Improvements in Longwall Downtime Analysis and Fault Identification

In this project we have developed a computer program for recording detailed information relating to face equipment downtime in longwall mining operations. This software is intended to replace the current manual recording of delay information, which has been proven to be inaccurate.

The software developed is intended to be operated from the maingate computer. Users are provided with a simple user interface requesting that nature of each delay in production, which is time-stamped in alignment with the SCADA system, removing the need for operators to estimate the start time and duration of each delay. Each instance of non-production is recorded to a database, which may be accessed by surface computers, removing the need for transcribing of the deputy’s report into the delay database.

An additional suggestive element has been developed, based on sophisticated fault detection technology, which reduces the data input required by operators, and provides a basis for the implementation of real-time fault detection.

Both the basic recording software and the suggestive element offer improvements in efficiency and accuracy to longwall operations. More accurate data allows improved maintenance planning and improved measures of operational KPIs. The suggestive element offers the potential for rapid fault diagnosis, and potentially delay forecasting, which may be used to reduce lost time associated with machine downtime.