28/08/2014

Hi Mining Week'1! Hi On Hi Mining IQ’s Top Tips for New Technology Adoption!.

Hi Mining Week'1! Hi On Hi Mining IQ’s Top Tips for New Technology Adoption!.


A Hit Mining imagine we run around 20 different mining technology events a year, all around the globe. 
Technology in mining is one of my personal favourite interest areas in the sector, as it’s always changing and evolving!
Whether you work in mobile maintenance in the workshop, operating a haulage truck, overseeing PLC systems in the plant or monitoring security on site – there’s always a new and shiny technology being lauded as the new best thing to happen to mining.
Technology is absolutely a fundamental enabler for the future of the sector, and must be embraced in order for the industry to claw back productivity levels and try to reduce cost levels across the board. 
However, poor technology (whether we’re talking software, hardware or equipment) purchases can be devastating to an operation. It can have negative effects on productivity, FINANCES or the safety of your workers.
Over the past 12 months attending numerous conferences around Australia hearing senior leaders from BHP Billiton, Rio Tinto, Glencore, Newcrest, Newmont, Anglo American and many, many more, discussing successes and failures in NEW TECHNOLOGY adoption at their sites. 

Here are the highlights of their key takeaways and 
lessons learned:
  • Ease of integration and legacy issues: this is now a fairly obvious statement to make, and yet still purchases are made every year in the sector without full consideration given to how much data can be moved over from past systems and how much the new one will “talk” to those it directly needs to interact with.
  • You must consider the impact on all other systems further down the value chain. If you’re upgrading scanners on the CONVEYOR SYSTEM within the processing plant, you cannot ignore any impact that may have on the PLC system, or the SCADA system. Mapping out the knock on effect of upgrades on all inter-related systems is critical to ensure there are no failures or glitches when the implementation occurs.
  • Beware of the vendor lock in! Open source is the way forward, and should absolutely be considered when creating supplier short lists and selections. It may whittle out the majority of the vendors, but will give you a far greater freedom to select add on products from the best providers, rather than being forced to purchase an overarching solution from one provider.
  • Don’t be afraid to source from overseas, but make sure you run the trials before you commit! More advanced mining nations such as Australia, Canada, Sweden, the USA and South Africa can sometimes be averse to purchasing from overseas regions that have historically been viewed as providing low-cost and low-quality equipment. However, procuring from overseas can sometimes supply significant pay off s, provided the equipment is tested early on and clear specifications provided.
  • Collect as much data early on as possible – it becomes harder further down the track to make changes, when more data becomes available, so you must be proactive in DATA COLLECTION early in the project, otherwise you risk making costly mistakes.
  • Involve operational staff early (if this is a decision being pushed by senior management), to help test products/systems. Feedback from them earlier on should be critical to help tweak errors, flaws or design issues. This will also help hugely with user engagement and adoption further down the track.
  • Always ensure you weight the upfront cost vs. life cycle cost and bear that in mind making any decisions based largely on cost. Whilst some products will inevitably be more expensive up front, that can also mean they come with better after-care from the supplier, longer warranties, higher quality parts or lower maintenance requirements (amongst other things).
  • Align any technology purchase or upgrade with the wider BUSINESS STRATEGIES and goals. If it is not in line with the wider business goals it will be harder to demonstrate ROI and value to the business when you are building the business case to purchase it, but also if you go ahead and implement it and then inevitably have to conduct a review.
  • Evaluate the interface design and usability: the technology is only as good as the people using it and if the NEW TECHNOLOGY is difficult to use, or it isn't clear how it can benefit the user to utilise it, then your operations staff are unlikely to fully engage with it.
  • Training for all staff that will be using the technology so they properly understand how to use it and what the full potential of the system is for improving both their JOB and the wider company results.

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Hi Green Tip #4: Hi Size and Select Fans Near Their Peak Total Efficiency.

Even the most efficient fan models can operate inefficiently if improperly sized.Fans selected close to their peak total efficiency (pTE) will use less energy. The 2012 International Green Construction Code requires selections within 10% of peak efficiency, and ASHRAE Standard 90.1,

Energy Standard for Buildings Except Low-Rise Residential Buildings, is considering language that would require a 15% allowable range. If a fan is selected to operate more than 15 point below its peak efficiency, it is probably undersized to result in the lowest purchase price (first cost). The smaller, less-expense fan will have to run much faster with higher levels of internal turbulence than its larger cousin to meet the required air flow, thus consuming a lot more energy.The cost difference to select a larger fan closer to peak operating efficiency is very small when compared to the energy saved.

Simple payback for 10% selections is usually less than one year. Smaller fans operating faster will also require more maintenance and earlier replacement. Smaller fans generate more noise as well.Below is a table showing the output from a fan manufacturer's sizing and selection program. All of the fans in the table would "do the job" of providing the required airflow at the required pressure.

The fan sizes range from 18-inches in diameter to 36-in. Notice that as the fan diameter increases, the fan speed decreases, as does the fan power (expressed as "brake horsepower"). The red region of the table indicates poor fan selection practice - none of these fans have an actual total efficiency (at the airflow and pressure required) within 15 points of peak total efficiency. The green region indicates proper fan selection process - all have an actual total efficiency within 15 points of peak total efficiency.

Note that the 30-in. diameter fan consumes roughly half the power of the 18-in. fan. The lowest cost fan shown is probably the 20-in. fan, with an efficiency of 49%, 29 points off the peak. If this fan runs 6,000 hours per year at a utility rate of 10 cents per kwh, it will cost $4,300 a year to operate. A more efficient selection might be the 24-in. fan because it is "Class I" and complies with both ASHRAE 90.1 and the Green code requirements. It has an actual efficiency of 69%, 10 points less than the peak efficiency of 79%. This fan would cost $3,100 to operate, which is probably more than the fan itself costs. A more efficient 30 inch selection is only 1 point from its peak efficiency of 83% and will consume only $2,600 per year, saving $500 a year relative to a 24-in. fan, and $1,700 a year over the lowest cost fan. Generally, the difference in initial cost of the most efficient fan selection is paid back in less than 5 years over more common less efficient alternatives. Perhaps this observation will bring it home.

Most fans consume more each year in energy cost than they are worth. So, when you buy a fan, think of it as a liability, not an asset. Your objective should be to make the liability placed on those who will pay future energy bills as low as possible. The leverage implicit in choosing a larger, more efficient fan is much greater than most people appreciate. And fans last a long time – 20 years plus – so choose wisely.The bottom line is this. Right-sizing a fan can yield energy savings and generate a lot of operating cost savings for the facility owner or occupants for many, many years.

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