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A study of operational deviation control to reduce diesel fuel consumption of a

hundred tons mine haultruck

Conference Paper  in  AIP Conference Proceedings · March 2019

DOI: 10.1063/1.5095261

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A study of operational deviation control to
reduce diesel fuel consumption of a hundred
tons mine haultruck
Cite as: AIP Conference Proceedings 2088, 020009 (2019); https://doi.org/10.1063/1.5095261
Published Online: 29 March 2019

Dewa Wirantaya, Totok Ruki Biyanto, and Nyoman Ade Satwika

AIP Conference Proceedings 2088, 020009 (2019); https://doi.org/10.1063/1.5095261 2088, 020009

© 2019 Author(s).
 A Study of Operational Deviation Control to Reduce Diesel
Fuel Consumption of A Hundred Tons Mine Haultruck
Dewa Wirantaya1, a) Totok Ruki Biyanto1 Nyoman Ade Satwika1,b)
1
Department of Engineering Physics, Institut Teknologi Sepuluh Nopember, Surabaya, 60111, East Java, Indonesia
a)
Corresponding author: Dewa.Wirantaya@gmail.com , b)nyomanadee@gmail.com

Abstract. Mining business is one of industrial activities that consume much fuel, especially diesel oil. There are many
operational deviation practices carried out by operators intentionally or unintentionally in the field causing waste of fuel
burned. The FSC - Fuel Saver Control system is developed through hardware connected to the ECM - Electronic Control
Module and integrated through an online radio frequency monitoring system thus operational deviation variable such as
engine over speeding, ground speed, overload, and excess dumping rpm performed by truck’s operator can be controlled
automatically by FSC control module, then the fuel burning is more efficient. Diesel oil average normal consumption of a
CAT 777D Truck is 55 litres/hour. Normal life cycle of 100 Ton Mine Truck around 20 years, for Truck’s Physical
Availability and Utilization set of 85% each. It means that a CAT 777D truck will consume total diesel fuel 6.96M litres
during its service life. The principle component analysis (PCA) is represented for this paper to control the data obtained
during monitoring system. This research achieved reduction of fuel consumption between 5-7% per hour thus a CAT 777D
unit will be capable of saving diesel oil between 348K - 487K litres within 20 years.

INTRODUCTION

World Mining industry is one of big users of fossil fuels in the world. Based on statistical data on the Global
Mining, the mining energy needs 35% fossil fuels, 32% electrical energy, and the remaining comes from in other
forms. Fossil fuel consumption is the world's largest mine. It is a diesel fuel which is used in the majority of the world,
for mine transport trucks for instance. 300 ton class trucks at maximum load average spend 180 liters of diesel oil per
hour and 100-Ton class trucks at maximum load average spending of 55 liters of diesel oil per hour. On the other
hand, the demands of the energy conservation is growing much faster than the economy growth, so it needs special
efforts through an integrated online monitoring system in full operation, which is the tool to take over the operator
control functions into function control tool. Some empirical research and implementation which were done in heavy
equipment fuel economy focused more on the fuel itself by the way of use of the additive into the fuel mixture [8] and
smooth grains fuel with the electromagnetic system and improvement of injection. The takeover drive systems most
components of the machine from the electrical system to the mechanical system proved to be lower fuel use [10].
Other research concern more on the operational management tools by means of reducing idle time tool [11] and
optimize the material factor and specification tools [6]. Therefore, the operator control functions can be replaced with
a function control tool by way of building the fuel control system (FSC – Fuel Saver controls) which are integrated
directly into the heavy equipment. The monitoring is conducted online, and has the capability independently to be able
to

METHODOLOGY AND CONFIGURATION ON FSC-COREDATAQ

Here There are a number of implementations using coredataQ as a fuel saving device optimization and statistical
processing of data linkages as PCA. They will be discussed as follows.

Advanced Industrial Technology in Engineering Physics

AIP Conf. Proc. 2088, 020009-1–020009-8; https://doi.org/10.1063/1.5095261
Published by AIP Publishing. 978-0-7354-1818-9/$30.00

020009-1
 FIGURE 1. Coredata-Q design system

CoredataQ system device and the FSC controller in Fig. 1 and Fig. 2 should be able to do two communications to
the ECM (engine control module) to get operational data engines and TCM (transmission control module). In addition
they should be able to get the data and speed parameters required the use of the transmission units, then FSC module
through a special logic will perform optimization for ordered the engines operating at the required horsepower
(optimum), by way of regulating the amount of volume of fuel entering the combustion chamber.

FIGURE 2. FSC Controller

FSC input in the form as follows:

 Signal accelerator pedal/Throttle pedal
 Data output ECM, through a connection CAN exist.
The output of the FSC includes:
 Signal input to the ECM accelerator
 Fuel reduction to the combustion system at optimum levels
This will limit the FSC device operator to suppress excessive pedal condition:
 Load the Engine has exceeded the limitation.

020009-2
  Raise the dump Body (body up).
 The speed of the moving unit exceeds a predetermined value.

FIGURE 3. Database server systems and applications on coredataQ

This MMS (modular mining system) employs radio frequency. In the initial development, CoredataQ network
system applies a single radio frequency, VLAN network system with MMS. Initially, the CoredataQ module is
installed on the unit with very small amounts, no intervention system, but after the module is installed in large
quantities, interference occurs by splitting the radio development with a varians of VLAN.

FIGURE 4. Realtimemap of operations and location of truck in the mining

The module application was developed with the aim of the system being able to display all truck entities during
operation and easy for the operator in the monitor. Map page, the user can see the position and movement as well as
the conditions of the unit through the colors in the unit icon.

020009-3
 FIGURE 5. Trend of all events in real time

The monitoring system using CoredataQ can saw a several problem during the operation. Fig. 5 shows the
percentage of several problem that produced by the process and also benefit on control room to maintain and repair
the system, so that the cost and process goes well.

RESULT AND DISCUSSION

The results of the study of system using FSC CoredataQ based on experimental and the principle component
analysis for the statistic analysis are represented on this paper. The main focus of this research is knowing the effects
of monitoring system using FSC CoredataQ for reducing the fuel consumption with the PCA analysis as the connective
the each of variable that has the most contribution during process on CAT 77D HT 2074.

January
0.75 February
March
0.70 April
May
0.65

0.60

0.55
Baseline

0.50

0.45

0.40

0.35

0.30
5 10 15 20 25 30 35
Day

FIGURE 6. Baseline on System

The implementation of system using FSC-Coredata Q CAD 77 HT 2074 lies in the decrease of fuel consumption,
monitored in real time. The process of comparison between baseline systems with the use of FSC-Coredata is located
on the fuel quantity ratio. Figure a shows the baseline values obtained during the operation of CAD HT 2074 with fuel

020009-4
consumption of an average of 56.78 liters/hour, with the distance and payload charged the same as the use of FSC-
CoredataQ. It is seen that between the graph shows the trend between months based on the value of the fuel ratio is
almost the same, with a smaller value leaning on the use of FSC CoredataQ, it indicates that during the operation of
the Caterpillar 770 D HT 2074 experienced the decrease in fuel consumption that has been done with the percentage
that will be used as a method of conventional fuel consumption savings.
January
0.65 February
March
0.60
April
May
0.55

0.50
After FSC

0.45

0.40

0.35

0.30

5 10 15 20 25 30 35
Day

FIGURE 7. FSC-CoredataQ on systems

With the warranty PA units of 80-85%, utilization factor for the unit of 85%, then in one year 1 (one) unit of the
truck will operate around (85% x 80% x 365 days x 24 hour) = 5,956 hours each year and the price of the solar industry
by $0.45/liters. The calculation of saving fuel ($) per unit of Truck CAT777D each year is done by taking the average
fuel consumption of the months of January to May. It can be elaborated as follows.
Saving Fuel = (56.78 – 53.33560307) x 5,956 x $0.45 = US $9,231/unit/years
The total of 60 units of truck = US $553.900/year.
The investments made for the CoredataQ unit of 60 = 60 x US $5,500/unit = US $330.000. Hard benefit gained
from saving fuel amounting to nearly about US $223.900/year and at the end of the first year, this investment capital
is back. Still a lot of other benefits that accrue, especially in terms of increased productivity of the production (tonnage)
whose value is much higher than saving fuel.

Fuel Ratio

0.12

0.10

0.08
Fuel Ratio

0.06

0.04

0.02

January February March April May

Month

FIGURE 8. Fuel ratio on fuel consumption on HT 2074

020009-5
 The trend obtained gives a positive impact on the use of the FSC CoredataQ with an increased ratio of fuel each
month. The highest values occurred in April, with savings reaching 11.58%. It does not escape the process of
accelerated system on the throttle pedal on the intervention by FSC CoredataQ at the time of the operation. Granting
open throttling accords with the mileage and duration of transport process allowing the open limit reaches 85%,
depending on the payload datri charged so that the response units will be more a result of the slowing flow the fuel
towards the combustion chamber is narrowed by the throtling with the same speed and torque. It contrasts the operation
in May, decreasing fuel ratio occurred with value of 5.76% (almost decrease doubly). It is not separated from the
payload which was charged against the fluctuating nature of 2074 HT at each delivery, so the operator does not allow
for the lowering valve throttling as in the case in April, and this indicates that narrowing and widening gradually at
throtling make the flow of the fuel conserved for a bit due to the back pressure given in the process of throtling, with
a back pressure makes the process optimization of fuel reduction will be disrupted in the area of the throtling so that
the resulting low fuel ratio.

FIGURE 9. PCA graph on HT 2074

The distribution of the variable in the above diagram indicates the set of PCA variables which form the patterns
into a single entity indicating that the variables are on the pattern of attachment between the variables, whereas some
variables are away from the pattern which has been made. It indicates that the existence of discrepancies on some
variables of operation of statistically controlled HT 2074. As it is known that the dominant variables on the
observation is the payload, the total distance, and fuel consumption.

6 Eigenvalue

4
Eigenvalue

0 2 4 6 8 10
Number of PCs

FIGURE 10. The eigenvalue on the HT 2074

020009-6
 The arrangement of the eigenvalue is always sorted from largest to smallest, the criteria that the eigenvalue under
one is not used in calculating the amount of the worst factor. As seen on Fig. 10, it shows several variables which
affect the operating system HT 2074. The variables are reduced to only 10 important variables based on the value of
the obtained eigenvalue. Most eigenvalue on the payload have a higher value than the value obtained by eigenvalue
5.53, meaning that the payload factor can explain 5.53 or 5.53% of total cumulative. On the other hand, the factors
that limit do not exceed the value of the eigenvalues of 1 dedicated up to number 5 (5.53, 2.5, 1.626, 1.393, and 1.11),
in other words the value of the PC 1-5 is the main component that affects the operating system HT 2074 payload,
namely: empty travel distance, loaded travel distance, total travel distance, and empty travel (minutes). Meanwhile,
the PC 6-10 has a value under the eigenvalue 1 (0.97, 0.89, 0.512, 0.265, and 0.07984).
Payload
Empty travel distance
Load travel distance
Total travel distance
Empty travel time
0.8 Empty stop time
Load time
Loaded stop time
0.6 loaded travel time
total cycle time
Cycle per hour
Average speed
0.4 Average empty speed
Average loaded speed
Load time 1
0.2

0.0
PC

-0.2

-0.4

-0.6

-0.8

-1.0
PC1 PC2 PC3 PC4 PC5 PC6 PC7 PC8 PC9 PC10
Feature

FIGURE 11. Correlation of the variables with the principal component

Fig. 11 shows the relationships between variables that affect the performance of the HT 2074 operating system.
These two variables may be related without appreciably affected by eigenvalue. The relationship between the payload
and the empty stop time has the lowest parameter because the payload itself is a load that is given on a truck that in
fact filled and ready to be delivered. However, if viewed from truck stops on the parameters load blank explains the
very low relationship between these two variables, so its value is small, whereas the highest values on the graph shown
correlation between loaded stop time and load time. It indicates that both variables have a very strong relationship
with the correlation that the load time is the time required to fill the imposition of payload on a truck while loaded
time is the estimated time required to conduct the recovery system reset after the load time was completed on a truck.
And there are some variables which have low and high relationship based on systematic operation of HT 2074.

SUMMARY

The installation of FSC-CoredataQ produces energy efficiency especially for mining trucks and heavy equipment.
It is proven by the application side of the field and computation engineering (mass energy balance). This tool, besides
giving benefit of saving fuel, also provides significant benefits in terms of productivity of production and the
availability of system equipment health monitoring online which is a predictive maintenance, thus reducing
breakdown on the unit. Based on the distribution diagram of the PCA, multiple variables are inversely proportional
from the pattern that has been made. It indicates that the existence of discrepancies on some variables of operation of
HT statistically controlled yet 2074. The most dominant variables in the process of operation are namely: the payload,
the total distance, and fuel consumption.

020009-7
 ACKNOWLEDGMENTS
The authors acknowledge PT. Vale Indonesia for their support. We would thanks to Instrumentation laboratory of
Engineering Physics Institut Teknologi Sepuluh Nopember for providing facility.

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