Editor: Laura White laura.white@outotec.com www.outotec.com

ISSUE 33April 2013OUTOTEC SEAP (SOUTH EAST ASIA PACIFIC) eNEWSLETTER

CONTENTS3D Laser Scanning / 1

Technical Seminars / 5

Prominent Hill case study / 6

Business News: Scanalyse acquisition / 9

Spare parts - the life cycle solution/ 10

Product News: New Courier 8 SL / 13 300+ TankCells / 14 Larox PF series addition / 15

3D laser scanning has been slow to make an appearance in the mining industry. However, over recent years the use of this technology at mine sites and plants has risen due to the distinct advantages offered compared to traditional survey methods.

Point cloud data uses a 3D set of vertices represented by X, Y and Z coordinates which is gathered via 3D laser scanners. Vast numbers

of points are collated from a given surface to produce a high point density representation of an area or object. Where this becomes particularly relevant to the mining industry is in its ability to tackle vast, complex and even underground sites with far greater simplicity and convenience than conventional surveying. Accuracy, time and cost efficiency are just some of the benefits laser scanning has to offer.

3D LASER SCANNING, AS SIMPLE AS X, Y, Z Author:

Jason Fryar

Raw point cloud capture of a thickener and associated infrastructure

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FROM A DETAIL DESIGN PERSPECTIVE...

Point cloud technology, from a detail design point of view, not only makes the job in hand that much easier, but minimises the potential for human error to almost zero. The captured data provides an ‘as built’ status, giving a real-time snapshot of the site as it currently is and the subsequent data processing that follows has a fast turnaround. This negates the risk of changes at site affecting plans, drawings and tenders.

The accuracy and coverage of the gathered data eliminates incorrect measurements or the need to make estimations. In conjunction with CAD technology, specific measurements can be extrapolated to provide exact calculations.

For QA purposes, using the point cloud data against prepared drawings is an excellent tool to clearly identify incompatibilities.

The data also has a multitude of other uses, such as clash detection of existing infrastructure and determining what aspects need to be removed, modified and in which order. New designs can be reviewed internally and externally with client and maintenance teams, prior to fabrication and installation to identify potential problems and amend accordingly. Additionally, the 3D point cloud data can be scanned to suit the plant coordinates or even a real-time satellite position. This allows the new area being modelled to be positioned into Google Earth or any other real-time satellite imagery, allowing site a true aerial preview of the new construction.

SIMPLICITY AND CONVENIENCE

The generation of a 3D replica of a physical object, regardless of size, layout or density can generally be performed while the plant is in production. Site personnel can continue with site activities as their presence does not interfere with data collection. This presents huge opportunities as the majority of the site can be surveyed during production without the need to schedule downtime and reduce productivity.

Where interior survey of, for example, a grinding mill is concerned, a short amount of downtime is necessary. However, by using a laser scanning service such as MillMapper (Scanalyse, now part of Outotec), it’s possible to scan mills in as little as 15

Rendered image from point cloud data

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minutes and this can be scheduled to coincide with a planned inspection shutdown. CrusherMapper, also from Scanalyse is used for gyratory crushers and MillMapper use patented, proprietary software to process laser scanning data and provide 3D files and wear reports of the liner thickness, cross-section and longitudinal profiles. Service life projections are given at the average and fastest wearing points. Localised critical areas of breakage, cracks and uneven wear are highlighted, resulting in significantly improved liner assessment being provided as the total surface is mapped, not just accessible areas.

In terms of safety, both internal and external scanning reduce the need to work at heights or in confined spaces as laser scanners can be placed strategically in vantage points for remote scanning.

Whilst the client may potentially expect higher up-front costs due to production and manipulation of the

data, the net results from minimised downtime alone will offset this cost. This, coupled with the convenience of the survey, quick procedure and turn-around, along with clear, highly accurate and informative imagery, more than compensate over the course of the entire project. The fabrication stage also benefits from the inherent precision in plans and drawings which will potentially reduce commissioning time.

A complete plant can be scanned within a day and the data files compiled into one or several 3D models and available to the design team within a short time frame.

HIGH DENSITY IMAGING

The data produced from the millions of points captured in a 3D environment is generally processed via a CAD programme. These high density CAD images offer numerous advantages - including versatility. Sections of an image can be isolated or cut and viewed from

any angle in the same way as a 3D CAD model. The extensive data also provides the same detailed information of surrounding areas. Exact calculations of space and measurement allow construction, access and craneage around existing infrastructure to be planned well in advance, without the need to revisit site.

When processed, point cloud data images provide the basis for digital manipulation, giving an accurate, impressive and true representation of the project. Whether rendered, false or true coloured, the images are highly detailed. Every fine point is captured which, by any other method, may have been missed -including non-documented assets such as cable trays, service piping and on-site modifications. With so much information readily available in the digital files, time spent sorting through and analysing multiple drawings and site sketches is greatly reduced.

Isolated point cloud capture of a float train and grinding mill

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BROWNFIELD SITES

Outotec has used 3D laser scanning at some of the largest mine sites and processing plants in Australia and overseas. At one particular mine site spanning over 30,000m2, where Outotec was engaged in retrofit and new design projects, no previous drawings or plans were available. Therefore, the 3D data produced from the laser scanning was an invaluable asset in providing new, detailed records of the entire concentrator plant, to within tolerances of +/-5mm. Scanning was completed in only eight days, with the data processed in just over two weeks. The level of detailed data captured could not have been achieved by traditional surveying methods. Using conventional methods for site verification alone would have taken approximately five weeks to complete.

Similarly, another project required a retrofit to an existing thickener within a tightly confined footprint at a site that had been in operation for over twenty years. The plant had undergone numerous non-documented modifications and again, was without a history of plans and drawings. The entire plant was laser scanned within 6 days, providing the client with full, current site plans and allowed the new installation to proceed without complication.

Using MillMapper at another site, several mills were scanned and the data processed via Scanalyse’s advanced forecasting software. The wear curve from the laser data indicated that the shell liners had worn down to their reline limit and would not last to the original shutdown date. The relines were

predicted up to four months in advance and gave valuable indication of the actual level of wear on the liners. This reliable forecasting gave clear indication of safe operating limits and enabled well organised and preventative maintenance which ultimately saved the mill operator considerable expense and disruption.

IN CONCLUSION

The benefits of laser scanning far outweigh the higher back-end office costs associated with the processing and manipulation of data and images. Some of the major savings include the potential for reduced installation downtime and commissioning through the accuracy and detail afforded in planning and fabrication. Fewer surveying personnel and detail design engineers are other

cost saving benefits. Additionally, the need to revisit site to make further investigations, take measurements missed initially, or verify estimates, is eradicated due to the blanket coverage of ‘as-built’ data captured. As such, travel and accommodation costs are also minimised.

High density data from 3D laser scanning provides a vast array of possibilities to extract, analyse and calculate specific areas to provide informative and high impact imagery, as well as being an invaluable resource to guarantee quality assurance. Used in conjunction with other software, the possibilities for predictability of wear, planning and scheduling go far beyond anything traditional surveying methods can offer.

About the author...Jason Fryar joined Outotec in 2001 as a Design Draftsman, becoming a Senior Draftsman in 2004. Currently Jason is a Senior Plant Designer with Outotec based in the Sydney region leading brownfield & greenfield projects globally. Jason has an Associate Diploma in Mechanical Engineering.

If you would like more information, click here to contactjason.fryar@outotec.com

MillMapper identifies the wear pattern on the inner discharge liner