04 05 08 09 Power station at Fortescue’s Christmas Creek mine comprises 27 QSK78 gensets. 16 17 One of the three EX2600-6 excavators achieving high availability at Iron Duke. When Contract Power decided to become the first major user of <strong>Cummins</strong> QSK78 generator sets in the world with the construction of a power station at Christmas Creek in the Pilbara, it could have been viewed as a bold move in such a remote and harsh region. At the time, Contract Power general manager Marc Grosser dismissed any possible concerns: “We like trying new equipment… we believe it gives us a leading edge over our competitors.” The power station in question was completed early in 2012, its generators vital to the operation of Fortescue’s Christmas Creek mine, in particular the two ore processing facilities that have an annual through-put capacity of more than 50 million tonnes. EX8000 recently loaded 110,440 tonnes in a day. This is the biggest diesel power station in Australia, designed and built by Perth-based Contract Power and owned and operated by the same company – a progressive outfit that boasts the ability to do power generation business “anywhere in the world”. It is also the largest single installation of prime power <strong>Cummins</strong> QSK78 generator sets in the world, each of the 27 units able to deliver 2 MW. In a previous issue of <strong>Cummins</strong> Commentary (Issue 34, August 2011), we featured the first development stage of the power station. Undertaken in 2011, this first stage saw the installation of 14 generators, while the second and final stage was completed early in 2012 with the commissioning of a further 13 QSK78 units. The reliability of the power station is A fleet of <strong>Cummins</strong>-powered haul mine is owned by Idemitsu Australia trucks and excavators is achieving Resources, a subsidiary of Japanese availability targets for mining petroleum company Idemitsu Kosan contractor Downer Mining at Boggabri Co., Ltd. Construction of the mine Coal in the Gunnedah Basin, NSW. began in January 2006 and the first coal was produced in October. <strong>Cummins</strong>’ on-site support also rates highly at Boggabri with the mine operating Downer Mining’s current contract with 24/7 and set to produce more than Idemitsu, which runs to December 5.0 million tonnes of coal in <strong>2014</strong>. 2016, involves drilling and blasting, mine planning, and loading and haulage. Downer Mining has been the mining contractor at Boggabri Coal since Overburden haulage at Boggabri is 2006 when production began. The spearheaded by 17 Komatsu 930E trucks The world’s first Hitachi EX8000 backhoe excavator is in full flight at Stanwell Corporation’s Meandu coal mine in south east Queensland, digging the big tonnages expected of it. With its dual Tier II <strong>Cummins</strong> QSK60 MCRS engines pumping out close to 4000 hp, the 837-tonne EX8000 went into service in September and is moving 2700 to 3000 BCMs (bank cubic metres) an hour. “The EX8000 is expected to move 14 million BCMs per year over the next three years, removing mainly overburden,” says Jim Young, Meandu Mine asset manager. A pointer to the machine’s capability is that it recently loaded 110,440 tonnes in a day. The EX8000 is equipped with a 45 cubic metre bucket and is moving around 75 tonnes per bucket load, feeding a fleet of 220-tonne capacity Komatsu 830E dump trucks. One of the biggest hydraulic excavators in the world, the EX8000’s dual 60-litre <strong>Cummins</strong> QSK60 engines power its hydraulic system – a system of 16 main pumps which move 8000 litres of oil a minute to achieve maximum working force. Although it’s early days yet for the EX8000 at Meandu Mine, Jim Young is confident the machine will achieve its targets based on his extensive knowledge of the Hitachi product. “We plan to have the machine operating around 5700 hours a year,” says the man who started at Meandu Mine during its construction in the late 1970s. It’s not surprising that Jim Young knows virtually every square metre of the Meandu complex which today comprises five active pits. Stanwell is a diverse energy company owned by the Queensland Government and has coal, gas and water assets that are used to generate electricity for Australia’s wholesale electricity market. Jim Young, Meandu Mine asset manager… “We plan to have the EX8000 operating around 5,700 hours a year.” critical to Fortescue – Australia’s third largest producer of iron ore behind Rio Tinto and BHP Billiton – as it continues to ramp up production. For Contract Power’s Marc Grosser, “hitting the maintenance targets” is one of the key pointers to the efficiency of the power station. “Mechanically, the engine/alternator package is performing very well,” he says without hesitation. “Some of the gensets have clocked up over 10,000 hours and are hitting the maintenance targets that we have in place with <strong>Cummins</strong>. “Our experience at Christmas Creek is that maintenance costs of the QSK78 genset are lower than competitors’ costs. “Fuel economy of the QSK78 is also very competitive,” he says. He points out the maintenance targets set with <strong>Cummins</strong> include injector change-out at 10,000 hours – a target that is being achieved. CUMMINS SOUTH PACIFIC SUMMER <strong>2014</strong> <strong>Cummins</strong> on-site technician Casey Haywood (right) with Downer Mining’s reliability supervisor Adam Morrison. with a 290-tonne payload capacity, and the force behind their tractive effort is the <strong>Cummins</strong> QSK60 engine rated at 2700 hp. The reliability of the 930E trucks is critical as they contribute significantly to a total annual overburden and coal movement of around 36 million BCMs. The oldest 930Es had clocked up around 9,000 hours near the end of 2013, with the youngest at 5000 hours. CUMMINS SOUTH PACIFIC SUMMER <strong>2014</strong> CONTENT mining <strong>Cummins</strong> mining <strong>Cummins</strong> 04 YOUR MINING MAGAZINE Muscling in at Meandu The world’s first Hitachi EX8000 backhoe excavator is in full flight at Meandu coal mine in south east Queensland. USER REPORT 08 Generation X The biggest diesel power station in Australia, at Christmas Creek mine in the Pilbara, features <strong>Cummins</strong> QSK78 generator sets. 04 MUSCLING IN AT MEANDU GENERATORS 12 Just keep on digging Two of the first operational Tier II <strong>Cummins</strong> QSK38 engines in the world have exceeded life-to-overhaul targets in mining in south east Queensland. GENERATION 15 Holding fire A containerised fire pump incorporating <strong>Cummins</strong> power has been built for a Pilbara mining project. 08 The generation of electrical power in Western Australia’s Pilbara region is critical as its iron ore riches continue to provide Australia with its biggest export earnings. 16 Behind the seams at Boggabri A fleet of <strong>Cummins</strong>-powered haul trucks and excavators is achieving availability targets at Boggabri Coal in NSW. 20 Ironing out the Duke Four <strong>Cummins</strong>-powered Hitachi excavators are exceeding production and availability targets at the Iron Duke mine in South Australia. 24 Now we’re pumping A mine dewatering pump, powered by one of the biggest <strong>Cummins</strong> CustomPaks in Australia, has gone to a mining <strong>Cummins</strong> project Mining in Africa. Magazine Published by <strong>Cummins</strong> South Pacific. 16 20 BEHIND THE SEAMS AT BOGGABRI <strong>Cummins</strong> power is specified in all the Cat excavators at Boggabri. 12 13 CUMMINS SOUTH PACIFIC SUMMER <strong>2014</strong> IRONING OUT THE DUKE Four <strong>Cummins</strong>-powered Hitachi excavators are exceeding production and availability targets at BGC Contracting’s iron ore mining operations at Iron Duke in South Australia. Three of the diggers are 254-tonne EX2600-6 units with Tier 2 <strong>Cummins</strong> QSK50 engines rated at 1500 hp, while the fourth is a 239-tonne EX2500-5 with a <strong>Cummins</strong> QSK45 rated at 1350 hp. All are configured as backhoes and they moved in excess of 15 million BCMs (bank cubic metres) in their first 12 months at the Iron Duke mine. USER REPORT <strong>Cummins</strong> Mining is published by <strong>Cummins</strong> South Pacific. 2 Carribbean Drive, Scoresby, Victoria 3179. Editor Murray Clifford Ph. 0419 268 289, Email: murray.clifford@cummins.com Marketing Manager Rachael Reinheimer rachael.reinheimer@cummins.com 02 03
On Site, On Demand, On Time. Whatever your power requirement, <strong>Cummins</strong> has a range of heavy-duty generator sets ready-to-run at your mine site. These generator sets are ready for mine site and mobile application, meaning they are toughened to withstand the harshest operating conditions. Designed as fully integrated power packages, <strong>Cummins</strong>’ generator sets span 20 kVA to 1250 kVA. And they are backed by <strong>Cummins</strong>’ unmatched service support network which includes the awardwinning 24/7 <strong>Cummins</strong> Support Centre. Find your nearest <strong>Cummins</strong> branch at www.cummins.com.au or call +61 3 9765 3120. To request product information or to arrange for a <strong>Cummins</strong> representative to contact you please get in touch with us by clicking here. Experience our rental capabilities power.cummins.com Our energy working for you
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