FATIGUE MONITORING
Operator at Mineração Usiminas ( MUSA ) iron ore mine in Brazil using Optalert glasses -based fatigue monitoring system
Over the years , Optalert has been deployed either in trials or larger rollouts by mining groups including Newgold at its San Xavier operation in Mexico , BHP ’ s Mount Keith , Spence and Escondida and Vale ’ s Carajas as well as by mining-related bulk transport companies like Bis Industries and Toll . Its most recent rollout in mining is at the iron ore mining operations of Mineração Usiminas ( MUSA ) in Minas Gerais , Brazil . MUSA recently stated : “ Through the Optalert device installed in glasses , the stages of tiredness are checked . From then onwards , visual and audible alerts are issued inside the cabin of the equipment itself and also in the monitoring centre , where there is a controller designated for this . The angle of the operator ' s eyelids is measured , with real-time monitoring , as soon as he starts operation on the work shift . From these measurements , a specific and calibrated fatigue scale is generated for each one , ranging from zero to 10 : from indicator 4.5 it is considered a state of attention and , above 5 , critical . The controller interacts with the operator , acts preventively to alert him and assesses the situation : the measures adopted include signalling to the supervisor the need for the operator to stop the activity , exercise at work , have a moment of rest or even the relay .” Today , MUSA has 114 off-road truck operators using the Optalert system and counting .
A good recent example of a DSS rollout is at Barrick ’ s North Mara . The mine contacted Cat dealer Mantrac to help resolve a recurring issue on their site . They were witnessing 12 accidents per year , including one where an operator was driving a truck that rolled over and injured him . Mantrac suggested and implemented state-ofthe-art DSS fatigue detection technology via a comprehensive change management program for the site . Mantrac designed a total safety and productivity solution that engaged 90 operators of 15 trucks over a three-month transition period . This included reactive and predictive solutions . With custom smartbands , operators were able to manage sleep and fatigue . The trucks were also fitted with DSS to detect microsleep events and alerts the operator with an audio signal and seat vibrations . A recording of the event is also sent to a team dedicate to managing health and safety on the worksite via SMS . “ By detecting eyelids closing , eyeball movements , chin orientation and distraction events , this technology from Mantrac caught instances of distracted driving , microsleep , speeding and more . The management received daily incident reports from Mantrac consultants , in addition to data dashboard access .”
Caterpillar is also having successes with many mid-tier operators . To give some examples over the past few years – Eldorado Gold has deployed the Cat DSS fatigue system across all the mine haul trucks at its Kisladag operation in Turkey , which includes install on 14 Cat 785C & 10 Hitachi EH4000 models with the system in use since April 2021 . At the Pavlik GOK gold mine in Russia ’ s Far East Magadan region , nine Komatsu 91 t class HD785-7 dump trucks operated by contract miner Detra LLC have been equipped with DSS . This decision was made based on the results of testing , which was carried out on five dump trucks over three months , from January to April 2020 .
Another good developing world mining example is in Laos at two mines owned by PanAust Ltd . “ At PanAust , our commitment to safety is underpinned by our Zero Harm philosophy whereby all incidents are considered preventable ,” says David Reid , General Manager Operations . “ The Driver Safety System supports our commitment to keeping people across our operations safe .”
PanAust ’ s operations in Laos are operated by Phu Bia Mining Limited ( PBM ), which is 90 % owned by PanAust and 10 % by the Government of Laos . PBM operates two open pit mines within PanAust ' s Phu Bia Mining Contract Area in Laos , approximately 190 km north of Laos ' capital city , Vientiane : Phu Kham coppergold operation and the Ban Houayxai gold-silver operation .
The loading and hauling operations at Phu Kham and Ban Houayxai consist of face shovels and excavators loading Cat 777D 90 t ( 100-ton ) trucks — 53 at Phu Kham and 11 at Ban Houayxai . Ancillary equipment includes Cat D10T dozers , Cat 16M motor graders and Cat 990 and 992G wheel loaders . PBM also relies on support from Cat dealer Metro Machinery Company Ltd ( MMC ). The authorised Cat equipment dealer in Thailand since 1977 , Metro
Cat DSS filtering down through the industry
Caterpillar ’ s DSS , supplied both direct and through its dealer network , continues its global market leadership in mining fatigue monitoring – first and foremost through relationships with Tier 1 miners – Newmont as stated standardised on DSS some time ago while others like Rio Tinto , Barrick and Newcrest also use the system across multiple sites .
Cat also offers Fatigue Risk Assessments including an on-site manager workshop , 90 day intensive data collection , and Fatigue
Avoidance Scheduling Tool
64 International Mining | JANUARY 2022