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mining Cummins

SUMMER EDITION 2012/2013 MINING

BUSINESS

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WORK

DUAL-FUEL QSK60 FOR HAUL TRUCKS: HERE SOON

www.cummins.com

WINNING RUN STOKED ON COAL IRON HORSES IN THE PILBARA DIGGING IN OVER COAL LONGER LIFE... HERE’S THE DRILL


Content

mining Cummins

YOUR MINING MAGAZINE

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Duel-fuel for mine haul

MINEXPO

Feature article - The big news from Cummins at MINExpo was the dual-fuel QSK60 for mine haul trucks.

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Longer life... here’s the drill Dramatically improved reliability and life-to-overhaul are key factors behind the repowering of rotary blasthole drills by Queensland company Sharps Heavy Equipment Repairs.

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Digging in over coal

ummins power was on full display at MINExpo, the mining show of mega proportions in Las Vegas, with more than 40,000 horsepower installed in haul trucks, excavators, loaders, drills, and support vehicles – significantly more than any other engine manufacturer.

LEFT Cummins featured a 49 hp to 4000 hp engine line-up at MINExpo representing the most extensive range the company has ever put on display. In the foreground is the new 4000 hp QSK95. RIGHT QSK95 high-speed diesel engine.

From an Australian point of view, Cummins’ major announcement was the dual-fuel QSK60 for mine haul trucks which is expected to be available later in 2013. Cummins Dual Fuel engine technology substitutes diesel fuel with natural gas in the combustion process,

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Cummins Dual Fuel engines will use integrated controls that will optimise the substitution rate based on operating conditions, and will seamlessly and automatically

transition between diesel fuel and dual-fuel modes. The technology will enable mining equipment to operate in 100 percent diesel fuel or in dualfuel mode, giving the customer flexibility depending on natural gas availability at the mine site. “The rapid expansion and abundance of natural gas in many areas of the world has driven a dramatic cost advantage of natural gas over diesel fuel. The ability to substitute diesel fuel with natural gas drives down the total cost of ownership of equipment,” said Mark Levett, vice president of Cummins high horsepower business. CUMMINS SOUTH PACIFIC

SUMMER 2012

DIGGING IN OVER COAL

“We have a team of guys here – fitters and planners – who are passionate about diggers. That’s one of the keys to the high availability.”

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ummins’ on-site support and the reliability of 31 Cummins QSK Tier 2 engines are key factors behind the high availability of a fleet of Hitachi excavators and haul trucks at the Middlemount Coal project in Queensland’s Bowen Basin.

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Stoked on coal

This is the biggest contingent of Tier 2 emission Cummins engines at a single mine site in Australia.

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Seven Hitachi excavators are the backbone of the mining operations being carried out by contractor NRW at Middlemount, and all are exceeding the availability target of 90%. “We have a team of guys here – fitters and planners – who are passionate about diggers. That’s one of the keys to the high availability,” says Jim Cakurs, maintenance

superintendent for NRW at Middlemount, Queensland. “The on-site support from Cummins also rates highly. Ashley (Berrigan) is here to support us and he’s very passionate and knowledgeable about Cummins engines. Cummins’ product support representative Bob Lenton along

with the Cummins Mackay branch further increase the service capabilities to the mine.

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ining began at Middlemount, in mid-2011. The project is the first greenfield coal mine developed in the Bowen Basin since 2007 and today is a joint venture between Peabody Energy and YanCoal. The core of NRW’s excavator fleet at

Middlemount was purchased from Comiskey Earthmoving in 2011. Comiskey was a well-known advocate of the Cummins-powered Hitachi brand.

IMAGE The biggest digger at Middlemount is the 3000 hp EX5600-6 with dual QSK50 engines.

CUMMINS SOUTH PACIFIC

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SUMMER 2012

Innovation

“If you see conflict, run at it not away from it.” That’s the edict Chris Bugeja lives by as manager of Cummins Mackay, the branch serving Australia’s biggest coal producing region, the Bowen Basin in Queensland. It’s an edict Bugeja expects his team to adhere to as well. His is a brand of strong, customer-focused leadership…and it gets results. A key man in the Bugeja leadership team is Quentin Tass, manager of field service operations for Cummins Mackay.

WINNING RUN

Iron horses in the Pilbara In the red dirt of Western Australia’s Pilbara region, Citic Pacific Mining’s Sino Iron project is expected to begin trial production in late 2012.

Cummins Mining Magazine Published by Cummins South Pacific. Pre-press and production by Sill Marketing Pty Ltd.

With outputs up to 2850 hp the 60-litre QSK60 is available in standard and high-altitude configurations, and both will be capable of substantially reducing fuel costs with Cummins Dual Fuel technology. Other dual-fuel QSK engines will follow the QSK60 release.

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Indian company Lanco Infratech, owner of Griffin Coal in Western Australia’s southwest, has ambitious plans for the coal miner.

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reducing the amount of diesel fuel required to operate mining equipment.

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Winning run “If you see conflict, run at it not away from it.” That’s the edict Chris Bugeja lives by as manager of Cummins Mackay.

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The big news from Cummins at MINExpo was the dual-fuel QSK60 for mine haul trucks.

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Mine talk

Seven Hitachi excavators are the backbone of the mining operations being carried out by contractor NRW at Middlemount, Queensland.

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DUAL-FUEL FOR MINE HAUL

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“Quentin knows the mining game, he knows how to make things happen,” says Bugeja. “We have high staff retention in field service today and that is largely due to Quentin.” Tass, who oversees a team of 32 field service technicians and customer service advisors, started with Cummins as a fitter in 1989 after serving his apprenticeship at the Norwich Park mine in the Bowen Basin.

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He left Cummins in 2007 before being encouraged back by Bugeja two years later to supervise field service operations and manage

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the challenges faced daily in servicing the mining industry. “We have to stay on top of our service support…maintaining a high standard is critical,” says Tass, whose team is responsible for a population of over 400 high horsepower engines – 19 to 78 litres – in the Bowen Basin. He says that “getting to know” people in his team is critical to a successful field service operation in the pressured environment of today’s mining industry. “I like to get a complete picture of our people and that means taking time to know them, having a yarn, being able to read them if something is wrong at work or outside work,” says Tass. He understands that attitude and pride and the two things that make good people and that good people are the secret to the success of any business. A man of quiet demeanour who is immensely popular among the Cummins Mackay troops, Tass is proud of the high staff retention in his field service team. “You need that core strength and stability in a team if you’re going to be successful,” he says.

TOP Quentin Tass… understands that attitude and pride and the two things that make good people. BELOW Tass with Cummins Mackay’s customer service advisors.

Taking that extra step to ensure safety is another Tass priority. “Safety in the field is a big thing,” he says. “In fact, making sure our people are safe is my No.1 priority.” Apart from the field service team, Cummins has another 25 technicians based in its Mackay workshop. Chris Bugeja points out the workshop has been turned into a “quick turnaround” facility to reduce haul truck and excavator downtime. “We can pull out an engine in the field in a shift, bring it back to Mackay, carry out the repair in an environment which is safer and where there’s no contamination, and get it back out to the mine site for refitting. “Our sole focus is minimising customer downtime,” he says.

CUMMINS SOUTH PACIFIC

SUMMER 2012

© Cummins South Pasific, © Sill Marketing. All material in Cummins Mining magazine is strictly copyrighted and all rights reserved. Reproduction without permission is strictly forbidden. Every care has been taken in compiling the contects of this magazine, but we assume no responsibility for the effects arising therefrom. All information was correct at the time of print.


Cummins is constantly working on hiring to develop apprentices.

News

Apprenticeships key to Cummins’ future Cummins is now recruiting its apprentices directly rather than through external agencies to gain greater control over their technical training while also providing personal responsibility and awareness skills. Cummins currently has 230 apprentices across Australia, New Zealand and Papua New Guinea. Over 200 are employed in Australia alone and are under the guidance of four apprentice program managers.

Attracting a diverse mix of people is another important element of the new apprentice strategy. Cummins currently employs 17 mature-age apprentices and 15 female apprentices in the South Pacific and aims to build on these numbers. Cummins is also building relationships with schools, community groups, TAFE colleges and government agencies to enlarge the pool from which it can attract apprentices.

In 2012, 90 new apprentices have been recruited by Cummins from over 600 applicants and next year there will be another significant intake. “Our strategy is to ‘hire to develop’...develop our apprentices as part of the Cummins family,” says Narelle Constable, general manager of apprentice strategy and development for Cummins South Pacific. “At a time when there’s a big skills shortage in Australia, developing our own talent is critical,” she adds. “We’re about developing the whole person, not just their technical skills.” Cummins has introduced an ‘on-boarding’ program for 1st year apprentices where they are brought into a central location during their first week at work and put through a four-day induction program. Each mechanical and electrical apprentice recruited by Cummins receives a fully equipped toolbox valued at $3,000 to $4,000.

Award-winner James Ripa. Narelle Constable... “Developing our own talent is critical.”

Building strong relationships with TAFE colleges in Australia continues to be important, with Cummins having donated fully operational training engines to many of these colleges. The importance of Cummins’ apprentice training is highlighted by James Ripa who served his apprenticeship with the company in Sydney and this year won Australia’s highest award made to heavy vehicle mechanics – the Workskills Australia National Gold Medal – after three days of competition.

CUMMINS SOUTH PACIFIC

SUMMER 2012


MINEXPO

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Cummins featured a 49 hp to 4000 hp engine line-up at MINExpo representing the most extensive range the company has ever put on display. In the foreground is the new 4000 hp QSK95.

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DUAL- FUEL FOR MINE HAUL The big news from Cummins at MINExpo was the dual-fuel QSK60 for mine haul trucks.

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ummins power was on full display at MINExpo, the mining show of mega proportions in Las Vegas, with more than 40,000 horsepower installed in haul trucks, excavators, loaders, drills, and support vehicles – significantly more than any other engine manufacturer. From an Australian point of view, Cummins’ major announcement was the dual-fuel QSK60 for mine haul trucks. Cummins Dual Fuel engine technology substitutes diesel fuel with natural gas in the combustion process, reducing the amount of diesel fuel

required to operate mining equipment. With outputs up to 2850 hp the 60-litre QSK60 is available in standard and high-altitude configurations, and both will be capable of substantially reducing fuel costs with Cummins Dual Fuel technology. Other dual-fuel QSK engines will follow the QSK60 release. Cummins Dual Fuel engines will use integrated controls that will optimise the substitution rate based on operating conditions, and will seamlessly and automatically transition between diesel fuel and

dual-fuel modes. The technology will enable mining equipment to operate in 100 per cent diesel fuel or in dual-fuel mode, giving the customer flexibility depending on natural gas availability at the mine site. “The rapid expansion and abundance of natural gas in many areas of the world has driven a dramatic cost advantage of natural gas over diesel fuel. The ability to substitute diesel fuel with natural gas drives down the total cost of ownership of equipment,” said Mark Levett, vice president of Cummins high horsepower business.

CUMMINS SOUTH PACIFIC

SUMMER 2012


“The abundance of natural gas in many areas of the world has driven a dramatic cost advantage of natural gas over diesel fuel.”

“For operators of high horsepower mining equipment where power density is critical and large quantities of fuel are burned, Cummins Dual Fuel technology will provide an opportunity for a dramatic reduction in dollars spent on fuel,” added Levett. In dual-fuel mode, the substitution rate, which is the percentage of natural gas relative to total fuel flow, is the critical parameter to fuel savings. In traditional operating conditions, engines with Cummins Dual Fuel technology can be expected to deliver a maximum substitution rate of 70 percent. “Cummins’ investment in dual-fuel technology responds to strong

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demand from our mining customers who are looking for a way to take advantage of low natural gas prices,” said David Geraghty, executive director of Cummins mining business. “Engines with Cummins Dual Fuel technology retain the same transient response as a diesel engine, remain on the same torque curve as a diesel engine and match diesel engine power output while maintaining current service intervals.” NEXT GENERATION QSK50 Another key Cummins announcement at MINExpo was the next-generation QSK50 engine ready to meet EPA Tier 4 Final ultra-low emissions standards with up to 2000 hp output

A diesel engine consumes $1.6 m of fuel in regular diesel mode but just over $1 m of fuel in dual fuel mode.


MINEXPO

FROM LEFT Next gen Cummins QSK50 with SCR aftertreatment. Atlas Copco’s new MT85 underground truck is powered by two Cummins engines.

for powering mine haul trucks, excavators and loaders. The Tier 4 Final regulations take effect from January 1, 2016, in North America for engines over 751 hp (560 kW). The 16-cylinder, 50-litre engine utilises a fully integrated Cummins Selective Catalytic Reduction (SCR) aftertreatment system, designed as a drop-in replacement for the exhaust mufflers. The SCR system, together with cleancombustion enhancements to the engine, enable the QSK50 to lower operating costs by 5 percent or more, due to significantly higher fuel efficiency and low levels of Diesel Exhaust Fluid (DEF) consumption.

Durability improvements to the engine, and the lower fuel burn, contribute to an extended life-to-overhaul for the Tier 4 Final QSK50, surpassing that of the best in class Tier 2 QSK50 engine. Operators can also expect oil and filter services to be extended to 500-hour intervals for Tier 4 Final. Cummins 19-litre-to-95-litre QSK engine range will utilise SCR technology to achieve Tier 4 Final emissions. ATLAS COPCO Powered by two Cummins engines, the new 85-tonne capacity MT85 announced by Atlas Copco at MINExpo is touted as the world’s largest articulated underground

mining truck. The two Cummins engines at the heart of the 1010 hp MT85 are the QSK19 rated at 760 hp and the QSB6.7 rated at 250 hp. In six-wheel-drive configuration, the 19-litre QSK19 drives the front and middle axles while the rear axle is driven electrically from the smaller 6.7-litre QSB on demand. The launch date of the MT85 will be announced during 2013. Atlas Copco points out that the MT85 is designed to fit the same drift dimensions of 50 to 60-tonne trucks and makes it more attractive to go for deeper ore bodies by ramp instead of sinking a shaft. The company says the MT85 is 3.4 metres wide by 3.5 metres high, easily fitting into 6 metre

CUMMINS SOUTH PACIFIC

SUMMER 2012


Cummins’ Tier 2 QSK60 engine is at the heart of the new EH5000AC-3 haul truck.

by 6 metre drifts, and despite its 14-metre length has an impressive turning radius of 40 degrees, due largely to its electro-hydraulic steering of the rear axle. The MT85 offers a high degree of modularity and options. The dump box can be tipped at the side of the vehicle as well as at the rear and there are three engine power alternatives (535, 760 or 1010 hp) as well as four-wheel or six-wheel drive. KOMATSU The new 730E haul truck with AC electric drive technology was debuted by Komatsu at MINExpo. Powered by the 2000 hp Tier 2 Cummins QSK50 engine, the 200-ton capacity

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730E (AC) builds on the success of the 730E DC-drive truck with advancements in structure, hydraulics and telemetry. Komatsu says the 730E (AC) features a 15 per cent higher speed than the previous model and also has an easily removable powertrain module, reducing the time needed for on-site maintenance. The 730E (AC) is slated for limited release in 2013 and full production in 2014. Komatsu also displayed the latest version of its PC4000 hydraulic shovel, now fitted with the Tier 2 Cummins QSK60 engine rated at 1875 hp. The PC4000 has an operating weight between 388 and 399 tonnes and a bucket capacity of 22 m3.

The company says the PC4000 has the highest digging forces in its class to increase mine productivity. HITACHI Cummins’ Tier 2 QSK60 engine is at the heart of the new EH5000AC-3 haul truck featured by Hitachi at MINExpo. The QSK60 is rated at 2850 hp at 1900 rpm, while the EH5000AC-3 – Hitachi’s largest haul truck – has a payload capacity of 296 tonnes (326 tons). The EH5000AC-3 is Hitachi’s first haul truck to feature the company’s new AC drive system. The advanced propulsion technology features pitch control, skid control, slip control for traction, and slide control for grip.


MINEXPO LEFT PAGE Komatsu’s new 730E features AC electric drive technology.

THIS PAGE Liebherr’s new T264 haul truck is powered by Cummins’ Tier 2 QSK60 engine rated at 2700 hp.

Hitachi’s new EH5000AC-3 haul truck is powered by the 2850 hp Tier 2 Cummins QSK60.

Sandvik unveiled its new Cummins QSK19powered TH663 underground truck at MINExpo.

The new system has sensors on all four wheels and incorporates additional feedback from the drive system, front wheels, steering, suspension, and other systems to enhance the slip/slide control feature. Hitachi is the only company in the industry that designs and manu- factures all components of its drive control system. Hitachi also announced at MINExpo that it aims to have an Autonomous Haulage System ready for the surface mining industry by 2017 where dump truck loading, haulage and dumping is automated.

LIEBHERR The new T264 haul truck, powered by Cummins’ Tier 2 QSK60 engine rated at 2700 hp, was one of the highlights of the Liebherr display. Liebherr says the new fuel efficient 240-ton class truck is sized to match its R966B and R9800 hydraulic excavators and with the QSK60 engine yields higher speed on grades. The T264 utilises Liebherr’s proven Litronic Plus AC-drive system which delivers up to 4425 hp of electric dynamic braking. Liebherr also announced a face shovel version of its R9400 excavator at MINExpo. The 353-tonne machine is powered by Cummins’ Tier 2 QSK50 engine rated at 1675 hp

and has a 22 m3 bucket in standard configuration. SANDVIK The new Cummins-powered TH663 underground mining truck was announced by Sandvik at MINExpo. The 63-tonne capacity truck, equipped with the QSK19 rated at 760 hp, will become available later in 2013. Sandvik says there are over 60 different safety features to protect the operator, maintenance staff and the truck itself. Ease of maintenance is another feature with particular attention given to the replacement time of large components such as the engine and transmission.

CUMMINS SOUTH PACIFIC

SUMMER 2012


Repowering

LONGER LIFE... HERE’S THE DRILL D

ramatically improved reliability and life-to-overhaul are key factors behind the repowering of rotary blasthole drills with the Cummins QST30 engine by Queensland company Sharps Heavy Equipment Repairs. The Mackay-based engineering firm has developed modules for both the Driltech D90K and Reedrill SKS drills featuring the QST30 engine, a 30-litre V12.

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To date, 13 drills have been repowered by Sharps and in all cases Caterpillar engines have been replaced with the Cummins QST30 which is rated at 1050 hp in the D90K and 850 hp in the SKS. The QST30 module was originally developed for the D90K drill in response to a customer request to replace the Cat and also direct-couple the compressor to the engine to eliminate the driveline and prevent premature compressor failures.


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he decision to replace the Cat was primarily due to the customer having drills in similar applications powered by the Cummins QST30. Reliability and durability of the QST30 made it an easy decision for the client to repower the drill with this engine.

He points out that the combination of the QST30 in a fully floating cradle and direct-coupling of the engine to the compressor in the D90K produces significantly less vibration than the original set up, thus significantly improving compressor life.

Rotary blasthole drilling is a tough application with engine load factors as high as 75%. Life expectancy of the QST30 is 16,000 to 20,000 hours – a level that other engine manufacturers struggle to achieve.

Noise is also reduced as much as 7 dBA in the cab, which is beneficial for the machine operator.

“We actually know of a factory-fitted QST30 (in a SKS drill) that achieved life to overhaul of 31,000 hours,” says Tony Harmsworth, who heads up Sharps’ drill division in Mackay.

“The QST30 module is proving very successful in terms of reliability and durability, with significantly reduced vibration,” says Harmsworth. In the Reedrill SKS drill, the engine and compressor are factory-fitted as a direct-coupling.

However, Sharps saw the need to improve alignment of the pump drive box to maximise its life, and also reduce the vibration transmitted by the engine to the chassis. The solution was to install a fully floating cradle supporting the engine, compressor and pump drive box, and also provide fully adjustable pump drive alignment.

FROM TOP LEFT One of the 13 rotary blasthole drills that have been repowered with the Cummins QST30 by Sharps. Cummins QST30 has replaced Cat engines to provide better reliability and durability. Tony Harmsworth who heads up Sharps drill division.

CUMMINS SOUTH PACIFIC

SUMMER 2012


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DIGGING IN OVER COAL

“We have a team of guys here – fitters and planners – who are passionate about diggers. That’s one of the keys to the high availability.”

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ummins’ on-site support and the reliability of 31 Cummins QSK Tier 2 engines are key factors behind the high availability of a fleet of Hitachi excavators and haul trucks at the Middlemount Coal project in Queensland’s Bowen Basin. This is the biggest contingent of Tier 2 emission Cummins engines at a single mine site in Australia.

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Seven Hitachi excavators are the backbone of the mining operations being carried out by contractor NRW at Middlemount, and all are exceeding the availability target of 90%. “We have a team of guys here – fitters and planners – who are passionate about diggers. That’s one of the keys to the high availability,” says Jim Cakurs, maintenance


superintendent for NRW at Middlemount, Queensland. “The on-site support from Cummins also rates highly. Ashley (Berrigan) is here to support us and he’s very passionate and knowledgeable about Cummins engines.” Cummins’ product support representative Bob Lenton along

with the Cummins Mackay branch further increase the service capabilities to the mine.

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ining began at Middlemount, in mid-2011. The project is the first greenfield coal mine developed in the Bowen Basin since 2007 and today is a joint venture between Peabody Energy and YanCoal. The core of NRW’s excavator fleet at

Middlemount was purchased from Comiskey Earthmoving in 2011. Comiskey was a well-known advocate of the Cummins-powered Hitachi brand.

IMAGE The biggest digger at Middlemount is the 3000 hp EX5600-6 with dual QSK50 engines.

CUMMINS SOUTH PACIFIC

SUMMER 2012


Planned life-to-overhaul of the QSK50 and QSK60 engines in the haul truck operation is 25,000 hours.

DIGGING FORCE All the excavators at Middlemount get their digging force from Tier 2 Cummins engines, their reliability being a strong factor in the high availability of the Hitachi machines. Cummins’ Tier 2 technology focuses on the modular common rail fuel system which enables cleaner, quieter and faster power delivery. The system is modular in that each injector has its own integrated accumulator to keep injection pressures – up to 1,600 bar (23,500 psi) – constant throughout the system. This prevents unbalanced fuelling between cylinders to significantly reduce engine vibration, noise and harshness.

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The biggest diggers at Middlemount are a 3000 hp EX5600-6 with dual QSK50 engines, and a 2800 hp EX5500-6 also with dual QSK50s. The rest of the fleet is made up of four EX3600-6 units, each with a QSK60 engine rated at 1950 hp, and an EX1900-6 powered by a QSK38 rated at 1085 hp. Planned life-to-overhaul for the QSK50 and QSK60 excavator engines is 18,000 hours – a “fair target”, says Jim Cakurs, pointing to the high engine load factors of 75 to 80%. The oldest QSK60 has already hit the 18,000-hour target, while two Cummins QSK50s are closing in on the mark.


Mine report

Regular engine condition monitoring includes oil sampling every 250 hours. The oil change interval for the Tier 2 engines in the Hitachi machines is 500 hours using an oil reserve system that virtually doubles sump capacity.

Tier 2 QSK60 rated at 2500 hp, while the 168-tonne capacity EH3500 has the 2000 hp Tier 2 QSK50.

While rating reliability of the Tier 2 engines highly, Jim Cakurs is concise in his opinion of fuel burn too. “We have no concerns with fuel consumption,” he says.

“That’s a good number,” says Jim Cakurs. “If we achieve that we consider we’ll be doing well.”

significantly in the mining and civil construction sectors, counting Rio Tinto, BHP Billiton and Fortescue among its customers.

Planned life-to-overhaul of the QSK50 and QSK60 engines in the haul truck operation is 25,000 hours.

NRW’s haul truck fleet at Middlemount totals 43 units, 22 of which are a mix of Hitachi AC-drive EH4000 and EH3500 units.

The Middlemount project is NRW’s first mining contract in Queensland. NRW was established in Western Australia’s goldfields in 1994 as a small, privately run civil construction and general plant hire firm.

A 228-tonne capacity truck, the EH4000 is powered by the

Since then, the now listed company has expanded its operations

FROM TOP LEFT Cummins’ on-site technician Ashley Berrigan is well regarded at Middlemount. EH4000 haul truck is powered by the Tier 2 QSK60 rated at 2500 hp. Seven Hitachi excavators are the backbone of the Middlemount mining operation.

CUMMINS SOUTH PACIFIC

SUMMER 2012


Customer support

WINNING RUN

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“If you see a problem, run at it not away from it.”

the challenges faced daily in servicing the mining industry. “We have to stay on top of our That’s the edict Chris Bugeja lives by service support…maintaining a as manager of Cummins Mackay, high standard is critical,” says the branch serving major coal Tass, whose team is responsible producing region, the Bowen Basin for a population of over 400 high in Queensland. It’s an edict Bugeja horsepower engines – 19 to 78 expects his team to adhere to litres – in the Bowen Basin. as well. His is a brand of strong, customer-focused leadership…and He says that “getting to know” it gets results. people in his team is vital to a successful field service operation A key man in the Bugeja leadership in the pressured environment of team is Quentin Tass, manager of today’s mining industry. field service operations for Cummins Mackay. “I like to get a complete picture of our people and that means “Quentin knows the mining game, taking time to know them, having he knows how to make things a yarn, being able to read them happen,” says Bugeja. “We have if something is wrong at work or high staff retention in field service outside work,” says Tass. today and that is largely due to Quentin.” He understands that attitude and pride and the two things that make Tass, who oversees a team of good people and that good people 32 field service technicians and are the secret to the success of customer service advisors, started any business. with Cummins as a fitter in 1989 after serving his apprenticeship A man of quiet demeanour who at the Norwich Park mine in the is immensely popular among the Bowen Basin. Cummins Mackay troops, Tass is proud of the high staff retention in He left Cummins in 2007 before his field service team. “You need that being encouraged back by Bugeja core strength and stability in a team two years later to supervise field if you’re going to be successful,” service operations and manage he says.

TOP Quentin Tass… understands that attitude and pride and the two things that make good people. BELOW LEFT Tass with Cummins Mackay’s customer service advisors. BELOW Cummins Mackay’s Manager Chris Bugeja.

Taking that extra step to ensure safety is another Tass priority. “Safety in the field is a big thing,” he says. “In fact, making sure our people are safe is my No.1 priority.” Apart from the field service team, Cummins has another 25 technicians based in its Mackay workshop. Chris Bugeja points out the workshop has been turned into a “quick turnaround” facility to reduce haul truck and excavator downtime. “We can pull out an engine in the field in a shift, bring it back to Mackay, carry out the repair in an environment which is safer and where there’s no contamination, and get it back out to the mine site for refitting. “Our sole focus is minimising customer downtime,” he says.

CUMMINS SOUTH PACIFIC

SUMMER 2012


User report

STOKED ON

COAL

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ndian company Lanco Infratech, owner of Griffin Coal in Western Australia’s southwest, has ambitious plans for the coal miner.

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Lanco, a leading infrastructure player in India with a presence in power generation, construction, engineering and property development, reportedly


paid close to $750 million for the mines of Griffin Coal in 2011. Western Australia’s oldest coal supplier, Griffin Coal had been in administration since January 2010. Its purchase by Lanco, a US$3 billion enterprise, is the biggest investment by an Indian company in Australia. Griffin Coal is currently producing 4 million tonnes a year and will increase this to 5.2 million tonnes in 2013.

Griffin Coal is currently operating 14 830Es powered by Cummins QSK60 engines rated at 2500 hp. Additional 830Es will be added to the fleet in 2013 to meet production targets.

MAIN IMAGE Komatsu 830E with Cummins QSK60 is the truck of choice at Griffin Coal. BELOW Griffin maintenance manager Graham Clegget...“Reliability of the QSK60 exceeds the industry standard.”

“Our experience on site is that the reliability of the QSK60 exceeds the industry standard,” says Cleggett. He points out that planned life-tooverhaul of the QSK60 is 20,000 to

“Cummins stands by its products...” With further mine development, an annual production increase to around 18 million tonnes is planned within three to four years. Most of the current coal production is used by three power stations in the region which feed into the southwest grid. Over one million tonnes will be exported in 2013. The significant ramp up in production in the next three to four years will see Lanco export the thermal coal for use in its power stations in India and to various Asian customers. The “truck of choice” at Griffin Coal is the AC-drive Komatsu 830E, according to Graham Cleggett, the mining company’s maintenance manager.

22,000 hours and all but one engine has hit this target. “Cummins stands by its product, provides good technical support, and continues to drive product improvements,” he says. Six Komatsu 630Es are also in service at the mine. Planned change-out for the 2000 hp Cummins K2000E engines in these trucks was initially 18,000 hours, but condition monitoring resulted in an increase to 22,000 hours.

The truck and excavator fleet is set to expand significantly with development of the Muja South mine and the associated ramp up in production. Graham Cleggett says Griffin Coal is currently going through the equipment selection process and that up to 50 trucks – most likely Komatsu 830Es – could be added to the fleet.

The main digging fleet at Griffin Coal – two Komatsu PC5500s, a Terex RH340 and a Liebherr 996 – is also dominated by Cummins power while two Komatsu WA1200 loaders have Cummins QSK60 engines.

CUMMINS SOUTH PACIFIC

SUMMER 2012


Mine development

FROM THE TOP Massive infrastructure includes four in-pit crushers. Two 4500 hp Terex RH400 excavators – the largest hydraulic face shovels in the world – have been working at the Sino Iron project since 2008.

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IRON HORSES IN THE PILBARA In the red dirt of Western Australia’s Pilbara region, Citic Pacific Mining’s Sino Iron project is expected to begin trial production in late 2012. Sino Iron is China’s largest investment in the Australian mining sector and also the biggest magnetite iron ore project in the country. It is estimated the final bill for construction of the mine and associated infrastructure will come in at around US$8 billion. Not surprisingly, some of the biggest mining machinery in the world is working at the mine, including a Cummins-powered excavator fleet containing the world’s largest available hydraulic face shovels. The sheer scale of what has been needed for construction of the mine is hard to visualise if you haven’t been to the site, 100 km south west of Karratha. The project has required massive investment in dedicated infrastructure, including a 450 megawatt gas-fired

CUMMINS SOUTH PACIFIC

SUMMER 2012


The distinguishing feature of the Tier 2 engines is the modular common rail fuel system. power station, a 51-gigalitre desalination plant, and a port built specifically for the project at Cape Preston. Other infrastructure includes four in-pit crushers, six giant grinding mills – the most powerful in the world, each mill line requiring 44 megawatts of power – and a 34 km slurry pipeline through which the magnetite concentrate is pumped to the port. Full production at the mine is expected to be around 24 million tonnes per year of magnetite concentrate. Since late 2008 two 4500 hp Terex RH400 excavators – the largest 20

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hydraulic face shovels in the world – have been working at the Sino Iron project, applying their awesome digging force to move millions of tonnes in pre-stripping and other earthworks. Dual Cummins Tier 2 QSK60 engines – 60-litre V16s – power the hydraulics system on each 980-tonne RH400. The engines’ total output of 4500 hp at 1800 rpm is backed up by enormous peak torque of 14,500 lb ft at 1500 rpm. The massive shovels, equipped with 37 and 42 cubic metre buckets which scoop up around 85 tonnes of material in one hit, carry 13,000

litres of hydraulic fluid and have eight main pumps which move 8,000 litres of oil a minute to achieve maximum working force. “They’ve been performing very well since the bugs have been sorted out,” says Peter Boonman, manager of heavy mobile equipment maintenance for Citic Pacific Mining. “They’re like any piece of equipment. You have to maintain them properly to keep them moving. The RH400s have become very cost-effective.” Planned life-to-overhaul of the Tier 2 QSK60s is 15,000 hours, and all engines are now into their second life.


Mine development

The QSK23 is well established in high duty cycle mining applications.

The distinguishing feature of the Tier 2 engines is the modular common rail fuel system. The high-pressure fuel pump generates around 1600 bar (23,500 psi) to enable cleaner, quieter and faster power delivery. The system also prevents unbalanced fuelling between cylinders to significantly reduce engine vibration, noise and harshness.

Six other high horsepower Cummins engines are delivering reliable power at the mine – 30-litre QST30s rated at 1050 hp in Reedrill SKF rotary blasthole drills. The oldest units have clocked up over 14,000 hours while heading for their planned life to overhaul of 18,000 hours.

FROM THE LEFT Vast concentrator area includes six grinding mills, the most powerful in the world. Gas-fired power station delivers 450 MW. The port at the Sino Iron project.

A third RH400 will join the Sino Iron project in 2013 to help mine 140 million tonnes a year once full production begins. The excavator fleet also includes RH340 and RH170 diggers, powered by dual Cummins QSK45 and KTA38 engines respectively. CUMMINS SOUTH PACIFIC

SUMMER 2012


Send your story ideas, comments and feedback on this issue of Cummins Mining to: rachael.reinheimer@cummins.com Cummins after-hours assistance One number for Australia-wide parts and service. Experienced Cummins technicians on hand to answer your calls. All 250 Cummins field service vehicles fitted with GPS. Improved efficiency in meeting customer needs. Cummins has one number for after-hours assistance. For best-in-class support, call Australia -1300Cummins (1300 286 646) New Zealand - 0800 286 846 Subscribe to the Cummins Mining Magazine - Click here

Cummins Mining Magazine Summer 2013  
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