Talpac Tutorial - Awsers 7216h

Talpac tutorial Version 10.2.1

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Contents 1

About this tutorial

1.1

............................................................................................................................................. 1 Conventions used in this document

1.1.1 1.1.2

Typographic ........................................................................................................................................... conventions 2 Icons ........................................................................................................................................... 2

2

Background to worked example

2.1

............................................................................................................................................. 3 Talpac overview

2.1.1 2.1.2 2.1.3

Technical ........................................................................................................................................... description 3 Tasks ........................................................................................................................................... 4 Questions ........................................................................................................................................... 10

2.2

............................................................................................................................................. 11 The material type

2.2.1 2.2.2 2.2.3

Technical ........................................................................................................................................... description 11 Tasks ........................................................................................................................................... 11 Questions ........................................................................................................................................... 13

2.3

............................................................................................................................................. 14 The shift roster

2.3.1 2.3.2 2.3.3

Technical ........................................................................................................................................... description 14 Tasks ........................................................................................................................................... 14 Questions ........................................................................................................................................... 15

2.4

............................................................................................................................................. 16 Selecting a loader

2.4.1 2.4.2 2.4.3

Technical ........................................................................................................................................... description 16 Tasks ........................................................................................................................................... 16 Questions ........................................................................................................................................... 18

2.5

............................................................................................................................................. 19 Selecting a truck

2.5.1 2.5.2 2.5.3

Technical ........................................................................................................................................... description 19 Tasks ........................................................................................................................................... 19 Questions ........................................................................................................................................... 22

2.6

............................................................................................................................................. 23 Setting up a haul cycle

2.6.1 2.6.2 2.6.3

Technical ........................................................................................................................................... description 23 Tasks ........................................................................................................................................... 23 Questions ........................................................................................................................................... 25

2.7

............................................................................................................................................. 26 Production analysis

2.7.1 2.7.2 2.7.3

Technical ........................................................................................................................................... description 26 Tasks ........................................................................................................................................... 26 Questions ........................................................................................................................................... 26

2.8

............................................................................................................................................. 27 Incremental analysis and results tables

2.8.1 2.8.2 2.8.3

Technical ........................................................................................................................................... description 27 Tasks ........................................................................................................................................... 28 Questions ........................................................................................................................................... 31

2.9

............................................................................................................................................. 32 Fleet size optimisation

2.9.1 2.9.2

Technical ........................................................................................................................................... description 32 Tasks ........................................................................................................................................... 32

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2.9.3

Questions ........................................................................................................................................... 33

2.10

............................................................................................................................................. 34 Fleet comparison

2.10.1 2.10.2 2.10.3

Technical ........................................................................................................................................... description 34 Tasks ........................................................................................................................................... 34 Questions ........................................................................................................................................... 35

2.11

............................................................................................................................................. 36 The equipment database

2.11.1 2.11.2 2.11.3

Technical ........................................................................................................................................... description 36 Tasks ........................................................................................................................................... 36 Question ........................................................................................................................................... 36

2.12

............................................................................................................................................. 37 Importing a haul cycle

2.12.1 2.12.2 2.12.3

Technical ........................................................................................................................................... description 37 Tasks ........................................................................................................................................... 37 Questions ........................................................................................................................................... 38

2.13

............................................................................................................................................. 39 Talpac options

2.13.1 2.13.2 2.13.3

Technical ........................................................................................................................................... description 39 Tasks ........................................................................................................................................... 39 Questions ........................................................................................................................................... 40

2.14

............................................................................................................................................. 41 Calibrating Talpac

2.14.1 2.14.2 2.14.3

Why ........................................................................................................................................... calibrate? 41 How ........................................................................................................................................... to calibrate 41 Points ........................................................................................................................................... to consider 42

3

Answers

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13

............................................................................................................................................. 45 Workshop 1 - Talpac overview

4

Talpac commands

4.1 4.2 4.3

............................................................................................................................................. 58 Embedded buttons

45

............................................................................................................................................. 46 Workshop 2 - The material type ............................................................................................................................................. 47 Workshop 3 - The shift roster ............................................................................................................................................. 48 Workshop 4 - Selecting a loader ............................................................................................................................................. 49 Workshop 5 - Selecting a truck ............................................................................................................................................. 50 Workshop 6 - Setting up a haul cycle ............................................................................................................................................. 51 Workshop 7 - Production analysis ............................................................................................................................................. 52 Workshop 8 - Incremental analysis and results table ............................................................................................................................................. 53 Workshop 9 - Fleet size optimisation ............................................................................................................................................. 54 Workshop 10 - Fleet comparison ............................................................................................................................................. 55 Workshop 11 - The equipment database ............................................................................................................................................. 56 Workshop 12 - Importing a haul cycle ............................................................................................................................................. 57 Workshop 13 - Talpac options

58

............................................................................................................................................. 59 Toolbars ............................................................................................................................................. 60 Function keys

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1

About this tutorial

This tutorial has been written so that s learn how to use Talpac. The intention is that by following the series of workshops set out in this booklet, you will be able to use Talpac, and have an appreciation as to the functionality of the program. Each of the workshops sets out a number of key Talpac concepts, what actually needs to be completed for each workshop and what the results should be at various points. As well, there are questions that should be answered for each workshop. Some of these questions are qualitative, so no numerical answer has been provided. The phrases listed as concepts in each workshop can all be found in the online help. In the answers section of this tutorial there are some answers to specific questions, and screen captures at certain points of the process which will enable you to check your progress. Often these screen captures contain the numeric answer. This tutorial does not cover every feature of Talpac. However, upon completion of this tutorial, you will have the skills required to successfully use Talpac, and to self-learn the Talpac facilities not covered here. Firstly, it is recommended that you read through an entire workshop before starting it. Talpac may be used to analyse the performance of existing fleets of equipment or to investigate the application of new equipment fleets in earthmoving and mining operations. In either case, the performance of a single fleet may be examined, or a comparison made of two or more different fleets. Typical Talpac applications are listed below: Calculation of truck travel time to allow a comparative analysis of haul route alternatives. Estimation of fleet productivities for use in long-term and short-term planning studies. Estimation and comparison of productivities using various loading methodologies to determine the optimum loading technique or loading unit bucket size. Sensitivity analysis in road design criteria to assess the relative importance of road maintenance. Calculation of tyre TKPH or TMPH ratings for use in tyre selection. Estimation of fuel usage. Determination (using discounted cash flow methods) of haulage contract costs and pricing. Truck fleet size optimisation to quantify the effect of over-trucking and under-trucking. Incremental analyses, in which simulations can be automatically run for a range of haulage segment lengths and the results used to generate productivity curves. Equipment loading analysis to optimise loader bucket size, truck capacity and number of es. Collation of results from calculations to examine the relationship between variables in the calculation, for example, haul distance versus productivity, haul distance versus truck fleet size.

1.1

Conventions used in this document

This section describes the conventions used in this document: Typographic conventions Icons

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1.1.1

Typographic conventions

The following list describes the typographic conventions that may be used in this document. Bold Used for buttons, commands, utilities, keystrokes, field names, menu items, file names and directories. Code example Used for code examples and sample text file output. Bold italics Used for formulas. Red bold Used within tables for warnings and dangers. Blue underline Used for hyperlinks.

1.1.2

Icons

The following is a list of the icons that may be used in this document.

This indicates general advice and useful information.

This indicates additional information about the topic or procedure.

This indicates important information regarding the topic or procedure. Failure to follow the information in a warning may cause problems with the program or procedure.

This indicates crucial or critical information. Failure to follow this information may cause data corruption or failure of the procedure.

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2

Background to worked example

A contractor has been invited to submit a tender for the removal of waste from an open cut mine, at 2.5 million BCM per year. The contractor uses the following equipment: Caterpillar 992K Front End Loaders (12.20 m3 bucket) Komatsu HD785-7 Rear Dump Trucks (94 tonne payload). In bidding for the waste removal contract, the contractor must determine how many trucks and loaders are required to meet the production target and the cost of production. The contractor is also unsure whether to continue with the same equipment or larger equipment. In the workshops of this tutorial, we will configure the required Talpac components to undertake this analysis.

2.1

Talpac overview

Key concepts: Project, Haulage system, Template

2.1.1

Technical description

This workshop is to generally discuss how Talpac works and the key areas of data input and output. The image below displays how a haulage system is made up of the unique combination of nominated templates. The templates are where the data is held for the Material, Roster, Loader, Truck and Haul Cycle. So, if you change data in one of the templates, then really you are simulating a different haulage system. In this way, many haulage systems can be stored in the one project.

Talpac data structure

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To set up a haulage system for the Waste Contract project, you will need to create a new haulage system, in a new Talpac project. Initially, we need to learn how to work with the templates. In later workshops we will begin entering data into these templates.

2.1.2

Tasks

Starting the tutorial: 1. Open Talpac by selecting Start > Programs > RPM Software > Talpac or double-clicking the Talpac icon on your desktop. 2. In the opening dialog box, select the Create a New Project radio button and click OK.

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3. In the Create a New Project screen, choose to Create an Empty Project and click OK.

4. In the file name box, type Waste Haulage Tutorial and open the file in your working directory. The Project Options dialog box displays. 5. It is important to enter report titles for your Talpac project. These titles are entered in the Print Titles tab and display on all Talpac output. Usually, you would enter appropriate project titles; in this instance enter the following: Project Title: Waste Haulage Tutorial Secondary Title: Workshops Prepared For: Talpac Training Prepared by: (enter your name) Company Name: (enter your company). Updating the titles lets you see what titles are -defined in Talpac, and which titles are fixed. 6. Click Edit under the loading unit to open the Edit Loading Unit Template dialog box.

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7. Delete DEMONSTRATION from the Loading Unit Template Name field and click OK.

8. Click Edit under the truck type to open the Edit Truck Template dialog box. 9. Delete DEMONSTRATION from the Truck Template Name field and click OK.

Talpac can operate and report using either Imperial or Metric units. This option is usually set during installation, but it is worth checking that the correct option is set before proceeding with the rest of this tutorial.

Selecting the required measurement units: 1. Select View > Customise Talpac (affects all projects). 2. Check that Metric Units is selected and simulation precision set to High.

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This setting is program, not project, specific. It affects all projects, not just the currently open project. Changing the Menu Language may require Talpac to be restarted.

In the following workshops you will learn how to set up each of the five haulage system components to represent a haulage situation.

Viewing details about the haulage system components: 1. Open the All Parameters sheet to display: Technical, stochastic and costing information for the loader and truck Roster and material information Cash flow options

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Loading options and bucket construction options.

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2. Open the Loading Analysis sheet and you will get information on material, truck and loader.

3. From the main screen, the material, roster, loader and truck templates may be edited. Click one of the list boxes to view a selection list.

4. To edit one of the templates, click the relevant Edit button. After editing, you can either click OK to save or Cancel to return to the main screen. Make sure you understand the difference between adding a new template to a list and editing an existing template.

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Adding templates: 1. Click the Haul Cycle drop-down list to get a selection list of haul cycles in this project. 2. Click Edit Haul Cycle to open the Haul Cycle dialog box. 3. Click any segment of the haul cycle and use either the cursor keys or the mouse to move around the haul cycle. 4. Right-click to add, edit or delete segments from the haul cycle. Note the automatic segments. 5. Close the Haul Cycle dialog box.

Editing templates: 1. Click the Haulage System drop-down list so that Haulage System-1 is highlighted. 2. Right-click the highlighted name and select Edit. 3. Rename the haulage system to Basic Waste Contract. 4. Click the lower portion of the screen so that the haulage system name is no longer highlighted. 5. Click OK on the toolbar.

2.1.3

Questions

1. What is in a TP7 file? 2. What are the five components of a haulage system? 3. What is a Talpac project? 4. Why would you want to print the ALL PARAMETERS sheet? 5. What are the options available on the right-click of the mouse when a template name is highlighted? 6. What types of Haul Segments can be used? 7. What is the difference between adding to a template list and editing a template?

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2.2

The material type

Key concepts: Density, Swell, Fill factor, Production measurement

2.2.1

Technical description

In this workshop, the characteristics of the material being hauled by the contractor are entered into a template. The characteristics of the waste are described below. The productivity results are to be reported by volume rather than weight. Since we are working in metric units, this will mean that productivities are expressed as bcm/op.hour, bcm/shift and bcm/year. The insitu bank density is the density of the material while it is in the ground. This parameter is used to convert an insitu bank volume to its equivalent weight, and vice versa. The material swell factors are used to convert bank volumes to loose volumes in the loader bucket and the truck tray. Note that both swell factors are based on insitu volume. The loader bucket fill factor is dependent on both the material type and the class of loader. It is the ratio of the loose volume of the material in the loader bucket to the volumetric rated capacity of the loader bucket. The volumetric rated capacity of the loader bucket may be expressed on either a struck or heaped basis. Similarly, the loader bucket fill factor may be expressed on a struck or a heaped basis. The fill factor is selected from a scale in the material template.

2.2.2

Tasks

Setting up the material type: 1. Create a new material template for the waste that the contractor is to haul. Click in the Material Template drop-down list and either right-click and select Add from the menu or click Add on the toolbar. 2. Call the new template Tutorial Waste. 3. Ensure the Bank Volume option is selected for the production measurement. 4. The waste has an insitu bank density of 2.20 tonnes/bcm. 5. The swell factors for the waste the contractor is to move are as follows: Description

Swell factor

Bank to Loader Bucket

1.20

Bank to Truck Tray

1.25

6. Click Edit Global Fill Factors.

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7. Select the View Heaped Values radio button and change the Poor (Struck) value for the Front End Loader to 0.720.

8. Click OK.

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9. Set the loader bucket fill factor to average for the contractor's loader mining waste. This should equate to a factor of 0.720 on a heaped basis for a front end loader.

2.2.3

Questions

1. What is the loose density in the loader bucket? 2. How would you use your own site-specific fill factors? 3. What else will affect the filling of the bucket?

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2.3

The shift roster

Key concepts: Roster, Delay, Scheduled, Unscheduled, Operating, Non-operating

2.3.1

Technical description

Working and operating hours for the loader and trucks are defined in the shift roster. The weekly shift pattern is specified, then lost shifts per year and delays within each shift are allocated. These lost shifts and delays are divided into the following categories: Scheduled lost shifts Unscheduled lost shifts Non-operating shift delays Operating shift delays. The choice of category for a delay depends on mine site work practices. By definition, scheduled delays are those that may be fixed in time, for example, the public holiday on 25 December. Unscheduled delays are delays that you expect, but don't know exactly when they will occur, for example, clean-up around the loader area and delays due to wet weather. Operating delays are those delays when the equipment's engine is running. Conversely, non-operating delays are those delays when the equipment's engine is not running.

2.3.2

Tasks

Setting up the shift roster: 1. Set up a roster template for the shift roster described below. Call it Tutorial Roster. 2. The contractor operates on two shifts per day, from Monday to Friday. In addition, there is one over-time shift on Saturdays. 3. The only rostered days of the year that are not worked are Christmas Day and Good Friday. 4. The contractor annually allows for ten shifts lost due to industrial action and ten shifts lost as a result of wet weather. 5. Each shift is ten hours long. The following delays occur within each shift: Description

Duration

Type

Crib (meal) break

30 minutes

Non-operating

Delays either side of crib

2 x 5 minutes

Operating

Delay at start of shift

5 minutes

Non-operating

Delay at end of shift

5 minutes

Operating

Delays for blasting

5 minutes

Non-operating

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Description

Duration

Type

Clean-up around loader

15 minutes

Operating

Refuelling is carried out outside normal production hours.

2.3.3

Questions

1. What are the total annual working hours for the loader? 2. What are the total fleet operating shifts for the year?

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2.4

Selecting a loader

Key concepts: Loader database, Distribution, Loader methodology

2.4.1

Technical description

The contractor wants to use Caterpillar 992K front end loaders. The characteristics of the loader have been determined from historical data. We need to use this data to correctly define how the loader is to be simulated.

2.4.2

Tasks

Selecting and configuring your loader: 1. Right-click the list of loaders and select Add. You will now be looking at the loaders section of the equipment database. 2. Choose Caterpillar from the Manufacturer drop-down list. 3. Scroll through the list of loaders and select the 992K. 4. Click Select.

5. You will now be back in the loader template. Call this template Contract Cat 992K. 6. The contractor's 992 loaders have an expected mechanical availability of 90% and the Bucket Cycle Time takes 35 seconds. Change the Bucket Cycle Time in seconds and the minutes will calculate automatically and vice versa.

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7. Click Bucket Selection.

8. The buckets available for the 992 display in the drop-down list. Examine all the options available. When you have finished, click Restore Defaults and click OK. 9. Click the Costing Data tab. The capital cost to the contractor of a 992K loader is $1 200 000. 10.The contractor bases its cash flow on a 10% salvage value (residual value) at the end of the loader life of 25 000 hours or five years (whichever occurs first). 11.The loaders are depreciated at a rate of 15% on a straight-line basis. 12.Complete the costing data with the following values:

Description

Cost

Operating Labour

$54.76/op. hr

Maintenance Labour

$19.52/op. hr

Lube

$3.79/op. hr

Tyre Replacement

$11.01/op. hr

Wear Items

$6.00/op. hr

Repair Parts

$45.00/op. hr

Major Overhaul

$18.00/op. hr

Liquid Fuels

$25.26/op. hr

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13.Click the Distribution Data tab, examine the options available but do not change anything. 14.Click OK when you are finished.

2.4.3

Questions

1. What is the total operating cost per hour? 2. Why can the template name be different to the database equipment name? 3. What does the default bucket payload represent?

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2.5

Selecting a truck

Key concepts: Truck database, Local characteristics

2.5.1

Technical description

Characteristics of the haul trucks in the fleet are stored in the truck template, which is structured in a similar way to the loader template. Our example contractor uses Komatsu HD785-7 rear dump trucks. The characteristics of the trucks are defined in the next task.

2.5.2

Tasks

Selecting and configuring your truck: 1. Right-click the list of Truck Type 1 and choose Add. You will now be looking at the trucks section of the equipment database. 2. Select Komatsu from the Manufacturer drop-down list. 3. Scroll through the list of trucks and select the HD785-7. 4. Click Select.

5. The contractor's trucks are equipped with standard motors and are designed to carry the manufacturer's rated payload. The Komatsu HD785-7 trucks have an availability of 85%. 6. Operational studies show a spot time at the loader is 24 seconds, dump spot time is 20 seconds and a dump time of 30 seconds.

Changing the seconds automatically updates the minutes, and vice-versa.

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7. Click the Costing Data tab. The truck capital cost is $850 000. A 10% salvage value at the end of the truck life of 30 000 hours or six years is assumed. The trucks depreciate at 25% on a straight-line basis. 8. Complete the costing data with the following values:

Description

Cost

Operating Labour

$46.37/op. hr

Maintenance Labour

$18.24/op. hr

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Description

Cost

Lube

$2.59/op. hr

Tyre Replacement

$10.91/op. hr

Wear Items

$4.30/op. hr

Repair Parts

$24.08/op. hr

Major Overhaul

$10.75/op. hr

Liquid Fuels

$17.24/op. hr

9. Click the Distribution Data tab, examine the options available but do not change anything. Click OK when you are finished.

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10.Set the number of trucks to Auto (not Auto-Max:1), so Talpac estimates the number of trucks required to keep the loader busy as follows:

2.5.3

Questions

1. What is the total operating cost per hour for the truck? 2. When would you use the different truck types in the same simulation?

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2.6

Setting up a haul cycle

Key concepts: Segment, Rolling resistance, Speed restrictions, Forward and reverse segments

2.6.1

Technical description

To perform a simulation, Talpac needs data regarding the haul route. This workshop describes how this data can be converted into a required format. The loading segments are automatically included at the start of each new haul cycle.

2.6.2

Tasks

Setting up a haul cycle: 1. Click Edit Haul Cycle to open the Haul Cycle dialog box. The drawing at the end of the workshop displays a typical haul profile on which the waste contract is based. Conditions to be expected in the mine are listed below: within 50 metres of the shovel and dump point, the truck speed is restricted to 30 km/h around corners, trucks should not exceed 30 km/h when traveling down ramps, trucks must not exceed 40 km/h. 2. Change the name of Haul Cycle 1 to Base Haul Route. 3. Add a new haul segment by clicking row 4 of the haul cycle and either click Add on the toolbar or use the right mouse menu. 4. Call the new haul segment Around Loader, the distance is 50 metres, the maximum speed is 30 km/h and all the other factors will use the default values. 5. The haul profile should be divided into the appropriate number of segments. The segments may be of any length, but should have a constant grade, rolling resistance and load. Don't forget to include loading, dumping and fixed time segments in the haul cycle and take into the speed restrictions. 6. Rolling resistance is expressed as a percentage of the component of the gross vehicle weight that is normal to the ground surface. For guidance on rolling resistance values to use, access the table from the rolling resistance column, right-click one of the cells in the Rolling Resistance column and click Select.

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7. We will be using the average conditions for this tutorial, so click in the Average column of the row in the table that best describes the current haul segment.

8. When you have added all of the haul segments needed, add the dumping segments. 9. As the haul route for the return journey is the same, it is possible to use the Reverse all segments option. Reverse all of the segments.

Haul cycle

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2.6.3

Questions

1. When is a new segment required? 2. How many segments are required? 3. What other methods are available for constructing a haul route in Talpac? 4. What is the benefit of using real names for segment titles? 5. What is the relationship between final and maximum speeds for segments?

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2.7

Production analysis

Key concepts: Calculation type, Full simulation, Stochastic, Excavation target

2.7.1

Technical description

Once the haulage system has been defined, it is ready to be analysed. In assessing the productive capacity of the system, you have the choice of using the quick estimate or the full simulation. The other types of calculations will be discussed later. Quick estimate assumes there is no variability in the truck and loader parameters, and a deterministic analysis is performed. Full simulation takes the variability of truck and loader parameters into using a stochastic analysis. Parameters that may be varied in the full simulation include loader bucket cycle time, loader bucket payload, truck travel time, truck dumping time and truck availability. The Excavation Target feature lets you specify a production target. When an excavation target is specified, the Production Summary Report lists how many days/years it takes to move the specified excavation target. The value for the target is dependent on the measurement basis chosen in the material template.

2.7.2

Tasks

Performing a production analysis: 1. Select the Type of Calculation drop-down list to view the options.

2. Select Quick Estimate and click Calculate to view the Quick Estimate Results (alternatively, simply press F9). 3. View the Quick Estimate results, and close when finished. 4. Select Full Simulation from the Type of Calculation drop-down list and click Calculate to view the Full Simulation results (alternatively, simply press F10). 5. Compare the differences between the Full Simulation results and the Quick Estimate results. 6. View the haul cycle details, the tyres and fuel consumption, and the cash flow screens. View the defined travel time graphs to identify the key segments of the haul cycle. 7. Enter an Excavation Target of 2 500 000 bcm, run a Full Simulation and view the results at the bottom of the Production Summary Report.

2.7.3

Questions

1. Why is it useful to have different calculation types? 2. What is the vertical height difference that the load is being elevated through? 3. Why can you get different results for successive runs? 4. How long does it take to reach the production target?

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2.8

Incremental analysis and results tables

Key concepts: Incremental analysis, Results tables

2.8.1

Technical description

The haul profile used so far is representative of haul routes at the mid-life of the waste contract. In the early years, the pit is shallower and, in the later years, it is deeper. The change in RL and the length of the ramp out of the pit vary as follows: Year

Length of pit ramp (metres)

1

200

2

300

3

400

4

500

5

600

6

700

7

800

The distance and elevation from the surface to the top of the waste dump do not change. In planning, we need to understand how the productivity requirements change for the life of the contract. Also we are interested in seeing the results tabulated in a different format to the standard results. Based on this information, determine the productivity of the fleet for each year of the contract.

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2.8.2

Tasks

Calculating and reporting fleet productivity: 1. Click Incremental Analysis. 2. Click Add in the Incremental Analysis window. 3. From the Item drop-down list, select Haul Segment Distance. 4. From the Forward Segment drop-down list, select Pit Ramp. 5. From the Reverse Segment drop-down list, select Pit Ramp (rev.). 6. Set the: First Value to 200 Last Value to 800 Step Value to 100 Increment Order to 1. 7. Click OK.

8. Click Calculate in the Incremental Analysis window. 9. Examine the information displayed in the Results Table.

The column headed Row 7: Distance: TT1 represents the pit ramp length.

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10.Try creating your own report by clicking Report and choosing fields from the left-hand pane.

11.Produce a graph of the ramp length versus the fleet productivity. Highlight the cells in the Results Table you want to graph and select Graph Selected Runs from the right-click menu.

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12.From the X drop-down list, select Row 7: Distance: TT1 and from the Y drop-down list, select Fleet Production Per Operating Hr.

13.Right-click on the graph and select Chart Designer from the menu.

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14.Try changing the chart type to a bar graph. Examine the options available and see what effect it has on your graph.

2.8.3

Questions

1. What is the key information? 2. How many variables are available for inclusion in the results table? 3. When should you consider purchasing another truck?

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2.9

Fleet size optimisation

Key concepts: Optimisation analysis, Marginal economics

2.9.1

Technical description

The optimum number of trucks in a fleet is a balance between productivity and cost. The fleet size optimisation carries out a series of production analysis for a range of truck fleet sizes. The results are summarised in a table displaying the fleet size, the fleet production and the discounted average cost. The results can also be displayed on a graph. The optimum fleet size is that with the lowest unit cost of production. The optimum fleet size will not necessarily have the highest production or provide the required output.

2.9.2

Tasks

Determining the optimum fleet size: 1. Create a copy of the Base Waste Contract haulage system, press F2 and rename it to Workshop Fleet Size. 2. Make a copy of the base haul cycle and rename it to Workshop Haul. 3. In Workshop Haul, change the pit ramp distance to 2000m. to change both the forward and reverse segments of the pit ramp. 4. Configure the rest of this haul system to have the same loader, truck, material and roster templates. Make sure you save this haul system after you have selected the appropriate items. 5. Do a Full Simulation calculation and note the number of trucks. 6. Now determine the optimum number of trucks for the contractor's fleet. Click Optimisation. 7. Select the Fleet Size radio button and click OK.

8. Plot a graph of the fleet size versus the marginal cost. 9. Compare the optimum with the truck match determined in the full simulation previously calculated in this workshop. 10.Export the Results Table by selecting File > Export.

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11.Click Browse and choose a name and location for the file. Make sure the Excel File (.XLS) radio button is selected. 12.Click OK.

13.Open your results file in MS Excel and examine the data.

2.9.3

Questions

1. What is the marginal cost of asg one more truck than the optimum? 2. Why are the marginal economics important, and not just the average cost? 3. What is the optimum fleet size?

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2.10

Fleet comparison

Key concepts: Haulage systems

2.10.1

Technical description

The contractor wants to investigate the cost benefits of moving to larger equipment for the waste removal contract. A new haulage system is going to be configured for the larger equipment. New truck and loader templates will be created.

2.10.2

Tasks

Creating a new haulage system for fleet comparison: 1. Add a new haulage system called Workshop Comparison. This will have the Tutorial Roster, Tutorial Waste and Base Haul Route from the Basic Waste Contract haulage system. 2. Create a new template for both the truck and loader. 3. Complete the details of the larger equipment items for the contractor below: Description

Shovel

Truck

Name

Komatsu PC3000-6

Komatsu HD1500-7 (Cont Retard)

Type

Hydraulic Shovel

Rear Dump Trucks

Capacity

16.0 cu.m heaped

144.2 tonne payload

Availability

90%

85%

Capital Cost

$2 000 000

$1 300 000

Residual Value

10%

10%

Life in Hours

35000

35000

Life in Years

8

8

Depreciation type

Straight line

Straight line

Depreciation Rate

15%

25%

Total Operating Cost

$222.73

$163.50

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4. With this equipment, each bucket cycle takes 30 seconds. Also, for the trucks, the spot time at the loader is 30 seconds. The spot time at dump is 30 seconds and the dump time is 30 seconds. 5. Select the Total Operating Cost check box to enter the operating cost.

6. Compare the discounted average cost for the equipment fleet above with the equipment fleet used in the Basic Waste Contract. In determining the discounted average cost, use the optimum truck fleet size for each option.

2.10.3

Questions

1. Which equipment fleet would you recommend the contractor purchase? 2. What factors affect this decision?

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2.11

The equipment database

Key concepts: -defined equipment

2.11.1

Technical description

The equipment database contains a large range of trucks and loaders used in surface mining operations. The data supplied in the equipment database represents standard equipment and has been verified by the appropriate manufacturer. For equipment not in the database or that has been changed, the is able to set up their own equipment items.

2.11.2

Tasks

Creating -defined equipment in the database: 1. Access the equipment database by selecting View > Equipment Database or clicking Equipment Database on the toolbar. 2. Use the Type, Manufacturer and Class drop-down lists to view the truck and loader data stored in the database for each equipment type. 3. Create a -defined equipment item by copying a standard item of equipment and giving it a new name. 4. To copy an item from the standard database to a database, select Edit > Copy Equipment. Rename your copy of the Komatsu HD785-7 to My Mines 785-7.

2.11.3

Question

1. What role would -defined equipment have at your operation?

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2.12

Importing a haul cycle

Key concepts: Importing a haul cycle from a text file

2.12.1

Technical description

In a previous workshop, we created a haul cycle by manually typing the required details for each segment. In Talpac, you can also import this data directly from a text file. In turn, this text file can be automatically generated in another system, such as a design package or a fleet monitoring/dispatch system. The text file import facility in Talpac can be quite sophisticated, and in this workshop only a small portion of the functionality is used. For more advanced requirements, refer to the help documentation or Runge.

2.12.2

Tasks

Importing a haul cycle: 1. Navigate to the Talpac\Tutorials directory. 2. Open the Test XYZ Space.txt file in a text editor (for example, Notepad). This file represents the coordinates of a haul route. 3. Close the file after inspection. 4. In Talpac, add a new haul system called Workshop Import. 5. Select File > Import > Import Haul Cycles from a Text File from the menu bar. 6. Click Add and create a new template called Tutorial. 7. Click Browse and find the file Test XYZ Space.txt.

If Text XYZ Space.txt is not initially displayed, select All Files (*.*) from the drop-down list next to the File name field.

8. Select the Space check box as the field delimiter character. If other field delimiter check boxes are selected, deselect them. 9. Leave the First Import Line as 1, and also leave the Comment Character as !. 10.Click Next Line twice so that line 3 of the file displays in the viewer. 11.Set the Import Data Type radio button to X,Y,Z co-ordinates. 12.Enter appropriate field numbers for the entities: X coord - 2 Y coord - 3

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Z coord - 4. 13.Ensure all other field numbers are set to 0. This means that you are accepting the defaults displayed for those fields. 14.When complete, select the Reverse all segments, setting load to "Empty" check box. 15.Click OK.

16.Inspect the results in Talpac. Check that the haul cycle Import Test Haul 1 has been imported.

2.12.3

Questions

1. Why is the new haul cycle called Import Test Haul 1? 2. How can this feature be used in your situation? 3. How else can the import facility be used?

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2.13

Talpac options

Key concepts: Project options, Customising Talpac, Project management, , Project properties

2.13.1

Technical description

There are many variables and options used in Talpac that are not contained in any of the templates that we have looked at so far. There are also a number of ways to customise Talpac - this workshop will guide you through these features.

2.13.2

Tasks

Accessing Talpac's options: 1. Select File > Data File Management and view the information available.

2. Click View the list of Templates and examine the options available. 3. Click Close. 4. From the menu, select Help > About Talpac and click the Send a suggestion link to automatically generate an email to Runge's desk to provide . 5. The following are the main items accessed from the View menu: Project Options Used to access travel options, loading options, cost data options and bucket construction ratings. Customise Talpac Used to access general options, distribution defaults, set colours and currency options. Project Management Used to view all haulage systems in this project, create new haulage systems and run simulations on all haul systems.

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2.13.3

Questions

1. When should you change the options settings? 2. How can you tell the location of the current database? 3. How can the project manager interact with mine planning?

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2.14

Calibrating Talpac

2.14.1

Why calibrate?

Talpac is a proven tool for conducting haul simulation using the numerous input parameters that impact truck and loader fleet performance. Variations in material characteristics, operating conditions, equipment changes and mine operating procedures can all have an impact on fleet performance. Calibrating Talpac to match actual productivities ensures that the results from the simulations reflect the individual conditions of your operating environment, letting you calculate and report with confidence in the results.

2.14.2

How to calibrate

Calibrating Talpac: 1. Open your project in Talpac and that the correct Haul Cycle, Loading Unit and Truck Types are selected. 2. Click All Parameters in the Talpac Data Entry screen and print the list of parameters. This print-out lists all of the data being used in your Talpac project, whether default values or data that you have entered. 3. Gather performance data from your mine site for the key parameters. Possible sources of data include: Truck and loader on-board performance monitors Mine fleet dispatch and monitoring systems Manufacturer-supplied specifications for the equipment at your site Pit and dump plans displaying elevations along the haul route "Time and Motion" field studies Production records - for example, truck counts, belt weightometers, surveyed volumes. 4. Run some test simulations and compare the results to real-world performance data from your site. Ideally, the performance data will be for a whole shift for a particular haulage system (otherwise, a few repetitive timings of a particular haulage system can be used). Adjust the model as necessary to ensure that the Talpac results are in line with actual performance data. Some of the common adjustments that you might make are: Type of data to adjust

Adjustment description

Equipment

If equipment specifications are significantly different to the data in the Talpac database, create " Equipment" in Talpac with the actual specifications and performance curves

Truck Travel Time

Compare measured travel times segment by segment with those in the Haul Cycle Report Vary the rolling resistances in the Haul Cycle Vary the Travel Time Correction Factor

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Type of data to adjust

Adjustment description

Set calculation mode to Quick Estimate (rather than Full Simulation) to eliminate variability in parameters during calibration

Truck Cycle Time

Check truck queuing and loading time (and number of trucks) Check truck spotting time and first bucket delay

Vary the non-operating shift delays and operating shift delays (roster template) to achieve the actual working hours

Truck Productivity

Set truck availability to 100% for the calibration exercise

Loader Productivity

Ensure that the number of es to fill truck reflect actual data

5. Re-calibrate at frequent intervals.

2.14.3

Points to consider

Here are a few points to consider when gathering the calibration data for your site. Material characteristics What is the In Situ Bulk Density and how is it measured? What swell factors are included in the data - In Situ into the Bucket, In Situ into the Truck? How well does the loader dig? What is the Bucket Fill Factor? Seasonal variations in material characteristics (for example, wet weather, snow). Is there "carryback" of sticky material in the empty trucks? Working roster What are the site values for hours/shifts/day for each day of the week? What are the site values for lost days per year (for example, weather, industrial, public holidays)? Are there delays that do not occur every shift (for example, blasting, equipment relocation, power outages)? What is the average operating time per shift (operator in the equipment, equipment in operating condition)? What are the average operating delays per shift (for example, loader waiting for dozer clean-up, moving large rocks)? Equipment physicals What equipment models are being used on the calibration haul? Do they differ from the Manufacturer's Handbook Specifications and, if so, what are the revised specifications (and the performance curves, if relevant)?

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Changing tyre size, engine power or gear ratio requires a revised set of truck performance curves.

Was all equipment purchased at the same time (differences in operating life will result in variations in performance)? Has the equipment been maintained in accordance with the manufacturer's recommended maintenance schedule (poorly maintained trucks may not perform in accordance with the manufacturer's performance curves)? Haul route What are the segment distances and grades? What operating conditions may affect equipment performance? Do seasonal variations affect the haul route and truck performance (for example, wet weather, fog, snow, dust storms)? What speed restrictions apply (for example, for safety, tire heating management)? What is the productivity of the truck drivers? Real-world performance data - truck Actual haul profile and speed limits Best estimate of rolling resistance for each haul segment Actual number of trucks assigned to the loader Actual truck travel times (empty and loaded) for each segment of the actual profile, including truck loading, spotting, dumping and queuing times Actual truck payload and empty truck weight. Real-world performance data - loader Loading regime (single-sided or double-sided) Actual number of loader es to fill truck Actual time waiting for trucks First bucket delay. Real-world performance data - fleet Actual number of working hours per shift Actual probability distributions for truck travel time, truck dumping time, truck availability, bucket payload and bucket cycle time. 'Representative' real-world performance data Fleet performance on a particular haulage system can vary over time due to several factors, including: Weather conditions Diggability at the loader face (blast performance)

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Haul road conditions Truck driver performance Loader operator performance Condition of the equipment Traffic density (night shift versus day shift) The number of trucks assigned to the loader.

Most s build one Talpac model for their site, so real-world performance data (for calibrating Talpac) is ideally representative of the long-term averages of the variables mentioned above.

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3

Answers

3.1

Workshop 1 - Talpac overview

1. What is in a TP7 file? The TP7 file is the data file stored in your working directory that contains all of the data and settings for the current project. 2. What are the five components of a haulage system? Material, Roster, Loader, Truck and Haul Cycle. 3. What is a Talpac project? A Talpac project is the collection of saved Haulage Systems that are in the same TP7 file. 4. Why would you want to print the ALL PARAMETERS sheet? For reference and auditing. For example, it is useful to print this file to have as a backup of the important Talpac configuration settings. This is haulage system specific. 5. What are the options available on the right-click of the mouse when a template name is highlighted?

6. What types of Haul Segments can be used?

7. What is the difference between adding to a template list and editing a template? Editing a template overwrites the data that already exists in the template. Adding a new template to the list means that a new template is created, and so all the original templates still remain.

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3.2

Workshop 2 - The material type

1. What is the loose density in the loader bucket? 1.83 t/m3 (see the image below).

2. How would you use your own site specific fill factors? Change the Global Variables table. 3. What else will affect the filling of the bucket? Fragmentation, operator experience, weather conditions, visibility, bucket geometry, material angle of repose.

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3.3

Workshop 3 - The shift roster

1. What are the total annual working hours for the loader? 4099 (see the image below). 2. What are the total fleet operating shifts for the year? 464 (see the image below).

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3.4

Workshop 4 - Selecting a loader

1. What is the total operating cost per hour? The total operating cost for each loader is $183.34/operating hour. 2. Why can the template name be different to the database equipment name? You may want to model variations of the same basic equipment. 3. What does the default bucket payload represent? The amount of material actually in the bucket, not the bucket capacity. The amount of material in the bucket is calculated by the following equation: Amount of Material in the Bucket = Bucket Size x Material Density x Bucket Fill Factor

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3.5

Workshop 5 - Selecting a truck

1. What is the total operating cost per hour for the truck? The total operating cost for each truck is $134.48/operating hour. 2. When would you use the different truck types in the same simulation? If you were simulating a fleet that had more than one type of truck.

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3.6

Workshop 6 - Setting up a haul cycle

1. When is a new segment required? Whenever there is a change to the conditions which control velocity. Thus gradient, rolling resistance and speed restrictions. 2. How many segments are required? See the image below. 3. What other methods are available for constructing a haul route in Talpac? Importing data from a text file. 4. What is the benefit of using real names for segment titles? So the can visualise, and hence validate, the haul cycle data. 5. What is the relationship between final and maximum speeds for segments? The maximum speed (specified in the Max km/h column) is the maximum speed reached over the complete segment; the final speed (specified in the Final km/h column) determines at what speed the truck finishes the segment.

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3.7

Workshop 7 - Production analysis

1. Why is it useful to have different calculation types? Mine planning requires different scenarios and options to be investigated. This means that different functionality is required. As well, this is useful to calibrate the model in Quick Estimate (deterministic) mode first. 2. What is the vertical height difference that the load is being elevated through? 60m. 3. Why can you get different results in successive runs? Due to the stochastic distributions used in simulation. 4. How long does it take to reach the production target? 307.35 days in Quick Estimate mode; slightly different in Full Simulation mode.

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3.8

Workshop 8 - Incremental analysis and results table

1. What is the key information? Key information is what you need to see, and so depends on the purpose of the simulation. In this instance, cost, time, productivity, fleet size and length of haul would be key. 2. How many variables are available for inclusion in the results table? 250. 3. When should you consider purchasing another truck? In year six, to ensure that a truck is ready for year seven. But what else should be considered?

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3.9

Workshop 9 - Fleet size optimisation

1. What is the marginal cost of asg one more truck than the optimum? Assuming the optimum is six trucks, $2.64/bcm for truck seven. 2. Why are the marginal economics important, and not just the average cost? Average costs disguise the impact of individual truck assignment. 3. What is the optimum fleet size? The run with the lowest fleet discount cost.

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3.10

Workshop 10 - Fleet comparison

1. Which equipment fleet would you recommend the contractor purchase? The larger fleet is the pure cost choice, but is this correct? 2. What factors affect this decision? Cost of capital, changes to working hours, flexibility of contract.

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3.11

Workshop 11 - The equipment database

1. What role would -defined equipment have at your operation? You can set up the specifications for the truck and loader that exactly match your configuration, rather than relying on the standard data.

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3.12

Workshop 12 - Importing a haul cycle

1. Why is the new haul cycle called 'Import Test Haul 1'? Set by the variable on line 2 of the import file. Otherwise, it will be imported and called the same as the import file name. 2. How can this feature be used in your situation? For example, from the mine design package, a string can be digitised which represents the haul route. This string can then be exported to a text file as a series of X, Y, Z points. From there it can be imported directly into Talpac. 3. How else can the import facility be used? To import complete haul systems.

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3.13

Workshop 13 - Talpac options

1. When should you change the options settings? Only after consideration of what they are doing. It is also suggested that if these are changed, then make sure that changes are properly recorded. The ALL PARAMETERS print outs and -defined reports in the Results Tables are two good ways of doing this. 2. How can you tell the location of the current database? Under View > Project Properties the location and name of the current database displays. 3. How can the project manager interact with mine planning? Can make the analysis of multiple simulations easier and more straight forward.

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4

Talpac commands

4.1

Embedded buttons Button

Function

Button

Function

Project Options

All Parameters

Loading Analysis

Project Manager

Fleet Planner

Optimisation Calculation

Incremental Analysis

Calculate Full Simulation or Quick Estimate

Edit Haulage System

Edit Material Template

Edit Loader Template

Edit Roster Template

Edit Truck Template

Edit Haul Cycle

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4.2

Toolbars Button

Function

Button

Function

Save

View Project Manager

Print

Help

Print Preview

Insert haul segment

Truck and Loader database

Delete haul segment

Edit Haulage System

Paste copied or cut segments in reverse

Edit Material

Reverse all haul segments

Edit Roster

Undo change

Edit Loader

Redo change

Edit Truck

Export haul cycle

Edit Haul Cycle

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4.3

Function keys Key

Function

Key

Function

F1

Help

F9

Run Quick Estimate

F2

Edit

F10

Run Full Simulation

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