OIL SANDS TRUCK-AND-SHOVEL MINING OPERATION WITH PERFORMANCE MONITORING AND CONTROL

Information

  • Patent Application
  • 20250092784
  • Publication Number
    20250092784
  • Date Filed
    September 20, 2023
    a year ago
  • Date Published
    March 20, 2025
    4 months ago
Abstract
This disclosure concerns techniques for monitoring and controlling mining operations, notably oil sands mining that involves trucks and shovels. The process can include monitoring key mining performance indicators (KMPI) comprising truck operating parameters; shovel operating parameters; and workforce performance parameters, and then controlling the trucks and the shovels based on a pre-developed model comprising the KMPI. The workforce performance parameters of shift change duration can be determined in various ways, such as determining a base shift change duration based on a shift-change code and adding to it a supplementary shift change duration based on certain additional stationary-state codes; and/or determining truck cycle times during a pre-determined time interval spanning the corresponding shift change, determining a longest truck cycle, determining an average truck cycle which excludes the longest truck cycle; and determining the shift change duration based on a difference between the longest truck cycle and the average truck cycle.
Description
TECHNICAL FIELD

The technical field generally relates to oil sands mining operations, and more particularly to monitoring and control of oil sands mining that employs trucks and shovels for enhanced performance.


BACKGROUND

Oil sands mining operations can include the use of trucks and shovels to retrieve oil sands ore from the mine face and transport it to extraction facilities. Deployment, monitoring and operation of mining equipment and associated workforce involves notable challenges.


SUMMARY

Various techniques are described herein for truck and shovel monitoring and control in oil sands mining operations.


In some implementations, there is provided a process for oil sands mining comprising: utilizing trucks and shovels to mine oil sands ore, wherein the trucks and the shovels are operated by a workforce comprising shift teams that include equipment operators and wherein the mined oil sands ore is input into an oil sands extraction operation to extract bitumen from mineral solids and produce a bitumen product; monitoring key mining performance indicators (KMPI) comprising: truck operating parameters related to the trucks; shovel operating parameters related to the shovels; and workforce performance parameters related to the workforce; and wherein the process also includes controlling the trucks and the shovels based on a pre-developed model comprising the KMPI.


In some implementations, the workforce performance parameters comprise: shift team performance parameters of the shift teams that make up the workforce; and operator performance parameters of the operators who make up the shift teams. In some implementations, the truck operating parameters comprise truck productivity, truck availability, and truck cycle indicators. In some implementations, the truck cycle indicators comprise loading, hauling, emptying, dumping, waiting and spotting. In some implementations, the shovel operating parameters comprise truck wait times at the shovels, under-loading conditions, over-loading conditions, and shovel productivity. In some implementations, the truck operating parameters and the shovel operating parameters each include key performance metrics and key performance thresholds. In some implementations, the shift team performance parameters comprise shift change time. In some implementations, the operator performance parameters comprise: individual operator performance parameters and group norm parameters; truck operator performance parameters comprising truck travelling speed, truck productivity, truck operator lunch break times, truck operator break times, and truck operator shift change parameters; and shovel operator performance parameters comprising under-loading metrics, over-loading metrics, shovel productivity, shovel operator break times, and shovel operator shift change parameters. In some implementations, the controlling of the trucks and the shovels comprises tactical decision making to impact in-shift performance. In some implementations, the tactical decision making comprises: in response to a long truck-wait at shovels or dumps corresponding to over-truck conditions, adjustment made by truck dispatchers to reduce the truck wait times; in response to truck bunching, adjustment made by truck dispatchers to reduce the truck bunching; in response to excessive truck overloading, adjustment made by shovel operators to reduce the truck overloading; in response to a disruption of tonnage during shift change, investigation of actual cause thereof and adjustment of approach in shift change in terms of time of shift change on individual trucks, order and/or location where shift change occurs; in response to excessive switch-out times corresponding to switching operators in shift on a given truck, determination of root cause and devising of alternative approach to switch-outs; and/or in response to ore blending upset, adjustments made by truck dispatchers to ensure that characteristics of ore blends return to expected levels in terms of ranges of bitumen and fines content. In some implementations, the controlling of the trucks and the shovels comprises strategic decision making to impact mining performance. In some implementations, the strategic decision making comprises: assessing truck inventory requirements including one or more of new truck purchases, truck rentals, truck fleet size, type of trucks, truck equipment features, and truck equipment size, optionally in 5 to 10 years; and/or assessing shovel inventory requirements including one or more of new shovel purchases, shovel rentals, shovel fleet size, type of shovels, shovel equipment features, and shovel equipment size, optionally in 5 to 10 years. In some implementations, the pre-developed model is further based on extraction facility parameters such that the controlling of the trucks and the shovels is performed based on monitored extraction facility parameters related to the oil sands extraction operation. In some implementations, the monitoring comprises displaying the KMPI and information derived therefrom on a dashboard and/or a scorecard to enable a user to evaluate performance based on the displayed KMPI.


In some implementations, there is provided a method for monitoring truck and shovel performance in an oil sands mining operation, the method comprising: providing a model comprising a plurality of databases housing information acquired from the oil sands mining operation; determining key mining performance indicators (KMPI) comprising: truck operating parameters related to the trucks; shovel operating parameters related to the shovels; and workforce performance parameters related to the workforce; and displaying the KMPI on interactive digital displays comprising dashboards and scorecards for assessment by a user, the digital displays showing KMPIs for both in-shift and past-shift time intervals


In some implementations, the truck operating parameters comprise truck productivity, truck availability, and truck cycle indicators, and wherein the truck cycle indicators comprise loading, hauling, emptying, dumping, waiting and spotting; the shovel operating parameters comprise truck wait times at the shovels, under-loading conditions, over-loading conditions, and shovel productivity; the workforce performance parameters comprise shift team performance parameters of the shift teams that make up the workforce, and operator performance parameters of the operators who make up the shift teams; wherein the workforce performance parameters comprise shift change time; and the digital displays comprise an overall mining scorecard comprising KMPI and qualitative information based on pre-determined codes, a truck performance dashboard including time-based truck performance monitoring; a payload performance dashboard; an overall team performance dashboard; a shovel performance dashboard; and shift change dashboard.


In some implementations, there is provided a method of monitoring shift change performance of trucks used in oil sands mining operations, the method comprising: receiving truck performance data from a truck fleet, the truck performance data comprising operator-input codes that include a shift-change code indicating when a shift change is occurring and stationary-state codes indicating states during which the trucks are stationary; determining a base shift change duration based on the shift-change codes; determining a supplementary shift change duration based on a selection of the stationary-state codes; and providing an adjusted shift change duration based on the base shift change duration and the supplementary shift change duration.


In some implementations, the selected stationary-state codes comprise an operator maintenance code, miscellaneous code, truck breakdown code, a hauling stopped code and/or an empty stopped code. In some implementations, the selected stationary-state codes exclude stationary-state codes corresponding to truck operation of dumping and loading. In some implementations, the selected stationary-state codes are used in determining the supplementary shift change duration when the codes are input within a pre-determined time interval proximate the shift change. In some implementations, the pre-determined time interval is within at most 30 minutes of the shift change. In some implementations, an average shift change duration is determined by dividing the adjusted shift change duration by a number of trucks in the corresponding truck fleet. In some implementations, the method also includes displaying a plurality of the adjusted shift change durations via a digital dashboard over time to provide in-shift and past-shift information.


In some implementations, there is provided a method of monitoring shift change performance of trucks used in oil sands mining operations, the process comprising: receiving truck performance data from a truck fleet, the truck performance data comprising truck cycle times; for each truck in the truck fleet: determining truck cycle times during a pre-determined time interval spanning the corresponding shift change, each truck cycle including loading, hauling, dumping, and dispatching; determining a longest truck cycle; determining an average truck cycle which excludes at least the longest truck cycle; and determining the shift change duration based on a difference between the longest truck cycle and the average truck cycle; and wherein the method also includes determining an average shift change duration for the truck fleet based on the shift change durations determined for the respective trucks.


In some implementations, if a given truck lacks cycle data, determining the shift change duration of the given truck is performed using the steps of: receiving truck performance data that comprise operator-input codes that include a shift-change code indicating when a shift change is occurring and stationary-state codes indicating states during which the trucks are stationary; determining a base shift change duration based on the shift-change codes; determining a supplementary shift change duration based on a selection of the stationary-state codes; and providing an adjusted shift change duration based on the base shift change duration and the supplementary shift change duration. In some implementations, determining the average truck cycle is based on truck cycles that are comparable in total distance travelled by the truck within at most 10 km. In some implementations, the method also includes displaying a plurality of the adjusted shift change durations via a digital dashboard over time to provide in-shift and past-shift information.





BRIEF DESCRIPTION OF THE DRAWINGS

The attached figures illustrate various features, aspects and implementations of the technology described herein. Certain figures intentionally include redactions.



FIG. 1 is a flow diagram illustrating an example framework for mining operation performance.



FIG. 2 is an example overall mining scorecard.



FIG. 3 is an example of an overall mining scorecard with an open drilled-down table regarding waste shovel productivity.



FIG. 4 is part of an example overall mining scorecard showing entry of codes based on a pre-determined selectable list of codes indicating causes of shortage, failure, or throughput upset.



FIG. 5 is an example truck performance scorecard showing hourly truck performance monitoring.



FIG. 6 is another example truck performance scorecard.



FIG. 7 is an example scorecard of time performance of a specific truck.



FIG. 8 is an example display for payload performance monitoring.



FIG. 9 is an example display of detailed payload transactions.



FIG. 10 is an example display of payload statistics for decision making.



FIG. 11 is an example display of overall team performance over a time period.



FIG. 12 is an example display of shovel performance information.



FIG. 13 is an example display of time-trended shovel performance.



FIG. 14 is a block diagram showing a typical cycle that each truck follows in hauling ore material between shovels and destinations, and also showing that there are state codes for the various tasks.



FIG. 15 is an example dashboard including shift change duration information.



FIG. 16 is another example dashboard including shift change duration information.



FIG. 17 is a further example dashboard including shift change duration information.





DETAILED DESCRIPTION

The present description relates to methods and systems for monitoring and controlling mining operations, notably oil sands mining that involves trucks and shovels. The oil sands mining method can include utilizing trucks and shovels to mine oil sands ore, the trucks and the shovels being operated by a workforce including shift teams that include equipment operators and the mined oil sands ore being input into an oil sands extraction operation to extract bitumen from mineral solids and produce a bitumen product.


The methods can include monitoring key mining performance indicators (KMPI) that include truck operating parameters, shovel operating parameters, and workforce performance parameters; and controlling operation of the trucks and the shovels based on a pre-developed model comprising the KMPI for enhanced performance. Various truck and shovel operating parameters can be used (e.g., truck productivity, truck availability, and truck cycle indicators that include loading, hauling, emptying, dumping, waiting and spotting; truck wait times at the shovels, under-loading conditions, over-loading conditions, and shovel productivity; truck switch-out; and shift change time and shift change throughput). The controlling of the trucks and the shovels can include strategic decision making to impact mining performance as well as tactical decision making to impact in-shift performance. The pre-developed model can also be based on extraction facility parameters such that controlling the trucks and shovels takes into account the monitored extraction facility parameters.


The methods can also include monitoring shift change performance of trucks used in oil sands mining operations. In one implementation, the shift-change monitoring method includes receiving truck performance data from a truck fleet, the truck performance data comprising operator-input codes that include a shift-change code indicating when a shift change is occurring and stationary-state codes indicating states during which the trucks are stationary; determining a base shift change duration based on the shift-change codes; determining a supplementary shift change duration based on a selection of the stationary-state codes; and providing an adjusted shift change duration based on the base shift change duration and the supplementary shift change duration. In another implementation, the shift-change monitoring method includes receiving truck performance data from a truck fleet, the truck performance data comprising truck cycle times; for each truck in the truck fleet: determining truck cycle times during a pre-determined time interval spanning the corresponding shift change, each truck cycle including loading, hauling, dumping, and dispatching; determining a longest truck cycle; determining an average truck cycle which excludes the longest truck cycle; and determining the shift change duration based on a difference between the longest truck cycle and the average truck cycle; and the method then includes determining an average shift change duration for the truck fleet based on the shift change durations determined for the respective trucks.


In terms of additional context for the present technology, mining is a complex and expensive operation with a goal to mine and deliver ore to extraction facilities in an effective and efficient manner. Achieving and sustaining an optimal mining operation is difficult for various reasons, including because the operation involves work from different groups and is subject to many constraints. Key processes among these groups are the operation of trucks and shovels, which have goals including to mine and move material (both ore and waste) in the most effective and efficient manner. Stewardship of key mine performance is often done daily (e.g., last 24 hours) and appropriate decisions are taken to address arising performance issues. If performance shortfalls are detected early and during shift, production staff can take timely actions to eliminate or mitigate negative outcomes. Another important limitation in the context of monitoring mining operations is the availability of mining performance information and the form in which it is available to production staff. Key performance information should be consistent and widely available to operations, not being limited to mining staff alone, but also easily visible to downstream processes such as extraction and tailings operations.


Oil sands operations can monitor mining performance using tools developed by suppliers and while these tools are sufficient in monitoring equipment and processes in mining, there are challenges and drawbacks in terms of the ability to allow staff to monitor process performance beyond the tool domain. For example, in this context, decision making often involves access to information available in downstream processes, such as extraction and tailings; and there are certain unique characteristics in each mining operation that are not directly addressed by current supplier tools that are available.


It has been found that decision support methods and systems described herein to manage mining performance has had beneficial results. Oil sands mining staff can rely on such techniques to monitor performance of trucks and shovels in real-time, to make tactical (e.g., in-shift) and strategic (e.g., long-term) decisions using captured structured data. In addition, staff at the extraction facilitates can also use this technology to investigate past recovery upsets and improve future performance.


As mentioned above, the technology described herein relates to performance monitoring strategies that allow operations to monitor and manage truck and shovel performance. In some implementations, the method starts with development of a framework, an example of which is shown in FIG. 1. The implementation of the framework includes the following components:

    • Development of a Key Performance Indicator (KPI) layer. This layer includes various processes that (a) create and maintain the KPI definitions; (b) extract-transform-load (ETL) process and truck dispatch data into the KPI database as background services; and (c) provide KPI data or additional calculated measures at run-times. The KPI data can include certain target parameters, such as shift-change, switch-out, and overload conditions for enahnced monitoring and performance.
    • Development of a presentation layer. This layer includes tactical and/or strategic performance dashboards deployed with visualization for clear and effective communication. Special dashboards can also be developed as part of administrative utilities to allow key domain experts and business team administrators to govern the definitions of KPIs and the write permissions for users in the system. The figures provide illustrations of example information and features of the scorecards and dashboards.


Mining performance assessment is possible during shifts via online monitoring of key performance metrics, allowing timely decisions to correct detected shortfalls. These metrics can be consistent whether they are derived during a short interval or are aggregated in a full shift, full day, or longer time period. Therefore, the performance information can be consistent for either tactical or strategic decision making.


Furthermore, the developed framework can be provided so as to be supplier-neutral, meaning that its methodology can be adapted to any commercial truck dispatch tool to provide production staff with consistent information. The framework is provided with the ability to integrate data which come from systems beyond truck-dispatch systems in mining, e.g., data that is provided from downstream extraction facilitates. A KPI database that is provided as part of the system can host all KPIs including those KPI's well known in the oil sands mining industry and others that may be specific to individual company operators. KPIs can be derived based on information from industry practice and local technical expertise in the mining staff using structured approaches.


In general, relevant performance elements in the mine monitoring framework can include the following. First, an overall mining scorecard can be provided and include all performance metrics for truck and shovel operation. The overall mining scorecard can capture codified performance levels and can include operator/leader comments on certain aspects of mining performance. The overall mining scorecard can be prepared to encapsulate and summarize key truck and shovel metrics. Second, truck operation performance can include various metrics including truck payload performance, truck wait times at shovel and dump points, productivity monitoring in a current shift and a historical shift, effect of shift change, and monitoring of truck operator performance. Third, shovel operation performance can include various metrics including shovel throughput and stewardship compared to the mining plan, shovel productivity and efficiency in deployment, shovel stewardship compared to the mining plan elevation per load (in-shift and past shifts). Fourth, team performance can be tracked, where each team can include group of individuals that are on a particular shift, truck, shovel, mine area, or the like.


Mining Performance Monitoring and Scorecard

Mining production staff can rely on the overall mining scorecard, an example of which is shown in FIG. 2, to assess an overall mining performance in a current shift or recent past shifts. The scorecard provides a consistent version of performance information, allowing staff from different business units/groups or across shift teams to communicate effectively. The scorecard can have various relevant pieces of information, including KPIs as well as plan targets and actual values for each KPI averaged over the operational equipment and teams. As shown in FIG. 2, the KPIs can include shovel availability, waste shovel productivity, truck availability, truck productivity, average payload, haul distance, cycle time, shift change time, wait at dump time, wait at shovel time, ore volume hauled and dumped, waste volume hauled and dumped, and total volume of material hauled and dumped.


Still referring to FIG. 2, the information for plan targets and actual values for each KPI can also be provided for different time intervals. For example, the information can be provided for each three-hour interval within a twelve-hour shift and arranged side-by-side within the scorecard table. The scorecard can also include colour-coding including an on-target colour (e.g., green) to highlight actual values that are at or performing positively with respect to the respective plan targets, and an off-target colour (e.g., red) to highlight actual values that are performing negatively with respect to the respective plan targets.



FIG. 2 also shows that the scorecard can include qualitative information that can serve to help explain the quantitative information. For example, the qualitative information can indicate certain mining restrictions. In FIG. 2, the certain example qualitative comments are provided regarding restrictions: (i) that there were issues with downstream extraction equipment that limiting rates in ore processing, and (ii) that there were soft dump conditions which caused light loading by the shovels. It can be seen that issue (ii) was present in the first time interval in FIG. 2, but was no longer an issue for future time intervals. The qualitative information can be provided by users that assess period performance and then assign a code selected from a pre-determined set of codes, which can provide enhanced consistency across users. The selected code corresponds to the area or equipment associated with a shortage, failure, or throughput upset, for example.



FIG. 2 also shows real-time information alongside recent performance information: the KPIs for the first two time intervals are for past performance; the KPIs for the third time interval are for a time interval that is in-progress which can be indicated by highlighting the time interval for example; and the actual values for the fourth time interval are blank showing that it is for future operations. There can also be a “shift-to-date” column that displays the average performance of the time intervals including real-time information as the shift progresses.


The scorecard can be provided with drill-down functionalities that enable staff to obtain further detailed information regarding performance of a given truck or shovel. Detailed information regarding each of the KPIs listed on the scorecard can be easily accessed by a user to further assess or investigate operational upsets or other information.


Referring to FIG. 3, the “waste shovel productivity” KPI can be assessed in further detail such that an additional window opens proximate the main scorecard. In this example, the drill-down information is displayed as a table that shows individual shovels as well as KPI information per shovel, such as priority designation, number of loads per time interval, and waste shovel productivity. Analogous drill-down tables can be provided for each of the other KPIs in the scorecard.


Referring to FIG. 4, in some implementations, users can assess period performance and assign one or more codes that correspond to the area or equipment associated with a shortage, failure, or throughput upset, if any during the time period. These coded data are captured over time and stored in a database. Data can be further analyzed using various methods to extract useful strategic information based on the entered codes. More specifically, the user can select one or more codes for a given time periods (e.g., “Restriction—Downstream” meaning there was a limitation due to downstream operations rather than related to the truck-and-shovel mining; “Dump Restricted” meaning there was a limitation related to the dump area conditions). The use can not only select a code but also add explanatory comments related to the selected code, as shown in FIG. 4. As shown in FIG. 4, the user can select the codes from a selectable list that includes all of the pre-defined codes.


Periodic generation of summary reports regarding the coded problems and their causes can be automated and made available for access by certain users, leaders or managers, which may be done in real time, allowing management to make pertinent decisions in a timely manner. For example, the system and summary reports can help assess and implement equipment maintenance or replacement.


Truck Performance Monitoring

Truck performance can be monitored and displayed in various ways, some of which are described below. In some implementations, mining staff monitors truck performance based on truck cycle times and individual cycle component, and can detect when a performance deviation occurs. As shown in FIG. 5, it can be relevant to monitor not only how trucks perform within the last hour, but also how performance varied recently in a current shift, last shift, and a specific past shift.


In FIG. 5, section A shows hourly trends of various metrics such as cycle times in minutes and truck productivity in tonne-per-net-operating-hour (t/noh). Specific colors can be used to correspond to a specific level of performance (e.g., red for under-performing, green for over-performing and yellow for on-spec performing within a pre-defined window). Similarly, section C displays an hourly trend of cycle times and key cycle components. Information focused on truck waiting times and spotting times at shovels or dumps alone is also available as an alternative to that of all cycle components. It is noted that different display sections can show (i) overall cycle time compared to target times for each time interval, and (ii) a breakdown for each time interval of the times taken to perform different tasks performed, to quickly show which tasks and components may have caused cycle time overruns.



FIG. 6 shows an alternative display of section C where the display provides a precise picture of truck performance at both end points with regards to waiting and spotting times. The truck performance scorecard can enable multiple display options for users for rapid assessment of various performance metrics.


In addition, section B (see FIG. 5) and section D (see FIGS. 5 and 6) show aggregate performance measures for a given time interval. It is noted that the aggregate performance measure can separate truck time components at front and back ends of the cycle (dumping together and loading together), where “hauling” in the middle is not shown in either one, if desired. Thus, display filtering is advanced and allows visualizing clusters of related tasks.


Truck performance can also be filtered down based on one or more of the following: all shovels, a specific group of shovels, and/or a given shovel; all dumps and/or a specific dump; and/or a specific truck. FIG. 5 illustrates options at the top of the table where the user can select the desired filters. Truck performance assessment can thus be related to other parts of the mining process, such as shovels, dumps, and so on, which can help to rapidly pinpoint problems and facilitate corrective action.



FIG. 7 shows an example of how a user can focus on monitoring performance of a specific truck. The user can visualize all state sequences of the truck (with duration in minutes, as per Section E) and how well the truck performs in each cycle. Information on operator names is also available via the tool if subsequent communication is needed.


Payload Performance Monitoring

Payload performance monitoring is related to both truck performance and shovel performance. Payload can be considered part of the truck performance as it affects the reliability of truck equipment and/or truck warranty, but it can also be related to the performance of shovel operators because it depends on how the operators work with loading ore material onto trucks. Thus, payload can be viewed as being associated with truck performance and the responses/actions related to shovel operators.


Various KPIs related to payload can be monitored, displayed and used to provide enhanced performance in mining operations. Certain display functionalities of the system will be further described below.


Payload monitoring is a relevant aspect of performance monitoring in a mining operation. Under-loading of trucks can correspond to inefficient usage while heavy overloading can lead to premature mechanical truck failures. Staff can routinely monitor truck payload during shifts and/or assess performance after each day of operation to guard against severe overloading and too much under-loading. It is advantageous that these conditions be detected early so that pertinent actions can be taken to avoid future repeated problems.



FIG. 8 shows an example interface that allows the user to monitor truck payload during a current shift, or a past shift or day. The display takes advantage of effective visualization techniques in communicating the information to the users quickly. At a glance, users can detect an under-loading condition and over-loading condition as well as the extent of overloading or under-loading condition. This display allows the user to identify which shovels need attention as well as which trucks incur undesired payload conditions. Section A1 shows average payload for each shovel for all fleets, while section A2 displays the same information but is narrowed down to individual truck fleets. Section C provides a distribution of payloads for each truck fleet. Finally, Sections D and E tabulate payload statistics for an individual shovel or truck.


Referring to FIG. 9, which illustrates another useful display function, the system can enable users to obtain detailed payload transaction information, including truck and shovel operators, loading and dumping times, payload, distance traveled, and the extent of overloading condition (if any). A hover-and-display feature can be provided for each shovel row.


In some implementations, in reference to FIG. 10, the system is configured such that users can visualize calculated payload statistics over a recent time duration and quickly obtain useful payload information for strategic decision making. The display gives a general assessment of payload conditions over recent time periods, such as the last 30 days, month-to-date, quarter-to-date, last quarter, year-to-date, or last year. Management can obtain team-specific payload performance and take appropriate action if needed.


Another operating parameter that can be considered and monitored is truck Switch-out, which generally corresponds to the time period (typically measured in minutes) during which operators are switched out. Target durations for truck switch-out can include one for ore trucks and another for waste trucks, and are used to measure the effectiveness of operator switching activity.


Workforce and Team Performance Monitoring

Various KPIs related to workforce team performance can be monitored, displayed and used to provide enhanced performance in mining operations. Certain display functionalities of the system will be further described below.



FIG. 11 illustrates a dashboard that allows leaders to view and compare operation performance between the teams during a given period. It can be used as an effective tool to allow a shift team to quickly become aware of recent a performance trend at the start of the first shift following a 6-day break period, for example. This display also allows shift teams to drill down to a specific past shift, and detailed shovel performance if needed.


As shown in FIG. 11, various KPI information can be provided for the team performance, including load number, average tonnes, truck availability, truck UA (Use of Available), average hauling, truck productivity in tonne-per-net-operating-hour, cycle time, shovel availability, shovel UA, material (e.g., ore or waste), target and actual material displaced, ore shovel information (e.g., UDL (Underload), OVLC1 (Class 1 Overload’ (overload with range between 10% and 20% above normal load), OVLC2 (Class 2Overload’ (overload with range beyond 20% above normal load). The information can be displayed in a tabular format, as shown in FIG. 11, and/or in other graphical formats.


Shovel Performance Monitoring

Performance of a shovel is assessed based on its throughput contribution and the efficiency with which it operates. Staff frequently observes whether shovels meet their throughput demand and their time efficiency in terms of loading and waiting times. Staff's objective is to detect any deviations early in shift so that they can take appropriate timely actions to mitigate its effect.


Referring to FIGS. 12 and 13, in some implementations, users can obtain shovel performance for a given time period (e.g., shift-to-date, last 12 hours, last 24 hours). Both displays show the same performance information, presented in different ways. The display in FIG. 12 contains more numerical values that can be helpful to users when they wish to compare actual to target values. On the other hand, the time-trended plots in FIG. 13, while presenting fewer data elements, facilitate users identifying when any deviation occurs.


Monitoring and Determination of Truck Shift Change Duration

In oil sands mining, shift change performance can be a relevant factor for steady ore throughput and accurate shift change monitoring can provide enhanced operations. Poor shift changes can have a negative impact on maintaining a steady ore throughput. Potential tonnage shortages during shift change have been seen to occur in both ore and overburden hauling. While ore shortage during shift change can affect ore supply to extraction facilitates for a short time for each event, such shortages can add up to a large reduction in bitumen produced each year. Improvement of shift change helps maintain a steady ore throughput, reduce truck resources required, and ultimately leads to reductions in overall truck operating costs.


Operations leaders have evaluated shift change performance by monitoring average shift change duration, which can be determined based on time durations when trucks are in a designated state. The designated state can be linked to a pre-determined “state code” that is entered by a truck operator at the end of their shift and then deactivated by the truck operator of the subsequent shift. However, it has been found that this state code, which is entered manually by truck operators, is not captured in a consistent manner. Therefore, this performance indicator does not correctly reflect shift change performance.


There is thus a need for a new metric to monitor the process while carrying out initiatives to improve shift-change performance. The below section describes novel approaches to determining shift change duration and quantifies the negative impact on tonnage during shift change. This information can be valuable in studies to determine appropriate actions that can be taken to improve shift change performance.


A project was initiated in a mining operation to reduce the average tonnage loss during shift change. It was found that the average shift change duration calculated based on a single designated truck code is not a consistently true measure of shift change performance. Work was performed to develop new approaches to determine average shift change using additional data and to integrate shift change data into new dashboards that help truck leaders monitor shift change performance in an effective manner. Dashboard users can monitor shift change and analyze data in such a way as to help identify key areas where actions can be taken to improve shift change performance.


Two new methods, labeled methods A and B below, were developed as alternatives in determining and reporting average truck shift changes. Method A was given an appropriate upper threshold and integrated into mining scorecards. New dashboards were also developed to allow truck leaders to monitor current shift changes and view how shift changes develop over time. More regarding methods A and B is described below.


Overall truck performance is monitored based on how efficiently its resource is deployed. Each truck is equipped with a WENCO™ hardware unit that allows operations to capture data on when and for how long a truck is in a given state. FIG. 14 shows a typical cycle that each truck follows in hauling ore material between shovels and destinations, and shows that there are state codes for the various tasks.


Wireless beacons, which are installed along truck routes and around shovels and dumps, allow automatic capture of truck state data such as those involving hauling, emptying, loading, dumping. However, there are also other states that require operators' input. These states include those associated with operation delays, breakdown codes, and standby/idle. Truck shift change data is captured via a specific state code, which is one of the operation delay codes. The shift change code will be referred to as code “SCC” herein. When a shift change begins, a truck operator manually inputs the truck in shift change mode. The number of minutes a truck is in this state will be captured as the shift change duration for this truck. Shift change durations are gathered for all trucks during a shift change and will be used to determine an average value, which will denote shift change for the shift. It has been found that the collected shift change data have been lower than the actual durations.


Excessively long shift changes result in tonnage shortage, which can be overcome by adding more truck resources. This solution is not optimal since it can lead to higher truck costs. It is likely not feasible to eliminate the negative impact of shift change entirely. A more practical approach is to minimize the effect of tonnage shortage and hold it within an acceptable limit. For example, a percentage between 5-15% for ore and 10-25% for waste could be used as upper thresholds of shortage of tonnage, but this can be adapted depending on various factors that may be specific to the given mine or facility.


Shift change duration determination methodologies were developed and will now be described:


Truck cycles are queried with detailed truck times during a period from 2 hours prior to 2 hours after shift change (or another pre-determined short time period). Truck cycle data is queried over a period of 4 hours to ensure that sufficient data is included: (a) to determine an expected hourly tonnage if shift change poses no tonne shortage for purpose of comparison, and (b) to ensure that sufficient truck time data is available for the calculation time duration.


In the “SCC” Method, shift change duration is simply derived from averaging all trucks' shift changes based on truck code SCC. A drawback of this approach is that it requires manual entry of specific code SCC by the operator to put a truck into shift change mode. Entries of shift change have not been consistent amongst operators and shifts, leading to inaccuracy in reporting of shift change data.


Method A

It has been observed that actual durations of shift change occur over many truck codes, other than SCC. Some trucks have also gone through shift changes without being put into code SCC at all. Method A proposes that shift changes are tallied when a truck is put into the following codes around shift change time: Shift Change (SCC), if it exists, in addition to other pre-determined state codes that can include operation delay code, breakdown codes, and standby/idle codes. For example, the additional codes can include that include operation delay codes: operation maintenance code, miscellaneous delay code, standby cod, breakdown code, hauling-stopped code(s), and empty-stopped code(s). Thus, the shift change data used to determine shift change duration includes the shift change code as well as other pre-determined codes of truck states where the truck is not moving around the time of a shift change and limited to a pre-determined time limit that would correspond to an approximate shift change. Certain additional codes, such as breakdown code, will only be captured within the shift change picture if its duration approximates a shift change duration, and thus longer breakdown durations will not be captured for shift change determination. This method helps to account for mistakes, forgetfulness, etc., of the operators and captures a more fulsome shift change picture.


As noted above, a time duration associated with each of these codes should be less than a pre-determined duration (e.g., 25 minutes) for it to be included in the shift change determination. This constraint is used to exclude long durations, which are used for the original intention of the code and not associated with shift changes. Average shift change is then obtained by dividing the accumulated minutes by truck count.


Method B

The following steps are followed for method B:

    • Step 1: For each truck:
      • determine all truck cycle times of complete cycles during the 4-hour period spanning a shift change period (or another pre-determined time period spanning the shift change period);
      • determine the longest cycle;
      • determine an average cycle (excluding at least the longest one from the calculation, though depending on fleet size and other factors there may be additional exclusions such and the two longest ones); and
      • subtract the average cycle from the longest cycle to determine shift change;
    • step 2: calculate the average shift change based on shift changes found for all trucks in step 1, where average cycle times for a given truck should be determined based on cycles that are comparable in total distance traveled (haul plus empty distance). Note that this condition is used to ensure that average cycle times are calculated correctly and consistently.


In the event that a shift change cannot be calculated with method B for one or more given trucks due to lack of cycle data, method A will be used for these trucks to calculate shift changes.


In terms of displaying the shift change duration information, dashborads can be equipped with the ability to view the data determined based on any one of the methods. For example, the average shift change data for the above three methods (i.e. the SCC method, method A, method B) can be calculated and saved for each shift over a period of time. They can then be made available for subsequent queries in several new dashboards, one of which is shown in FIG. 15. Truck leaders can view the latest shift-change statistics as well as monitor how the statistics change over time. Users can effectively use this dashboard as a validating tool following implementation of a new effort to improve shift change.


Referring to FIG. 16, another dashboard can also be used as a tool for leaders to focus on a specific shift change, on a given truck, and/or on detailed truck or shovel transactions that are associated with this truck. FIG. 16 illustrates this new dashboard that allows users to focus on a given truck with the list of associated cycles over the shift change period. Users can select a specific cycle to obtain a detailed chronological sequence of states that the truck has been through. This capability enables leaders to obtain useful insight into how shift change is conducted. With this information, leaders can obtain an understanding of the issues and are able to develop suitable measures that help improve shift change performance. Using this dashboard, leaders can monitor how often truck operators use code SCC to capture shift change duration. In addition, leaders can investigate and identify codes other than SCC that operators mistakenly use during shift change. This information can facilitate helping leaders to understand the overall shift change situation and implement appropriate solutions to improve shift change performance.



FIG. 17 shows another dashboard that allows leaders to obtain detailed truck information from a new perspective. Using this dashboard, users can select a specific operator and display their time statistics in a given truck state, which can be, for example, Empty-Stopped, Hauling-Stopped, Wait@Shovels, Wait@Dumps, Shift-Change, Oper-Maint., Misc, Standby, or Breakdown. A drill-down capability enables users to focus on a given shift, obtain a list of cycles, and further select a desired cycle to obtain a detailed list of truck states.


The new dashboards can report shift change data based on three approaches for comparison. Method SCC is unrealistically short because not all truck operators use the SCC code consistently. As a result, method A is proposed because the shift change calculation takes into account specific non-SCC codes during shift change. However, method B goes beyond method A in that it does not depend on non-SCC codes, but relies on a comparison between the longest cycle and an average cycle among equivalent cycles of a given truck. It has been generally found that with method A, shift change data are more realistic than with the SCC-based method, but not as long as those calculated with method B.


In conclusion, the new shift change metrics appear to reflect a truer measure of shift change durations. The newly developed dashboards have been used by leaders effectively to monitor shift change performance. Users can also rely on these new dashboards to continually evaluate the appropriateness of shift change calculations and make the necessary changes to improve the metric.


An architecture was developed that includes database objects, such as tables or views, and stored procedures that are invoked by external programs to either insert or update data into the databases and provide the information to the dashboards. The system can implement a batch process, which can be scheduled to run once per shift following a shift change period. The batch process is responsible for capturing and inserting shift change data into the database. Shift change data is captured and maintained in the databases to allow truck leaders to monitor current shift changes and to observe its trend over a given period. Shift change data is pre-determined and stored in the database ahead of users' queries such that users do not incur a slow response when querying the data for visualisation on the dashboards.


Decision Making Examples

Various types of decisions can be made in response to the monitored KPI's regarding truck and shovel operation. For example, tactical decisions can include (a) in response to a disruption of tonnage during shift change, investigation of actual cause thereof and adjustment of approach in shift change in terms of time of shift change on individual trucks, order and/or location where shift change occurs; (b) in response to excessive switch-out times corresponding to switching operators in shift on a given truck, determination of root cause and devising of alternative approach to switch-outs; and/or (c) in response to ore blending upset, adjustments made by truck dispatchers to ensure that characteristics of ore blends return to expected levels in terms of ranges of bitumen and fines content. Strategic decisions cam be made with a more longer term view, such as decisions for operations that will occur between 5 to 10 years. For example, strategic decisions can include assessing truck inventory requirements including one or more of new truck purchases, truck rentals, truck fleet size, type of trucks, truck equipment features, and truck equipment size, optionally in 5 to 10 years; and assessing shovel inventory requirements including one or more of new shovel purchases, shovel rentals, shovel fleet size, type of shovels, shovel equipment features, and shovel equipment size, optionally in 5 to 10 years. Based on monitored truck and shovel productivity, planners can make strategic decisions regarding whether there are enough trucks currently in the fleet for the mine plan in 5 to 10 years and whether new trucks should be bought or rented. In addition, the type of trucks and certain features can be strategically determined based in part on the monitored KPIs; for example, based on certain KPIs it can be determined what type of tires and what size of trucks would be optimal for the mine plan in 5 to 10 years. For instance, if the mine plan includes opening a new area of the mine with longer hauling routes, a strategic decision may be taken to use enhanced tires on the trucks that will be used for that new mine area. Decisions can thus be planned for and made regarding various truck and shovel parts and functions that may be optimal for future truck and shovel operations. Additional decisions can be made in relation to extraction operations based on the truck and shovel KPIs as well. For instance, the extraction process could be controlled to blend certain ores together, increase or reduce chemical (e.g., caustic) dosing, and the like, based on monitored truck and shovel data. For example, if the trucks are providing a higher quantity of poor ore with higher fines content, extraction could be modified by adding more caustic for primary separation to separate the hydrotransport slurry into bitumen froth and primary tailings. It is also possible to monitor extraction variables and use that data to adapt truck and shovel operations.


Several alternative implementations and examples have been described and illustrated herein. The implementations of the technology described above are intended to be exemplary only. A person of ordinary skill in the art would appreciate the features of the individual implementations, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the implementations could be provided in any combination with the other implementations disclosed herein. It is understood that the technology may be embodied in other specific forms without departing from the central characteristics thereof. The present implementations and examples, therefore, are to be considered in all respects as illustrative and not restrictive, and the technology is not to be limited to the details given herein. Accordingly, while the specific implementations have been illustrated and described, numerous modifications come to mind.

Claims
  • 1. A process for oil sands mining comprising: utilizing trucks and shovels to mine oil sands ore, wherein the trucks and the shovels are operated by a workforce comprising shift teams that include equipment operators and wherein the mined oil sands ore is input into an oil sands extraction operation to extract bitumen from mineral solids and produce a bitumen product;monitoring key mining performance indicators (KMPI) comprising: truck operating parameters related to the trucks;shovel operating parameters related to the shovels; andworkforce performance parameters related to the workforce; andcontrolling the trucks and the shovels based on a pre-developed model comprising the KMPI.
  • 2. The process of claim 1, wherein the workforce performance parameters comprise: shift team performance parameters of the shift teams that make up the workforce; andoperator performance parameters of the operators who make up the shift teams.
  • 3. The process of claim 1, wherein the truck operating parameters comprise truck productivity, truck availability, and truck cycle indicators.
  • 4. The process of claim 3, wherein the truck cycle indicators comprise loading, hauling, emptying, dumping, waiting and spotting.
  • 5. The process of claim 1, wherein the shovel operating parameters comprise truck wait times at the shovels, under-loading conditions, over-loading conditions, and shovel productivity.
  • 6. The process of claim 1, wherein the truck operating parameters and the shovel operating parameters each include key performance metrics and key performance thresholds.
  • 7. The process of claim 1, wherein the shift team performance parameters comprise shift change time.
  • 8. The process of claim 1, wherein the operator performance parameters comprise: individual operator performance parameters and group norm parameters;truck operator performance parameters comprising truck travelling speed, truck productivity, truck operator lunch break times, truck operator break times, and truck operator shift change parameters; andshovel operator performance parameters comprising under-loading metrics, over-loading metrics, shovel productivity, shovel operator break times, and shovel operator shift change parameters.
  • 9. The process of claim 1, wherein the controlling of the trucks and the shovels comprises tactical decision making to impact in-shift performance.
  • 10. The process of claim 9, wherein the tactical decision making comprises: in response to a long truck-wait at shovels or dumps corresponding to over-truck conditions, adjustment made by truck dispatchers to reduce the truck wait times;in response to truck bunching, adjustment made by truck dispatchers to reduce the truck bunching;in response to excessive truck overloading, adjustment made by shovel operators to reduce the truck overloading;in response to a disruption of tonnage during shift change, investigation of actual cause thereof and adjustment of approach in shift change in terms of time of shift change on individual trucks, order and/or location where shift change occurs;in response to excessive switch-out times corresponding to switching operators in shift on a given truck, determination of root cause and devising of alternative approach to switch-outs; and/orin response to ore blending upset, adjustments made by truck dispatchers to ensure that characteristics of ore blends return to expected levels in terms of ranges of bitumen and fines content.
  • 11. The process of claim 1, wherein the controlling of the trucks and the shovels comprises strategic decision making to impact mining performance.
  • 12. The process of claim 11, wherein the strategic decision making comprises: assessing truck inventory requirements including one or more of new truck purchases, truck rentals, truck fleet size, type of trucks, truck equipment features, and truck equipment size, optionally in 5 to 10 years; and/orassessing shovel inventory requirements including one or more of new shovel purchases, shovel rentals, shovel fleet size, type of shovels, shovel equipment features, and shovel equipment size, optionally in 5 to 10 years.
  • 13. The process of claim 1, wherein the pre-developed model is further based on extraction facility parameters such that the controlling of the trucks and the shovels is performed based on monitored extraction facility parameters related to the oil sands extraction operation.
  • 14. The process of claim 1, wherein the monitoring comprises displaying the KMPI and information derived therefrom on a dashboard and/or a scorecard to enable a user to evaluate performance based on the displayed KMPI.
  • 15. A method for monitoring truck and shovel performance in an oil sands mining operation, the method comprising: providing a model comprising a plurality of databases housing information acquired from the oil sands mining operation;determining key mining performance indicators (KMPI) comprising: truck operating parameters related to the trucks;shovel operating parameters related to the shovels; andworkforce performance parameters related to the workforce; anddisplaying the KMPI on interactive digital displays comprising dashboards and scorecards for assessment by a user, the digital displays showing KMPIs for both in-shift and past-shift time intervals.
  • 16. The method of claim 15, wherein: the truck operating parameters comprise truck productivity, truck availability, and truck cycle indicators, and wherein the truck cycle indicators comprise loading, hauling, emptying, dumping, waiting and spotting;the shovel operating parameters comprise truck wait times at the shovels, under-loading conditions, over-loading conditions, and shovel productivity;the workforce performance parameters comprise shift team performance parameters of the shift teams that make up the workforce, and operator performance parameters of the operators who make up the shift teams; wherein the workforce performance parameters comprise shift change time; andthe digital displays comprise an overall mining scorecard comprising KMPI and qualitative information based on pre-determined codes, a truck performance dashboard including time-based truck performance monitoring; a payload performance dashboard; an overall team performance dashboard; a shovel performance dashboard; and shift change dashboard.
  • 17. A method of monitoring shift change performance of trucks used in oil sands mining operations, the method comprising: receiving truck performance data from a truck fleet, the truck performance data comprising operator-input codes that include a shift-change code indicating when a shift change is occurring and stationary-state codes indicating states during which the trucks are stationary;determining a base shift change duration based on the shift-change codes;determining a supplementary shift change duration based on a selection of the stationary-state codes; andproviding an adjusted shift change duration based on the base shift change duration and the supplementary shift change duration; or wherein the method comprises:receiving truck performance data from a truck fleet, the truck performance data comprising truck cycle times;for each truck in the truck fleet: determining truck cycle times during a pre-determined time interval spanning the corresponding shift change, each truck cycle including loading, hauling, dumping, and dispatching;determining a longest truck cycle;determining an average truck cycle which excludes at least the longest truck cycle; anddetermining the shift change duration based on a difference between the longest truck cycle and the average truck cycle; anddetermining an average shift change duration for the truck fleet based on the shift change durations determined for the respective trucks.
  • 18. The method of claim 17, wherein the selected stationary-state codes comprise an operator maintenance code, miscellaneous code, truck breakdown code, a hauling stopped code and/or an empty stopped code; wherein the selected stationary-state codes exclude stationary-state codes corresponding to truck operation of dumping and loading; and wherein the selected stationary-state codes are used in determining the supplementary shift change duration when the codes are input within a pre-determined time interval proximate the shift change.
  • 19. The method of claim 17, wherein an average shift change duration is determined by dividing the adjusted shift change duration by a number of trucks in the corresponding truck fleet.
  • 20. The method of claim 17, wherein, if a given truck lacks cycle data, determining the shift change duration of the given truck is performed using the steps of: receiving truck performance data that comprise operator-input codes that include a shift-change code indicating when a shift change is occurring and stationary-state codes indicating states during which the trucks are stationary;determining a base shift change duration based on the shift-change codes;determining a supplementary shift change duration based on a selection of the stationary-state codes; andproviding an adjusted shift change duration based on the base shift change duration and the supplementary shift change duration.