delivery expertise in turnkey solutions are helping improve asset management in energy industries.

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