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Pueblo Viejo Mine - Payload Study for

Caterpillar Model 789C & 789D

February 14th 2015

The Project Objective

The objective of this project was to perform a Study of Payload, according to the
Standard Payload Management Policy for the haul Truck Fleet of Pueblo Viejo
Mine for detecting Improvements Opportunities related to Efficiency and
Productivity and the defect elimination on the Equipment scale systems.

The deliverable of this project expected to cover the following points:

1. To perform preventive maintenance to the scale pads property of PVDC.


2. To calibrate the scale pads under OEM standard.
3. Train PV Fleet Management personnel to perform Maintenance and
Calibration prior to start a new study.
4. To do training on the Job for Mine Maintenance and Fleet Management
personnel on How to do a Payload Study using TRANSCALE System.
5. To investigate whether or not the truck manufacturers permitted
Maximum Gross Vehicle Weight (MGVW) was being exceeded. It is
important that exceeding this target could raise safety issues in relation to
Brake and Steering Systems that are certified using the Max GVW. The
MGVW for a 789C is 317,515 tonnes, for a 789D it is 324,319 tonnes.
6. To check on the empty weights of the trucks used for calculation of TKPH
and Payload in the on-board weighing systems
7. To confirm that the payloads distributed in compliance with the Caterpillar
10/10/20 Payload Policy. This policy states that no more than 10% of the
total number of haul cycles can be over 110% of rated payload, and no
single cycle can be more than 120% of rated payload
8. To investigate the load placement in the truck body is correctly centered.
9. Correlation of the on-board truck weighing system with the Transcale
weight scales. The on-board system is sensitive to correct load placement
(see Point 4 above).
10. To confirm the OHT are under specification of load for the Tire Model
PV is using.
11. To deliver a list of recommendations for Mine Operations and Mine
Maintenance strategies, to maximize the Productivity and The Life Cycle
Cost of the Components.

The Maintenance and calibration of the scale pads

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Mine Maintenance Reliability Engineering
Prepared by Alejandro Zappa
14 February 2016
Pueblo Viejo Mine - Payload Study for
Caterpillar Model 789C & 789D
The maintenance of the scale pad took place on the Truck Shop were the
personnel from Maintenance and Fleet Management Systems was trained on the
Job.

The scales looked very good unless for the dirt and dust accumulated due to the

inappropriate storage after the last study in 2014.

It is recommended to storage the Pads in a close place away from the rain and
dust if possible, when not being use or place appropriate covers if outside.

The Study:

The study took place in OHT Parking Area of 180, over 3 day weighing trucks
getting full data collection of 170 payloads.

There were weighed 10 CAT789C and 10 CAT789D, to establish tare weights


followed by weighing > 150 CAT789C and CAT789D to look at loading patterns
and on-board versus off-board weight correlation.

Operation Center CarryBack check Positive


Communication

The load placement was capture on pictures to correlate it with the payload read
by the pads scales and with the Loader/Shovel the truck was loaded.

Loading practices determine the following to consider a good practices

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Mine Maintenance Reliability Engineering
Prepared by Alejandro Zappa
14 February 2016
Pueblo Viejo Mine - Payload Study for
Caterpillar Model 789C & 789D

About the Carry Back: The Carry-Back has been checked before each time an
empty truck was weighted. As you can see down below, no carry back was
observed in all the trucks weighted empty. This is a good indication for this time
of the year. During the rain season, it is possible to have some carry back.

It is important to say that, on the night shift of the second day it rains but no
carry back was observed during the next day.

Preliminary Results:

The preliminary results of the study can be summarized as follows:

1. The numbers for calculating Targets and maximum Weight allowable

TGMW (Target gross machine weight) for the trucks is the total weight
recommended for a machine for Optimum productivity and cost per tonne.
The values as per specification are:

CAT789C TGMW = 317.5 Tonnes (Caterpillar SEBU7174 - 789C)

CAT789D TGMW = 324.3 Tonnes (Caterpillar SEBU8242 - 789D)

2. The average empty weight of each model was measured for calculating
the targets. It is important to say that 789D trucks are heavier due to the
different dump body design (longer headboard) and differences in frame
and components.
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Mine Maintenance Reliability Engineering
Prepared by Alejandro Zappa
14 February 2016
Pueblo Viejo Mine - Payload Study for
Caterpillar Model 789C & 789D
Based on the study the Empty machine Weight was:

CAT789C EMW = 144.1 Tonnes

CAT789D EMW = 150.3 Tonnes

At present the on-board systems are set to an empty weight of 147 tonnes
for both 789C & 789D.

These numbers will be changed as soon as possible to 144 tonnes on


789C trucks and 150 tonnes on 789D trucks in order to improve payload
and TKPH calculation accuracy.

3. The New Targets payload for PV Fleets should be set to:

Target payload= TGMW789C EMW789C = 317.5 144.1 = 173.4 Tonnes

Target payload= TGMW789D EMW789D = 324.3 150.3 = 174 Tonnes

Important: Actual Targets are set up to 185 Tonnes for both models, what
is 10 Tonnes over the new Target.

This has to be corrected as soon as possible.

However, at a first sight to the Scale data, PV is in compliance with the


Caterpillar 10/10/20 Payload Policy and No Overloads were detected.

Also, first data analysis tells us PV probably be under loading 789D trucks
and has an opportunity to improve productivity on 789C.

A more detailed information will be provide on the final report.

4. Load placement accuracy in the truck body by the loader operators was
not optimal, especially with 994 loaders. Hitachi Shovels were not tested
as there was no material being hauled from this type of equipment.

Loaders Operators generally tended to load on the Left side of the truck
The reason is because the trucks are generally spotted to be loaded from
the LH side. Also the 994 loader operators tended to load to the rear, so
here there is an improvement opportunity for training department.

As the in last report done in 2014, we still have a combination of loading


towards the LH side of the truck combined with the fact the trucks are
heavier empty on the LH side (cab & fuel tank) plus the camber of the
mine haul roads will direct an excessive amount of weight on to the LH

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Mine Maintenance Reliability Engineering
Prepared by Alejandro Zappa
14 February 2016
Pueblo Viejo Mine - Payload Study for
Caterpillar Model 789C & 789D
side tyre resulting in significantly higher TKPH values on those tyres than
on the RH tyres.

5. The correlation between on-board VIMS and off-board (Scales) payloads is


currently not good.
There is a 30% of the trucks having inaccurate readings and not in
compliance with the normally-accepted target of +/-5% or less.

This difference could be most likely due to a system configuration,


electrical problem on sensors, suspension issues, or poor load
centralization in the truck body.

A load biased to the rear of the truck, as was the most in many cycles, will
cause the on-board system to weigh significantly heavy. So with
improved front-to-rear load placement the correlation between on and off-
board systems should improve.

Preliminary Recommendations and Go-do:

1. Is it necessary Payload Study to be performed every 4 month, in order to


follow up on recommended actions.

2. To Set Up the new targets for Payload, Empty Machine Weight parameters
on The OnBoard VIMs systems.

3. To modify Jigsaw-Jview reports as per the new calculated targets.

4. A final Report with Load Distribution details and other recommended task
will be available the following week.

5. A more convenient location in the min for installing the scales and control
room, would be recommended for having more information on all the
loading equipment and material types.

6. A more safe facility is also recommended as the personnel doing the job,
is exposed to the tires & rims all the time, as they have to guide the truck
on the correct position. This facility would minimize the risk of having an
accident.

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Mine Maintenance Reliability Engineering
Prepared by Alejandro Zappa
14 February 2016
Pueblo Viejo Mine - Payload Study for
Caterpillar Model 789C & 789D

There is an idea of PV FMS and Maintenance Engineering for automating


and using remote displays for doing the Payload Study, with The Jigsaw
System and In-Motion payload usage.

7. From the attached photos it can be seen that the pictures taken did not
necessarily give the best illustration of the front to-rear or side-to-side
load bias because they were taken from ground level. To produce
representative photos it would be recomended to install a scanner
system which would deliver a more accurate Load Placement, Material
density, fragmentation, carry back, volume.

Transcale Ltd, offers a solution for it (Transcale Volumetric System). As


soon as possible we will be requesting a quotation for presenting a
Business Case Analysis of installing one of this system.

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Mine Maintenance Reliability Engineering
Prepared by Alejandro Zappa
14 February 2016