As of Thursday, Nov 6, 2014 we have completed the first seven units. We are now on the second part of MineSight for Open Pit Design.
All remaining work is due by when the final exam for this class would be done if we had one (ie - 1:00 pm on Thursday). This will be the Carlson Unit 4, and unit 9 assignment 2 and the project.
Some people seem not to know what a mine layout as required by the Carlson project is. A mine layout is the 2 D view showing your mains, submains, and mining panels (obviously leaving out the shaft or slope pillar area since you would not undermine your shaft pillar or your slope).
In your unit on handling fluids you selected a pump or series of pumps to move 2500 gpm of water from a sump in a mine. You will now select the motor and drive for that pump (or those pumps as the case may be).
1- What type of motor will you select (DC, AC synchronous, AC induction, switched reluctance). Explain why you made that selection.
2- What speed will the motor turn at? Explain how you know it will turn at that speed.
3- What speed must your pump turn at? How much horsepower must be present at the pump shaft for the pump system to work?
4- How will you connect the motor output power to the shaft of the pump? How will you get your motor turning at one speed to drive a pump that may need to turn at a different speed?
5- What kind of efficiency do you expect to get on transmission of power from the motor to the pump? Where did you get the estimate for your efficiency?
6- What size motor do you propose to buy? Show calculations to justify the claim that your motor will drive your pump load.
You earlier in the conveyor unit designed a slope belt conveyor. For your unit project you will match a motor or motors to the belt conveyor.
1- Using your belt analyst output identify the belt tension needed to lift the material up your slope. Also identify the belt tension needed to overcome friction.
2- Explain the type of belt drive you have (single drive - dual drive etc). Identify the size of your drive pulley or pullies. Identify the horsepower that must be applied to the shaft of each pulley to drive the belt. Identify your belt speed.
3- Put together a low cost but effective motor system to start and run your conveyor.
Cost Estimates AC Induction Motors type B (the last column is the price
Assume that I can buy a C class induction motor for 50% more than the corresponding B class motor above.
The following list pertains to DC
If you want to use a gear reducer to adjust speed look up the price of a type B induction motor for the required HP and figure the gear reducer will be about 15% of the motor price.
If you want to use AC frequency control use the following for rough costs
50 HP $7,000
200 HP $15,000
400 HP $20,000
1000 HP $45,000
2000 HP $70,000
(linear interpolate between values)
Assume Static AC to DC converters are 90% of the price of AC frequency control.
If you want a computer controller to regulate the starting torque of motor assume the cost will be half of the cost of an AC frequency controller.
Assume you can get a magnetic coupler that will adjust speed for about 90% of the cost of AC frequency control
Assume that a non-speed controlling magnetic coupler is about 60% of the cost of AC frequency control
Assume that fluid couplers are about 75% the cost of AC frequency control.
4- Describe your motor (motors) including motor type, motor size and motor speed (Assume DC motors can turn as slow as the minimum speed given in the cost table above on up 6000 rpm depending on the applied voltage). If your motor is DC it will be assumed that you have a static rectifier to convert AC current to DC. For an AC motor you will have to describe any attached controllers such as AC frequency controller or soft start computerized controller.
5- Describe how your motor is coupled to the shaft of your drive pulley. Indicate if the coupling system you are using is providing speed reduction between the motor and the pulley drive shaft.
6- Itemize the cost of all your components in your motor and power transmission system.
7- Demonstrate by calculation that your system has the capacity to start a fully loaded belt and that the break-down torque of the motor will not exceed the strength of your belt.
8 - Demonstrate by calculation that your system can run the belt at the required speed.
9- Explain any special virtues of your system and why you chose to design it in the fashion you specified.
The Unit #7 project will be to determine the number of trucks and loaders needed for production for each of the 3 fleets you proposed in the assignment, to figure the cost per ton to move material with those fleets, to make a recommendation, and of course to turn in the associated FPC files. It should be noted that it will take 27 FPC runs to get the numbers you need to accomplish the project. The project has a revised due date of Nov. 17 to allow another work review session
Cost data to help with projects
Cat 797 price $5,040,000 life 50,000 hrs tires $63,600 each 841 tmph fuel consumption 70 gal/hr repair $52/hr
Cat 793 price $3,476,000 life 50,000 hrs tires $51,000 each 545 tmph fuel consumption 42 gal/hr repair $42/hr
Cat 789 price $2,916,000 life 50,000 hrs tires $36,500 each 475 tmph fuel consumption 33 gal/hr repair $39/hr
Cat 785 price $2,300,000 life 50,000 hrs tires $23,000 each 340 tmph fuel consumption 25 gal/hr repair $24/hr
lubrication cost estimation - Terex rule of thumb lubrication is 10% of fuel cost
P+H 5700 price $11,000,000 life 125,000 hrs
P+H 4100 price $9,250,000 life 125,000 hrs
P+H 2800 price $8,775,000 life 125,000 hrs
Cat 5230 Hydraulic Front Shovel price $4,900,000 life 50,000 hrs fuel 52 gal/hr repair $81/hr
Your Carlson Unit
The project you will do (just one) - is explained in the slides below.
0 Unit Explanation.pptx
The materials below are presented in a suggested study order. You have several types of files to deal with. Word documents are obviously to be read as a "text". Powerpoint slides are obviously for viewing. Most of the power point slides will direct you to Carlson's website and have you watch specific Carlson Videos. One last power point slide set was a Carlson teaching powerpoint slide show.
1 AutoCAD Tips.docx
2 Geology Basics and Set-up.docx
3 Drillhole Importing Editing and Reporting.docx
4 Carlson Videos to View.pptx
5 Grid File Utilities.docx
6 Carlson Videos to View.pptx
7 Underground Mapping & Quantities.docx
8 Block Modeling.docx
9 Geology Stratigraphic Modeling.docx
10 Faults and Strata Polylines.docx
11 Users Group Underground Projections.doc
12 Carlson Videos to View.pptx
13 2012 UG - Underground Timing Project Manager.docx
13b 2012 UG - Underground Timing.docx
14 Timing Model - Dan Sypersma.pptx
•Turn in your project file
(The Isopack map of coal seam thickness is provided below)
(Note on isopack map - since this is not a Carlson Readable file map you probably cannot read it directly to Carlson. You can, however, through simulated drill holes or approximate tracings get the essence of the data into Carlson. Individual maps will not be absolutely identical to each other or the master map. For this exercise it is only important that you get a reasonable approximation of this isopack in for determining coal seam thickness).
Assignment #3 - Due by Sept. 30, 2013
Unit Project - Due by Oct. 1, 2013
There will be a short class progress meeting at 10:00 on Thursday, Sept. 26, 2013. Normal classes will resume on Thursday Oct. 3, 2013.
If someone is interested in using ventilation air to dilute diesel emissions and wants to know how much air to use the following items may be helpful.
The first paper is some MSHA suggestions on controlling DPM (Diesel Particulate Matter). It especially mentions problems one might have with recirculating DPM in open spaces in underground non-coal mines where you may be using booster fans. The paper contains drawings of how air might recirculate in poorly designed systems and how it might be better handled.
Diesel Particulate Matter (Louisville).pdf
The second paper describes a spreadsheet one can use to estimate the quantity of air needed to control emissions using spreadsheet MSHA developed. In this case you use column B which does estimates based on horsepower. The paper does not tell you how clean the air must be but the magic number that you must achieve is 200 (the figures in the spreadsheet are total carbon in the air of which about 80% is DPM - DPM is limited to 160 but total carbon is usually used as a more easily measured substitute - thus the 200 target number). Below the link to the paper is a link to MSHA's estimator spreadsheet
MSHAs paper on using DPM Estimator.pdf
It is again noted and credit is given to MSHA for this spreadsheet and the pdf documents from the links above.
If someone wants to get truck travel times using rimpull or retarder curves the following slide show might be helpful.
Determining Truck Speeds using Rimpull and Retarder Curves.ppt
These manufactures truck brochures might allow you to practice on a Volvo A40D (used in the example) and a John Deere 400D
John Deere 400D.pdf
If someone is interested in predicting blast vibrations the following slide show may be of interest
Vibration and Fly Rock.ppt
If someone is interested in Cannon Drills the following brochures may be of interest
Oldenburg Group Incorporated Jumbo Drill Brochure.pdf
The gods of SIU (ok its only the Chancellor and Provost) have decreed that final exams can only be given during times they designate and that mere mortals such as students or faculty no longer have the right of choice even if they can reach a consensus. They have also decreed that the exam time must be written in materials at the beginning of the semester. Accordingly the final exam for this class is Tuesday, Dec. 11 from 12:50 to 2:50 - excuses such as being deceased or comatose are no longer being accepted except under exceedingly rare circumstances that administrators alone can discern.