Reducing haul truck fuel costs

through rule-based data

analysis
Cristian Ramrez
Modular Mining Systems

Agenda

Introduction
Data logging
Trend workshops
Project details
Methodology
Results
Conclusions

Introduction
Mine operators are constantly looking for ways to maximize
the efficiency in the use of consumables
Fuel and tires represent most of the operating costs of a mining truck

A mine operator in Brazil discovered the opportunity to save

fuel by changing operator behavior at dumps
The opportunity was validated and quantified using Modular
Minings maintenance management software, MineCare

Data logging
Historically, all data was measure, collected and stored on
onboard devices
Delay in getting de data (donwload process required)
Huge volumes of data to analyze

High capacity telecommunication networks allowed to

transmit data on demand or in real-time to central servers for
processing
Still requires analyzing huge amounts of data, a slow process
Need dedicated personnel for real-time monitoring

Data logging
Real-time monitoring

Rule-based triggers
(trends)
Start monitoring when pre-defined conditions are met
Reduced volume of recorded data
Faster analysis

No need for real-time monitoring personnel

Integration with mine management systems (e.g.
Dispatch) allowing correlation with operational data
haul cycle, location, operator, etc.

Trends are predictive analysis tools used for advanced

monitoring and detection of impending failures

Trend workshops
Who
Maintenance personnel (preventive, planning, etc.), MMS
consultants, facilitator

Goal
Discussion on early detection of operational problems or
undesirable operational conditions or abuse of equipment

Output
Formal document to facilitate the upload of this
information into the MineCare configuration

Project details
Brazilian iron-ore producer, 72 truck fleet
Situation
240-ton haul trucks automatically increased engine speed
from a 700 rpm idle to 1500 rpm while lifting the bed.
It was discovered that operators were applying additional
throttle (over 1900 rpm) to lift the bed faster

Study
Determine the impact of this situation on dumping time
and fuel consumption, and
estimate the potential benefits from correcting the
practice.

Methodology
Trend workshop
Modulars consultant selected a sample of 26
Caterpillar Model 793C 240-tonnes
Data was collected during a month
Specific parameters to monitor
Engine speed (rpm)
Fuel burn rate (l/hr)
Dump time from mine management system (Dispatch
and VIMS events)

Methodology
MineCare Trend
Trend 1
Conditions

If conditions
are met

Trend 2

Engine speed is greater than 1500 rpm

and less than 1600 rpm

Engine speed is greater than 1900 rpm

Truck bed is up

Truck bed is up

Truck location is a dump

Truck location is a dump

Record engine speed (rpm)

Record engine speed (rpm)

Record burn rate (l/hr)

Record burn rate (l/hr)

Results
Week

Number of alarms
exceeding 1900 rpm

Affected loads
(%)

1564

27.1

1928

33.5

527

9.1

2289

39.7

2334

40.5

Average

1728

30.0

Alarms of excessive rpm at dumps

- On average, 5763 loads are dumped by this sample per week

Results (contd)
Normal idling engine
speed
Engine
speed (rpm)

Fuel rate
(l/hr)

Excessive engine speed

Engine
speed
(rpm)

Fuel rate (l/hr)

Truck 1

1,580

74.3

1,915

124.7

Truck 2

1,582

74.2

1,911

130.6

Truck 3

1,571

80.2

1,936

137.8

Truck 4

1,544

85.3

1,930

134.8

Truck 5

1,557

72.6

1,919

133.8

Truck 6

1,536

57.2

1,935

136.2

Truck 7

1,567

77.6

1,929

142.7

Average

1,562

74.5

1,925

134.4

Relationship between engine

speed and fuel burn rate

Results (contd)
In 30% of the dumps on average, operators apply
excessive throttle
At dumps, fuel burn rate nearly doubles when engine
speed exceeds 1,900 rpm
Average fuel consumptions following manufacturer
recommendations: 74.5 l/hr
Average fuel consumptions applying excessive throttle: 134.4
l/hr

The average dump time across all loads was measured at

20 seconds
No observable difference in dump time between the two
studied conditions

Conclusions
Excessive engine speed during dumping only
increased fuel consumption without a noticeable
improvement in dumping time
If dumping practices were standardized to comply
with manufacturer recommendations, mine could
save on fuel consumption

Conclusions
Calculating fuel savings
Considering the 26-truck sample
representative of the whole fleet of 72 trucks,
30% of the total loads are dumped over
speeding the engine
This is 4,788 loads per week

Per each load, 20 seconds of extra throttle

consumes an extra amount of fuel of
20 [seconds] x (134.4 74.5) [l/hr] = 0.33 litres

Conclusions
Calculating fuel savings
4,788 extra throttle loads per week,
where each dump consumes 0.33 extra liters
of fuel,
result in extra fuel consumptions of 82,853
liters per year
@ US$ 1/liter, this is more than US$ 80,000 savings per
year

Conclusions
Summary
Substantial cost-savings opportunities exist
within a 20 second part of a 40 minute hauling
cycle
Maintenance Management systems can be
used to identify those opportunities

Thank you
Cristian Ramirez
Senior Engineer - Value Add Services
Modular Mining Systems Canada Ltd.
+1 604 468 8715
ramirezc@mmsi.com
www.modularmining.com