Performance Audits

To provide a thorough audit/evaluation, OCC proposes to break this project into four phases.

Phase 1- Existing conveyance equipment/system design audit

This initial phase includes collecting all conveyor geometry, components and system design and operating requirements and providing a complete engineering evaluation.

This information required consists of all current conveyor data per individual flight. Conveyor information required includes conveyor geometry (length, elevations), tonnages, material characteristics and size, belt speeds and width. Component data would include belting information (belt type, belt strength, cover thickness, modulus of elasticity), idler information (types, designs, roll sizes, spacing), pulley information (diameters, face widths, bearing sizes, wrap angles), drive information (i.e. total HP on main drive and trippers, if applicable, motor information and conveyor starting times) and take-Up Unit information (winch; hydraulic or electric, cylinder, gravity, etc). Complete system information would include the mine conveyance layout in relation to the longwall and mining machines, any bins/bunkers and all transfers stations and chute capacities.

We would also request a copy of downtime reports (conveyor issues, etc.) of the individual conveyors and the entire system such that we can analyze the history.

Deliverables

1- Simulate all conveyors under the existing operating conditions on a static basis utilizing OCC’s Belt Analysis II software. Evaluate all system parameters and components for design suitability. Provide report of system and component problems found and risk analysis. Provide client with all files of existing conveyors and one license for Belt Analyst II in order to view all files and do “what if” calculations in the future.

2- Advanced dynamic analysis using proprietary OCC “Dynamic Analyst” program has not been included in this phase due to the time and cost requirements of this type analysis and the unknown nature of the Shoal Creek conveyance system. However, after the static review is made, a preliminary dynamic review will be made by OCC to determine if potentially harmful dynamic problems could be causing system downtime. If its determined, this more detailed analysis is necessary, a presentation of dynamic issues will be made to mine personnel and further review recommendations will be provided.

3- Evaluate the conveyance system with CMBCS (Coal Mine Belt Conveyor Simulator) software. Simulate performance of mining machines and conveyor capacities for system performance and conveyor transfer design problems.

Milestone 1- Phase 1 report

Phase 2- Existing conveyance equipment/system maintenance/operation audit

After the completion of Phase 1, OCC would set up a team to visit the mine and visually observe each conveyor in operation. At this time, OCC would collect field data or measurements (conveyor loads, motor amps, etc.) to supplement and/or verify the Phase 1 evaluation.

One problematic conveyor transfer could be nominated by Shoal Creek for specific evaluation by the team (one is selected only for the purpose of providing Shoal Creek with an example of OCC’s transfer evaluation process and design recommendations. Of course additional conveyor transfers could be nominated at this time at a higher cost if necessary).

Team members (see resumes attached) would include:

RJ Ganey- Extensive expertise in all underground conveyance components and manufacturing
Mark Alspaugh- Extensive expertise in underground components, system design and belting
Bud Viren- Extensive expertise in underground mining, operations and maintenance

Deliverables

1- Report covering all maintenance and operating issues observed and their affect on component life and system downtime and risk analysis.

2- Conveyor transfer simulation (DEM) of mass flow of the nominated transfer chute. An analysis of the existing chute parameters will be provided as well as design changes (AutoCAD wireframe drawing excluding construction details) required to solve the problems. Digital animations of both before and after will be provided.

Milestone 2- Phase 2 report

Phase 3- Future system conditions/changes

We would like to review the future mine plans to evaluate future conveyor requirements (conveyor extensions, etc.) and simulate these scenarios as well using Belt Analyst and CMBCS. Simulating future conveyor applications will allow the mine to evaluate their existing conveyors and plan for the future conveyor needs accordingly.

OCC would like to discuss all possible future considerations in which the mine may be evaluating (standardization of belting strength, horsepower requirements, reducers, couplings, etc.)

Deliverables

Same of Phase 1 above.

Milestone 3- Phase 3 report

Phase 4- Ongoing progress

Of course this complete evaluation exercise is of no use unless the result is improved availability/reliability of the conveyance equipment, increased production and lower operating/maintenance costs. It is expected OCC will be making several recommendations based on the evaluation, site visit, discussion with Shoal Creek personnel and historical records. There are always many ways to implement changes but the most important aspect of system changes is recording progress and documenting benefits. This is an ongoing process.

System wide performance improvements requiring equipment upgrades or design changes such as transfer station improvements are not often obtainable over night. However, slow steady progress can have significant long term benefits.

OCC have ongoing relationships with other mining companies where we provide advise, engineering analysis and recommendations on all belt conveyance projects. Having an outside expert with specialized knowledge can be very cost effective as we keep up to date on all product improvements and technical advances and are intimately familiar with state-of-the-art equipment expectations.