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Dictionary
Fourth Edition
2014
Dragline Dictionary
Fourth Edition
2014
Fourth Edition
2014
In September 2013 PwC acquired the GBI Mining Intelligence business
(GBI). This is core to PwCs Mining Intelligence business which
provides mining clients with asset benchmarking, productivity and
analytics services.
The First Edition of this dragline dictionary was started in 2005 by
GBI and first released in 2009. Many hundreds of hours were spent
sourcing photos and writing information.
Special recognition is made of the work of former GBI staff. Bevin
Horton in the early stage collated, travelled, photographed and
generally provided the foundations of this publication. More recently,
Jan Eike Sapper has shouldered the organising role and contributions
have been made by Trevor Trott. Graham Lumley started working on
the dictionary in early 2008. He added the productivity information
and reformatted it firstly to an A4 size and now the A5 size.
Eight years of work has gone into this fourth edition of the Dragline
Dictionary. A number of new entries have been made along with a
large number of photos and expanded writing on productivity issues.
There will always be variations in terminology across sites and it would
be impossible to capture all of these. We do however continue to
encourage your input. If there is something not included in this
dictionary please send us details and if possible photos. Send to:
Graham.Lumley@au.pwc.com
Wherever we are aware of the use of information and/or photos
provided by people outside PwC we will acknowledge this. If you wish
to discuss copyright please contact us.
Our aim is to produce the fifth Edition in 2015.
2 legs of the
A-Frame
The A frame connections to the boom and the structure of the dragline
are critical maintenance / inspection points. A failure of any one of
these connections can be catastrophic (as shown on the picture on the
following page where the A frame connection to the dragline structure
failed.
Access Stairs
Dragline
Bucket
Adaptors
Tooth
http://arm.com.au/images/
gallery/drag_adapt_11.jpg
Advance Bench
Air Horn
Dozers are the most common ancillary equipment and the action of
using the dozer effectively is a major contributor to efficient dragline
operation.
Mine Spec
Cable Boat
Cable Reeler
It should be appreciated that the angle of repose may vary within a pit
and also depending on how the spoil is dumped.
The following table defines ranges of measured angles of repose.
Boom Foot
3.00
2.50
Relative Damage
2.00
1.50
1.00
0.50
0.00
http://www.vrsteel.co.za/ http://arm.com.au/index.htm
products/dragline-buckets/
Assuming mines work the full 8760 hours in a year (most best practice
mines schedule >8700 hours per year) the following are the average
maintenance delay hours per day for best practice and average for
draglines.
Best Practice Maintenance Delay 1.7 Hrs/day
Average Maintenance Delay 3.6 Hrs/day
The value proposition of maintenance is keeping the equipment
running and available to operate. Consequently, the difference
between an individual mines maintenance delay and best practice
(average of the best 10% - what is actually achievable) represents the
opportunity to increase operating time.
There are always opportunities to improve performance in both the
production and maintenance departments at all mining operations
and the key is that everyone understands the organisations objective
and works together to achieve that goal.
There is a large component of focus and attitude built into this aspect
of best practice operations. Best practice operations analyse and report
on their maintenance practices and continually strive to eliminate
actions which are reducing the value-adding outcomes for the
maintenance department.
Low-wall Bench
Bench
Batter
Bench
Width
End
Wall
High Wall
100%
95%
6.0% 5.3%
90% 4.9%
2.6%
85%
81.6%
80%
Best Allocated Process Machine PURSL PER 2013FY
Cycle Time 200BFY
Practice Standby Utilisation Availability
BUW
Bucket Weight
BUVW
BTFW
Bucket Capacity
Berm or Bund
Front End
Hydraulic
Excavator
Ancillary
tic/Class
Dragline
(Dozers,
Graders
Electric
Mining
Loader
Trucks
Shovel
Drills
Rope
etc.)
Number of
18 32 51 22 87 60 38
Models
Number of
174 171 432 298 2,596 286 713
Machines
Number of
74 38 70 58 66 41 22
Mines
Equivalent
Years of 1,171 496 869 704 6,510 552 1,850
Data
No of
321M 93M 136M 65M 64M
Cycles
Evidence of
black jack
application
A Typical Overburden
Blast
After a Blast
Blast Profile
The blast design should focus on the required outcome, geology and
the variations across the blast area. The importance of rock response
time should also be considered as this also has a significant effect on
blast results and fragmentation. The down-the-hole timing and surface
timing are critical. There are a number of initiation sequencing /
optimisation tools available now and these should be used.
In the absence of blasting expertise on site, mines should access this
expertise through the use of blasting consultants.
The outcome of blasting is only determined when the blasted material
has been dug. The measure of the outcome is called diggability.
Monitor measures of diggability have not been sufficiently accurate to
provide useful information to work with. The best measure of
diggability is payload divided by energy to fill and this should be used
across the digging area to prepare a diggability map for input into the
blast model. This may prove a problem for some mines which have
either no monitor or an inaccurate monitor or a monitor which doesnt
measure energy to fill the bucket.
There are other tools available to measure fragmentation and these
should be considered if the mine is unable to quantify the fill energy
through the monitor. The following figure shows the output from a
fragmentation photo and the interpretation of that. This is useful
information but this data should be linked to digging outcomes where
the photo was taken.
Blast Model
Blast Design
Actual Fragmentation Forecast
Fragmentation
Blast
GAL
Historical
Fragmentation Steel Wt.
Width of
Block
Block
Length of Block
Boom
Boom
Intermediate
Intermediate Suspension
Suspension
Sheaves
Sheaves Ropes
Ropes
Intermediate
Intermediate
Boom boom boom
Boom Suspension
Point
Point
Suspension
Sheaves Ropes
Ropes (IBS)
(IBS)
Sheaves
Mast
Mast
Lacings
Lacings Main Chord (4)
Main Chord (4)
Boom Angle
Boom
Boom
Footing
Different Blocks
Boom
Suspension
Ropes
Brake Air
Isolator
Dragline Building
Bridge
Wright
Earth Eater
Esco
Scoop
P&H
BE HPS
A bucket is made up of different parts. The front ring can be either cast
or fabricated and includes the arch and the nose. The basket has a
skeleton of steel for strength. The top rail gives the bucket increased
strength
Top Rail
Nose
Basket
Cast Front
Ring
X CuM
Boiling
Fill material
6. Face of the lip shroud runs down the centre line of the
teeth
The action of the teeth when digging into spoil is to create a line of
break or fracture ahead of and between the teeth. This fracture line
runs along the plane following the centre line of the teeth. Digging is
easiest when the spoil can travel into the bucket smoothly along this
plane in the spoil.
Direction of Movement
Direction of
Movement
Dead zone
created by
spoil at the
front of the
bucket
Spoil movement
impeded by
boiling action
Bucket cheek of large blocks
being bulldozed
http://www.arm.com.au/images/Ne
w_51_M_Bkt._Jaw_and_Wing_Shr
ouds.jpg
In this case the mine had previously determined the BER to be 2.00
t/m3 and the target suspended load to be 160 tonnes. The rigging
weight was 22 tonnes. In addition the mine has determined the value
http://www.arm.com.au/
images/blaircoal.JPG
Dead load
Dead
(4)
load (4)
Tooth
Tooth
VirginVirgin
material
(1)material (1) Bucket
Bucket
profile
Initial laminar profile
Initial
laminar
layer (2)
layer (2)
Typical Plot of Fill Distance (and Fill Time) vs. Engage Point
The two issues which a mine has a control over which relates to the
filling of a bucket are;
1. Controlling the location of the centre of gravity
2. Creating a sloped digging face
BE 2570W
BE 1570W
Berm or Bund
Dragline Cable
Cable Boat
Typical
Cable
Handling
Cable
Pipe
Plug Stands
Cable
Stand
Cable
Plug
Cable Towers
Rear Cable
Winch
Winch
Rail
Cam
Carry
Angle
Prime Cast
to spoil
Centre
Pintle
Chasing
Coal Edge
Chords
Struck Volume
Overburden
Coal
Seam
Coal
Edge
Contour
Banks
Conventional
Buckets
Cotton
Reel
Coupling
Hoist Hoist
Gearbox Motor
High
wall Crest
The following five plots demonstrate and explain each of the five key
pieces of information which can be used to distinguish the cycle
components.
3.5
2.5
1.5
0.5
0
10/05/2003 0:00 11/05/2003 0:00 12/05/2003 0:00 13/05/2003 0:00 14/05/2003 0:00 15/05/2003 0:00 16/05/2003 0:00
http://www.arm.com.au/images/
Large_Drag_Shackle_A.R.M_Hardfaced.jpg
Dig Plan
on Paper
3G Dig
Simulator
Dip
Sweet Roll
After Disengage
Spot
Dozer cleaning
High Wall
Disk
Brake
Drum
Brake
Drag
Chains
Drag Chain
& Shackle
Drag Cluster
Drag
Socket
Drag Dump
Cluster Shackle
Drag
Chains
Drag
Payout
Drag
Lever
Drag Gear
Box
Drag
Hitch
Drag Ropes
Drag Rope
Winch
Dragline
Access
Dragline
Ramp
http://www.rpmglobal.com/mining-software/dragline-simulation-
dragsim
Drifts
Dump
Block
Dump Equaliser
Dump Chains
Dump Rope
Dump
Height
Operational
Dump Radius
Specification
Dump Radius
Dump Rope in
carry mode
Dump Rope in
dump mode
Total Damage
Rope Damage
Optimum
Rope Diameter
This table suggests that a smaller diameter rope should last longer. It
is known however, that a 57 mm diameter rope will not last 64.4 days
in most operations. It is also known that most 83mm ropes wont last 2
weeks consistently. This again supports the fact that external damage
plays a major role in the life of dump ropes.
It has been demonstrated that the load carried by a rope affects its
useful working life - this is particularly so when a rope passes around a
sheave. There is little published data on dump rope loads. The major
knowledge is as follows:
the rigging geometry can cause different loads in the dump
rope,
bucket geometry does cause different dump rope loads,
the load in the dump rope is more dependent on bucket
location than load carried,
loads in dump ropes for BE1370W and M8050 class machines
are mostly below 50 tonnes but can exceed 150 tonnes during
disengage at the drag limits and during the swing part of the
cycle,
the most rapid dump rope loading occurs during disengage,
the highest loads experienced by the dump rope are about one
third to one half the way up the boom on the tight line
envelope, and
there is a relationship between dump rope load and hoist rope
load.
It is well known that the majority of internal and external damage
occurs while the dump rope is passing over the dump sheave. The
magnitude of the damage is a function of the load in the rope and the
Dump
Block
Dump
Sheave
Elevated bench
Encoder
Pit Completion
End wall
Pit
Beginning
End wall
High Wall
Back of Block
Excitation
Button
Extended
Bench
Since faults do not usually consist of a single, clean fracture, the term
fault zone is used when referring to the zone of complex deformation
that is associated with the fault plane. The two sides of a non-vertical
fault are called the hanging wall and footwall. By definition, the
hanging wall occurs above the fault and the footwall occurs below the
fault.
Other dig methods may leave spoil on the high wall for removal by the
dozer.
Drum
Brakes
Insulators
Intermediate
All mines should have a Safety Management plan and process for
Positive Isolation under the existing legislation.
Extended Key
The power cable to the working machinery in the house come through
slip rings attached to the king post.
The King Post is also called the Centre Pintle.
Reporting period
Lacings Lacings
Low Wall
Benchh
Most operations have around 5-10 metres of bench to contain and stop
rocks falling into the pit. A bench on the low wall allows access for pit
lighting plants and easier access for OCE Inspections. When spoil
room is at a premium and stability isnt an issue, some operations will
not worry about having a low
wall bench.
Preparing the
Low Wall Ramp
Lube
Tanks
Lube
Drums
Lube Panels
Lube Pumps
Machinery
House
Main Boom
Chords
Mast Foot
MG Sets
Beniscelli et al (2000)
Clearly the focus for planning is to establish a good plan, make sure
there is a process in place for ensuring compliance to the plan, and
providing the mining department ongoing equipment performance
data and identifying where and when gaps in performance have
occurred. This will allow precise corrective action.
http://www.ventyx.com/en/enterprise/technical-mining-
operations/mine-planning
Bucket
Lip
Nose
Further to this the second area of safety risk is at the rear of the house.
Dozers working in the swing arc of the dragline boom (at the rear)
should always make their intentions known and be in constant
communication with the dragline operator. All draglines and dozers
should have proximity sensors fitted so that if the dozer comes too
close to the house an alarm sounds. This proximity should be
established by the mine but as a general rule 25 metres from the centre
line of the dragline is a good distance for keeping the dozer away from
the rotating dragline house.
3. Abilities testing
The Link between Productivity and Safety on a Cattle Farm and Meat
Processing Factory .
http://en.wikipedia.org/wiki/Dragline_excavator
http://en.wikipedia.org/wiki/Dragline_excavator
In 1988 Page was acquired by the Harnischfeger Co., makers of the
P&H line of shovels, draglines, and cranes.
Data accessed from PwC Database and valid until 31 December 2014.
If a particular dragline has a different RSL to those noted then simply
multiply the specific RSL by the payload/RSL factor for the make and
model to determine the target payload. Note that payload/RSL is unit
less.
There are many factors that impact on payload but the starting point
for optimising payload is to set a general target as follows:
Min. Target Payload (tonnes) = 2 x Rated Capacity of the
Bucket (cu m)
i.e. for a bucket with Rated Capacity = 47 m3, the target Payload = 94 t
Engage Location
Disengage Location
Maximise disengaging in the sweet spot.
Analyse and report performance vs disengage location.
Operator
The operators actions will have the greatest impact on payload filling
technique.
Report Specific Dragline Output (normalises for bucket, machine make and
model, pit geometry and diggability).
Bucket Characteristics
Different buckets will achieve different payloads.
Buckets performance changes over their life.
Analyse bucket performance and develop a bucket strategy.
Report bucket performance periodically.
Rigging Characteristics
It is essential that the rigging performance matches the digging technique.
Report rigging to digging periodically.
http://www.mineware.com.au/pegasysdraglinemonitoring.php
Disengage frequency
Prime
2000
1800
1600
1400
Seconds
1200
1000
800
600
400
200
0
0 5 10 15 20 25 30
No. of Steps
The difference in Y axis intersection are the set-up losses while the
difference in slope indicate the per step losses.
In all analysis the zero walk step events are removed and reported
separately.
The following factors should be reported regularly both with reference
to previous performance and against machine best practice;
Time spent walking (total and average)
Number of steps (total and average) in particular the
number of zero step walk events
Number of walk events
Each make and model has declined over time but the primary message
in this plot is the significant differences between different makes and
models. The most productive make and model achieved 106,000 BCM
/ t of RSL while the least productive achieved 66,000 BCM / t of RSL.
The lowest is 38% below the top.
There is an interesting characteristic of this data which is worth noting
and plotting in a different form. The unit capacity increases with
increasing machine size. In the case of draglines this is not a strong
trend but it is gaining strength with time as larger draglines have
tended to perform better relative to smaller draglines over the last
three years. This is demonstrated in the plot in the next figure which is
Output versus RSL. Bigger machines move more than smaller
machines even after the results are modified to normalise differences
1
89% of the difference in output amongst makes and models can be
explained by the difference in RSL.
Fill Efficiency
8.33
t/sec Payload Av. Drag Load
143.2 174 Single Fill
SDE t t 93.3%
231
kJ/t Energy Fill Distance
33.1 19.4
000 MJ m Fill Distance
5.2
Fill Time Fill Rate Bucket Lengths
17.2 1.13
Avg. Fill Sec m/sec
Time
19.5
Sec Fill Time Fill Rate
Average 51.9 0.91
Cycle Time Sec m/sec Fill Distance
75.2 12.6
Secs Energy Fill Distance Bucket Lengths
52.6 47.0
000 MJ m
SDE
404 Payload Av. Drag Load Repasses
kJ/t 130.2 114 6.7%
t t
Fill Efficiency Total Swings
2.51 271,452
t/sec Swing Angle
92.2
Deg
Swing Rate
Return Return Angle 3.67
Time 99.3 Deg/sec
22.6 Deg
Sec
Return Rate
4.39
Deg/Sec
Spot
Time
5.5
Sec
Propel Gearbox
Propel Motor
Propel Switch
on a BE1570W
~25m block
Coal
Reclamation in Progress
0.00
0.50
1.00
1.50
2.00
2.50
3.00
No r mal
U nd erhan d /Cho p
Dragline Dictionary
N or mal Ove rh and
Du mp o n t he Fly
Clip S po il
Ho is t Wh ile D ump
Jar Ro pes
S wi ng Bu cket
Ou t
Ba ck Bla de
M ult i-pa ss
Bo un ce to S in k
Email: graham.lumley@au.pwc.com
433
Repass (Multiple Pass) Dragging the
Bucket in more than once to fill it
Repassing or multiple passes refers to the action of an operator
disengaging a bucket at the drag limits and taking it back to have
another attempt to fill it properly. It should be minimised as it is
unproductive. There may be times, especially when defining (pulling) a
batter when it cannot be avoided. Under normal operations it is only
poor operating practices that contribute to this practice.
Revolving Frame
Rigging -
Rigging
Excluding
the bucket
Note as
Noteas
drain
drainfills,
fills,
rocks
rocks areare
getting
getting
through
through the
the drain
drain
When pushing the roll, it is important that the dozer doesnt round
over the dig face but keeps a square face as the dragline will sit in that
position when it is at the face.
Roller
Circle
______________________________
MRC
Dragline - BE1370W
Average Competency - 4
FMM = 1.018
MRC = 48 * 2.07
= 99.4 tonnes
FSA = 1 + 2 * ( 100 95 )
[(11+9)/2] * 69
FSA = 1.014
FD = 1.09
= 2,673 / 99.4
SG Specific Gravity
Specific gravity is the term used for describing the density of the
overburden or coal.
The correct density entered into the production monitors, should give
a closer correlation of the monitor production results to survey results.
Coal Parting
Seams
Shoe Guides
Sidewinder
Signal Bell
Signal Bell
Next strip
Spoil
Spoil
Spoil Heaps
Spoil to be
pulled back
A Completed Pullback
An operation with
shallow digging &
plenty of spoil
room available
An operation with
maximum dig
depth and tight
spoiling
Spot Time
20
Seconds
15
10
0
Minutes in Shift
Dump Spreader
Bar
Hoist
Spreader
Bar
Dragline
Stripping
Overburden
Main
Power Stub Line
Line
Stub Line
Termination
Dragline Substation
Sweet Spot
Swing Angle
Swing Brakes
Swing Gearboxes
Swing Pinion
Swing Rack
Swing Pinion
Tight Line
Envelope
When the
bucket is in this
trajectory, it will
be tight lining
Low
Wall
Toe
High
Wall
Toe
Spoil
Toe
Dragline
bucket teeth
with hard
surfaces tips
Adaptor
fitted to the
bucket
Tooth fitted to
the adaptor
Cam Degrees
Shoe
Park
Top Rail
Stockpiled Topsoil
Trailing cable
Scale
Dragline
Scale
Sand
Pit
Tritronics Monitor
Tritronics
Typical Large
Scale Truck
and Shovel
Operation
Typical
Smaller Scale
Truck and
Excavator
Operation
Tub being
assembled
Tub hooks
If the ground under the tub gets wet and the dragline starts to slip /
spin the dragline should be walked off the pad, the top dozed and the
dragline walked back on.
Portable or Hand-
held 2 Way Radio
In Action
CQMS
Scoop
bucket
Under
Hand
Digging
http://www.vrsteel.co.za/
http://www.vulcan3d.com/e_dragline.html
Walk road
Walk road
2000
1800
1600
1400
Seconds
1200
1000
800
600
400
200
0
0 5 10 15 20 25 30
No. of Steps
Walking
Shoes
Socket
Wedge
Witches Hats
7 Wraps on Drum
2014 PricewaterhouseCoopers, ABN 52 780 433 757. All rights reserved. PwC refers to the
Australian member firm, and may sometimes refer to the PwC network. Each member firm is a
separate legal entity. Please see www.pwc.com/structure for further details.