Talpac Tutorial

Talpac tutorial
Version 10.2.1
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Contents
1 About this tutorial 1

1.1 Conventions used in this document
............................................................................................................................................. 1
1.1.1 Typographic
...........................................................................................................................................
conventions 2
1.1.2 Icons
........................................................................................................................................... 2
2 Background to worked example 3

2.1 Talpac overview
............................................................................................................................................. 3
2.1.1 Technical
...........................................................................................................................................
description 3
2.1.2 Tasks
........................................................................................................................................... 4
2.1.3 Questions
........................................................................................................................................... 10
2.2 The material type
............................................................................................................................................. 11
2.2.1 Technical
...........................................................................................................................................
description 11
2.2.2 Tasks
........................................................................................................................................... 11
2.2.3 Questions
........................................................................................................................................... 13
2.3 The shift roster
............................................................................................................................................. 14
2.3.1 Technical
...........................................................................................................................................
description 14
2.3.2 Tasks
........................................................................................................................................... 14
2.3.3 Questions
........................................................................................................................................... 15
2.4 Selecting a loader
............................................................................................................................................. 16
2.4.1 Technical
...........................................................................................................................................
description 16
2.4.2 Tasks
........................................................................................................................................... 16
2.4.3 Questions
........................................................................................................................................... 18
2.5 Selecting a truck
............................................................................................................................................. 19
2.5.1 Technical
...........................................................................................................................................
description 19
2.5.2 Tasks
........................................................................................................................................... 19
2.5.3 Questions
........................................................................................................................................... 22
2.6 Setting up a haul cycle
............................................................................................................................................. 23
2.6.1 Technical
...........................................................................................................................................
description 23
2.6.2 Tasks
........................................................................................................................................... 23
2.6.3 Questions
........................................................................................................................................... 25
2.7 Production analysis
............................................................................................................................................. 26
2.7.1 Technical
...........................................................................................................................................
description 26
2.7.2 Tasks
........................................................................................................................................... 26
2.7.3 Questions
........................................................................................................................................... 26
2.8 Incremental analysis and results tables
............................................................................................................................................. 27
2.8.1 Technical
...........................................................................................................................................
description 27
2.8.2 Tasks
........................................................................................................................................... 28
2.8.3 Questions
........................................................................................................................................... 31
2.9 Fleet size optimisation
............................................................................................................................................. 32
2.9.1 Technical
...........................................................................................................................................
description 32
2.9.2 Tasks
........................................................................................................................................... 32
COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION ii

2.9.3 Questions
........................................................................................................................................... 33
2.10 Fleet comparison
............................................................................................................................................. 34
2.10.1 Technical
...........................................................................................................................................
description 34
2.10.2 Tasks
........................................................................................................................................... 34
2.10.3 Questions
........................................................................................................................................... 35
2.11 The equipment database
............................................................................................................................................. 36
2.11.1 Technical
...........................................................................................................................................
description 36
2.11.2 Tasks
........................................................................................................................................... 36
2.11.3 Question
........................................................................................................................................... 36
2.12 Importing a haul cycle
............................................................................................................................................. 37
2.12.1 Technical
...........................................................................................................................................
description 37
2.12.2 Tasks
........................................................................................................................................... 37
2.12.3 Questions
........................................................................................................................................... 38
2.13 Talpac options
............................................................................................................................................. 39
2.13.1 Technical
...........................................................................................................................................
description 39
2.13.2 Tasks
........................................................................................................................................... 39
2.13.3 Questions
........................................................................................................................................... 40
2.14 Calibrating Talpac
............................................................................................................................................. 41
2.14.1 Why
...........................................................................................................................................
calibrate? 41
2.14.2 How
...........................................................................................................................................
to calibrate 41
2.14.3 Points
...........................................................................................................................................
to consider 42
3 Answers 45
3.1 Workshop 1 - Talpac overview
............................................................................................................................................. 45
3.2 Workshop 2 - The material type
............................................................................................................................................. 46
3.3 Workshop 3 - The shift roster
............................................................................................................................................. 47
3.4 Workshop 4 - Selecting a loader
............................................................................................................................................. 48
3.5 Workshop 5 - Selecting a truck
............................................................................................................................................. 49
3.6 Workshop 6 - Setting up a haul cycle
............................................................................................................................................. 50
3.7 Workshop 7 - Production analysis
............................................................................................................................................. 51
3.8 Workshop 8 - Incremental analysis and results table
............................................................................................................................................. 52
3.9 Workshop 9 - Fleet size optimisation
............................................................................................................................................. 53
3.10 Workshop 10 - Fleet comparison
............................................................................................................................................. 54
3.11 Workshop 11 - The equipment database
............................................................................................................................................. 55
3.12 Workshop 12 - Importing a haul cycle
............................................................................................................................................. 56
3.13 Workshop 13 - Talpac options
............................................................................................................................................. 57
4 Talpac commands 58
4.1 Embedded buttons
............................................................................................................................................. 58
4.2 Toolbars
............................................................................................................................................. 59
4.3 Function keys
............................................................................................................................................. 60
COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION iii

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION iv
1 About this tutorial
This tutorial has been written so that users learn how to use Talpac. The intention is that by following the
series of workshops set out in this booklet, you will be able to use Talpac, and have an appreciation as to the
functionality of the program.
Each of the workshops sets out a number of key Talpac concepts, what actually needs to be completed for
each workshop and what the results should be at various points. As well, there are questions that should be
answered for each workshop. Some of these questions are qualitative, so no numerical answer has been
provided. The phrases listed as concepts in each workshop can all be found in the online help.
In the answers section of this tutorial there are some answers to specific questions, and screen captures at
certain points of the process which will enable you to check your progress. Often these screen captures
contain the numeric answer.
This tutorial does not cover every feature of Talpac. However, upon completion of this tutorial, you will have the
skills required to successfully use Talpac, and to self-learn the Talpac facilities not covered here.
Firstly, it is recommended that you read through an entire workshop before starting it.
Talpac may be used to analyse the performance of existing fleets of equipment or to investigate the
application of new equipment fleets in earthmoving and mining operations. In either case, the performance of a
single fleet may be examined, or a comparison made of two or more different fleets. Typical Talpac
applications are listed below:
Calculation of truck travel time to allow a comparative analysis of haul route alternatives.
Estimation of fleet productivities for use in long-term and short-term planning studies.
Estimation and comparison of productivities using various loading methodologies to determine the optimum
loading technique or loading unit bucket size.
Sensitivity analysis in road design criteria to assess the relative importance of road maintenance.
Calculation of tyre TKPH or TMPH ratings for use in tyre selection.
Estimation of fuel usage.
Determination (using discounted cash flow methods) of haulage contract costs and pricing.
Truck fleet size optimisation to quantify the effect of over-trucking and under-trucking.
Incremental analyses, in which simulations can be automatically run for a range of haulage segment
lengths and the results used to generate productivity curves.
Equipment loading analysis to optimise loader bucket size, truck capacity and number of passes.
Collation of results from calculations to examine the relationship between variables in the calculation, for
example, haul distance versus productivity, haul distance versus truck fleet size.
1.1 Conventions used in this document

This section describes the conventions used in this document:
Typographic conventions
Icons
COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 1

1.1.1 Typographic conventions
The following list describes the typographic conventions that may be used in this document.
Bold
Used for buttons, commands, utilities, keystrokes, field names, menu items, file names and directories.
Code example
Used for code examples and sample text file output.
Bold italics
Used for formulas.
Red bold
Used within tables for warnings and dangers.
Blue underline
Used for hyperlinks.
1.1.2 Icons
The following is a list of the icons that may be used in this document.
This indicates general advice and useful information.
This indicates additional information about the topic or procedure.
This indicates important information regarding the topic or procedure. Failure to follow the
information in a warning may cause problems with the program or procedure.
This indicates crucial or critical information. Failure to follow this information may cause data
corruption or failure of the procedure.

2 Background to worked example
A contractor has been invited to submit a tender for the removal of waste from an open cut mine, at 2.5 million
BCM per year. The contractor uses the following equipment:
Caterpillar 992K Front End Loaders (12.20 m3 bucket)
Komatsu HD785-7 Rear Dump Trucks (94 tonne payload).
In bidding for the waste removal contract, the contractor must determine how many trucks and loaders are
required to meet the production target and the cost of production. The contractor is also unsure whether to
continue with the same equipment or upgrade to larger equipment.
In the workshops of this tutorial, we will configure the required Talpac components to undertake this analysis.
2.1 Talpac overview

Key concepts: Project, Haulage system, Template
2.1.1 Technical description

This workshop is to generally discuss how Talpac works and the key areas of data input and output.
The image below displays how a haulage system is made up of the unique combination of nominated
templates. The templates are where the data is held for the Material, Roster, Loader, Truck and Haul Cycle.
So, if you change data in one of the templates, then really you are simulating a different haulage system. In
this way, many haulage systems can be stored in the one project.
Talpac data structure

To set up a haulage system for the Waste Contract project, you will need to create a new haulage system,
in a new Talpac project. Initially, we need to learn how to work with the templates. In later workshops we will
begin entering data into these templates.
2.1.2 Tasks
Starting the tutorial:

1. Open Talpac by selecting Start > Programs > RPM Software > Talpac or double-clicking the Talpac
icon on your desktop.
2. In the opening dialog box, select the Create a New Project radio button and click OK.

3. In the Create a New Project screen, choose to Create an Empty Project and click OK.
4. In the file name box, type Waste Haulage Tutorial and open the file in your working directory. The
Project Options dialog box displays.
5. It is important to enter report titles for your Talpac project. These titles are entered in the Print Titles tab
and display on all Talpac output. Usually, you would enter appropriate project titles; in this instance enter
the following:
Project Title: Waste Haulage Tutorial
Secondary Title: Workshops
Prepared For: Talpac Training
Prepared by: (enter your name)
Company Name: (enter your company).
Updating the titles lets you see what titles are user-defined in Talpac, and which titles are fixed.
6. Click Edit under the loading unit to open the Edit Loading Unit Template dialog box.

7. Delete DEMONSTRATION from the Loading Unit Template Name field and click OK.
8. Click Edit under the truck type to open the Edit Truck Template dialog box.
9. Delete DEMONSTRATION from the Truck Template Name field and click OK.
Talpac can operate and report using either Imperial or Metric units. This option is usually set during
installation, but it is worth checking that the correct option is set before proceeding with the rest of this
tutorial.
Selecting the required measurement units:

1. Select View > Customise Talpac (affects all projects).
2. Check that Metric Units is selected and simulation precision set to High.

This setting is program, not project, specific. It affects all projects, not just the currently open
project. Changing the Menu Language may require Talpac to be restarted.
In the following workshops you will learn how to set up each of the five haulage system components to
represent a haulage situation.
Viewing details about the haulage system components:

1. Open the All Parameters sheet to display:
Technical, stochastic and costing information for the loader and truck
Roster and material information
Cash flow options

Loading options and bucket construction options.

2. Open the Loading Analysis sheet and you will get information on material, truck and loader.
3. From the main screen, the material, roster, loader and truck templates may be edited. Click one of the list
boxes to view a selection list.
4. To edit one of the templates, click the relevant Edit button. After editing, you can either click OK to save
or Cancel to return to the main screen.
Make sure you understand the difference between adding a new template to a list and editing an existing
template.

Adding templates:
1. Click the Haul Cycle drop-down list to get a selection list of haul cycles in this project.
2. Click Edit Haul Cycle to open the Haul Cycle dialog box.
3. Click any segment of the haul cycle and use either the cursor keys or the mouse to move around the haul
cycle.
4. Right-click to add, edit or delete segments from the haul cycle. Note the automatic segments.
5. Close the Haul Cycle dialog box.
Editing templates:
1. Click the Haulage System drop-down list so that Haulage System-1 is highlighted.
2. Right-click the highlighted name and select Edit.
3. Rename the haulage system to Basic Waste Contract.
4. Click the lower portion of the screen so that the haulage system name is no longer highlighted.
5. Click OK on the toolbar.
2.1.3 Questions
1. What is in a TP7 file?
2. What are the five components of a haulage system?
3. What is a Talpac project?
4. Why would you want to print the ALL PARAMETERS sheet?
5. What are the options available on the right-click of the mouse when a template name is highlighted?
6. What types of Haul Segments can be used?
7. What is the difference between adding to a template list and editing a template?

2.2 The material type
Key concepts: Density, Swell, Fill factor, Production measurement

In this workshop, the characteristics of the material being hauled by the contractor are entered into a
template. The characteristics of the waste are described below.
The productivity results are to be reported by volume rather than weight. Since we are working in metric units,
this will mean that productivities are expressed as bcm/op.hour, bcm/shift and bcm/year.
The insitu bank density is the density of the material while it is in the ground. This parameter is used to
convert an insitu bank volume to its equivalent weight, and vice versa.
The material swell factors are used to convert bank volumes to loose volumes in the loader bucket and the
truck tray. Note that both swell factors are based on insitu volume.
The loader bucket fill factor is dependent on both the material type and the class of loader. It is the ratio of the
loose volume of the material in the loader bucket to the volumetric rated capacity of the loader bucket. The
volumetric rated capacity of the loader bucket may be expressed on either a struck or heaped basis.
Similarly, the loader bucket fill factor may be expressed on a struck or a heaped basis. The fill factor is
selected from a scale in the material template.
2.2.2 Tasks
Setting up the material type:

1. Create a new material template for the waste that the contractor is to haul. Click in the Material
Template drop-down list and either right-click and select Add from the menu or click Add on the toolbar.
2. Call the new template Tutorial Waste.
3. Ensure the Bank Volume option is selected for the production measurement.
4. The waste has an insitu bank density of 2.20 tonnes/bcm.
5. The swell factors for the waste the contractor is to move are as follows:
Description Swell factor
Bank to Loader Bucket 1.20
Bank to Truck Tray 1.25
6. Click Edit Global Fill Factors.

7. Select the View Heaped Values radio button and change the Poor (Struck) value for the Front End
Loader to 0.720.
8. Click OK.

9. Set the loader bucket fill factor to average for the contractor's loader mining waste. This should equate to a
factor of 0.720 on a heaped basis for a front end loader.
2.2.3 Questions
1. What is the loose density in the loader bucket?
2. How would you use your own site-specific fill factors?
3. What else will affect the filling of the bucket?

2.3 The shift roster
Key concepts: Roster, Delay, Scheduled, Unscheduled, Operating, Non-operating

Working and operating hours for the loader and trucks are defined in the shift roster. The weekly shift pattern
is specified, then lost shifts per year and delays within each shift are allocated. These lost shifts and delays
are divided into the following categories:
Scheduled lost shifts
Unscheduled lost shifts
Non-operating shift delays
Operating shift delays.
The choice of category for a delay depends on mine site work practices. By definition, scheduled delays are
those that may be fixed in time, for example, the public holiday on 25 December. Unscheduled delays are
delays that you expect, but don't know exactly when they will occur, for example, clean-up around the loader
area and delays due to wet weather. Operating delays are those delays when the equipment's engine is
running. Conversely, non-operating delays are those delays when the equipment's engine is not running.
2.3.2 Tasks
Setting up the shift roster:

1. Set up a roster template for the shift roster described below. Call it Tutorial Roster.
2. The contractor operates on two shifts per day, from Monday to Friday. In addition, there is one over-time
shift on Saturdays.
3. The only rostered days of the year that are not worked are Christmas Day and Good Friday.
4. The contractor annually allows for ten shifts lost due to industrial action and ten shifts lost as a result of
wet weather.
5. Each shift is ten hours long. The following delays occur within each shift:
Description Duration Type
Crib (meal) break 30 minutes Non-operating
Delays either side of crib 2 x 5 minutes Operating
Delay at start of shift 5 minutes Non-operating
Delay at end of shift 5 minutes Operating
Delays for blasting 5 minutes Non-operating

Description Duration Type
Clean-up around loader 15 minutes Operating
Refuelling is carried out outside normal production hours.
2.3.3 Questions
1. What are the total annual working hours for the loader?
2. What are the total fleet operating shifts for the year?

2.4 Selecting a loader
Key concepts: Loader database, Distribution, Loader methodology

The contractor wants to use Caterpillar 992K front end loaders. The characteristics of the loader have been
determined from historical data. We need to use this data to correctly define how the loader is to be
simulated.
2.4.2 Tasks
Selecting and configuring your loader:

1. Right-click the list of loaders and select Add. You will now be looking at the loaders section of the
equipment database.
2. Choose Caterpillar from the Manufacturer drop-down list.
3. Scroll through the list of loaders and select the 992K.
4. Click Select.
5. You will now be back in the loader template. Call this template Contract Cat 992K.
6. The contractor's 992 loaders have an expected mechanical availability of 90% and the Bucket Cycle Time
takes 35 seconds. Change the Bucket Cycle Time in seconds and the minutes will calculate automatically
and vice versa.

7. Click Bucket Selection.
8. The buckets available for the 992 display in the drop-down list. Examine all the options available. When
you have finished, click Restore Defaults and click OK.
9. Click the Costing Data tab. The capital cost to the contractor of a 992K loader is $1 200 000.
10.The contractor bases its cash flow on a 10% salvage value (residual value) at the end of the loader life of
25 000 hours or five years (whichever occurs first).
11.The loaders are depreciated at a rate of 15% on a straight-line basis.
12.Complete the costing data with the following values:
Description Cost
Operating Labour $54.76/op. hr
Maintenance Labour $19.52/op. hr
Lube $3.79/op. hr
Tyre Replacement $11.01/op. hr
Wear Items $6.00/op. hr
Repair Parts $45.00/op. hr
Major Overhaul $18.00/op. hr
Liquid Fuels $25.26/op. hr

13.Click the Distribution Data tab, examine the options available but do not change anything.
14.Click OK when you are finished.
2.4.3 Questions
1. What is the total operating cost per hour?
2. Why can the template name be different to the database equipment name?
3. What does the default bucket payload represent?

2.5 Selecting a truck
Key concepts: Truck database, Local characteristics

Characteristics of the haul trucks in the fleet are stored in the truck template, which is structured in a similar
way to the loader template. Our example contractor uses Komatsu HD785-7 rear dump trucks. The
characteristics of the trucks are defined in the next task.
2.5.2 Tasks
Selecting and configuring your truck:

1. Right-click the list of Truck Type 1 and choose Add. You will now be looking at the trucks section of the
equipment database.
2. Select Komatsu from the Manufacturer drop-down list.
3. Scroll through the list of trucks and select the HD785-7.
4. Click Select.
5. The contractor's trucks are equipped with standard motors and are designed to carry the manufacturer's
rated payload. The Komatsu HD785-7 trucks have an availability of 85%.
6. Operational studies show a spot time at the loader is 24 seconds, dump spot time is 20 seconds and a
dump time of 30 seconds.
Changing the seconds automatically updates the minutes, and vice-versa.

7. Click the Costing Data tab. The truck capital cost is $850 000. A 10% salvage value at the end of the
truck life of 30 000 hours or six years is assumed. The trucks depreciate at 25% on a straight-line basis.
8. Complete the costing data with the following values:
Description Cost
Operating Labour $46.37/op. hr
Maintenance Labour $18.24/op. hr

Description Cost
Lube $2.59/op. hr
Tyre Replacement $10.91/op. hr
Wear Items $4.30/op. hr
Repair Parts $24.08/op. hr
Major Overhaul $10.75/op. hr
Liquid Fuels $17.24/op. hr
9. Click the Distribution Data tab, examine the options available but do not change anything. Click OK when
you are finished.

10.Set the number of trucks to Auto (not Auto-Max:1), so Talpac estimates the number of trucks required to
keep the loader busy as follows:
2.5.3 Questions
1. What is the total operating cost per hour for the truck?
2. When would you use the different truck types in the same simulation?

2.6 Setting up a haul cycle
Key concepts: Segment, Rolling resistance, Speed restrictions, Forward and reverse segments

To perform a simulation, Talpac needs data regarding the haul route. This workshop describes how this data
can be converted into a required format.
The loading segments are automatically included at the start of each new haul cycle.
2.6.2 Tasks
Setting up a haul cycle:

1. Click Edit Haul Cycle to open the Haul Cycle dialog box.
The drawing at the end of the workshop displays a typical haul profile on which the waste contract is
based. Conditions to be expected in the mine are listed below:
within 50 metres of the shovel and dump point, the truck speed is restricted to 30 km/h
around corners, trucks should not exceed 30 km/h
when traveling down ramps, trucks must not exceed 40 km/h.
2. Change the name of Haul Cycle 1 to Base Haul Route.
3. Add a new haul segment by clicking row 4 of the haul cycle and either click Add on the toolbar or use the
right mouse menu.
4. Call the new haul segment Around Loader, the distance is 50 metres, the maximum speed is 30 km/h
and all the other factors will use the default values.
5. The haul profile should be divided into the appropriate number of segments. The segments may be of any
length, but should have a constant grade, rolling resistance and load. Don't forget to include loading,
dumping and fixed time segments in the haul cycle and take into account the speed restrictions.
6. Rolling resistance is expressed as a percentage of the component of the gross vehicle weight that is
normal to the ground surface. For guidance on rolling resistance values to use, access the table from the
rolling resistance column, right-click one of the cells in the Rolling Resistance column and click Select.

7. We will be using the average conditions for this tutorial, so click in the Average column of the row in the
table that best describes the current haul segment.
8. When you have added all of the haul segments needed, add the dumping segments.
9. As the haul route for the return journey is the same, it is possible to use the Reverse all segments
option. Reverse all of the segments.
Haul cycle

2.6.3 Questions
1. When is a new segment required?
2. How many segments are required?
3. What other methods are available for constructing a haul route in Talpac?
4. What is the benefit of using real names for segment titles?
5. What is the relationship between final and maximum speeds for segments?

2.7 Production analysis
Key concepts: Calculation type, Full simulation, Stochastic, Excavation target

Once the haulage system has been defined, it is ready to be analysed. In assessing the productive capacity
of the system, you have the choice of using the quick estimate or the full simulation. The other types of
calculations will be discussed later. Quick estimate assumes there is no variability in the truck and loader
parameters, and a deterministic analysis is performed.
Full simulation takes the variability of truck and loader parameters into account using a stochastic analysis.
Parameters that may be varied in the full simulation include loader bucket cycle time, loader bucket payload,
truck travel time, truck dumping time and truck availability.
The Excavation Target feature lets you specify a production target. When an excavation target is specified,
the Production Summary Report lists how many days/years it takes to move the specified excavation target.
The value for the target is dependent on the measurement basis chosen in the material template.
2.7.2 Tasks
Performing a production analysis:

1. Select the Type of Calculation drop-down list to view the options.
2. Select Quick Estimate and click Calculate to view the Quick Estimate Results (alternatively, simply
press F9).
3. View the Quick Estimate results, and close when finished.
4. Select Full Simulation from the Type of Calculation drop-down list and click Calculate to view the Full
Simulation results (alternatively, simply press F10).
5. Compare the differences between the Full Simulation results and the Quick Estimate results.
6. View the haul cycle details, the tyres and fuel consumption, and the cash flow screens. View the defined
travel time graphs to identify the key segments of the haul cycle.
7. Enter an Excavation Target of 2 500 000 bcm, run a Full Simulation and view the results at the bottom of
the Production Summary Report.
2.7.3 Questions
1. Why is it useful to have different calculation types?
2. What is the vertical height difference that the load is being elevated through?
3. Why can you get different results for successive runs?
4. How long does it take to reach the production target?

2.8 Incremental analysis and results tables
Key concepts: Incremental analysis, Results tables

The haul profile used so far is representative of haul routes at the mid-life of the waste contract. In the early
years, the pit is shallower and, in the later years, it is deeper. The change in RL and the length of the ramp
out of the pit vary as follows:
Year Length of pit ramp (metres)
1 200
2 300
3 400
4 500
5 600
6 700
7 800
The distance and elevation from the surface to the top of the waste dump do not change. In planning, we need
to understand how the productivity requirements change for the life of the contract.
Also we are interested in seeing the results tabulated in a different format to the standard results.
Based on this information, determine the productivity of the fleet for each year of the contract.

2.8.2 Tasks
Calculating and reporting fleet productivity:

1. Click Incremental Analysis.
2. Click Add in the Incremental Analysis window.
3. From the Item drop-down list, select Haul Segment Distance.
4. From the Forward Segment drop-down list, select Pit Ramp.
5. From the Reverse Segment drop-down list, select Pit Ramp (rev.).
6. Set the:
First Value to 200
Last Value to 800
Step Value to 100
Increment Order to 1.
7. Click OK.
8. Click Calculate in the Incremental Analysis window.
9. Examine the information displayed in the Results Table.
The column headed Row 7: Distance: TT1 represents the pit ramp length.

10.Try creating your own report by clicking Report and choosing fields from the left-hand pane.
11.Produce a graph of the ramp length versus the fleet productivity. Highlight the cells in the Results Table
you want to graph and select Graph Selected Runs from the right-click menu.

12.From the X drop-down list, select Row 7: Distance: TT1 and from the Y drop-down list, select Fleet
Production Per Operating Hr.
13.Right-click on the graph and select Chart Designer from the menu.

14.Try changing the chart type to a bar graph. Examine the options available and see what effect it has on
your graph.
2.8.3 Questions
1. What is the key information?
2. How many variables are available for inclusion in the results table?
3. When should you consider purchasing another truck?

2.9 Fleet size optimisation
Key concepts: Optimisation analysis, Marginal economics

The optimum number of trucks in a fleet is a balance between productivity and cost. The fleet size
optimisation carries out a series of production analysis for a range of truck fleet sizes. The results are
summarised in a table displaying the fleet size, the fleet production and the discounted average cost.
The results can also be displayed on a graph. The optimum fleet size is that with the lowest unit cost of
production. The optimum fleet size will not necessarily have the highest production or provide the required
output.
2.9.2 Tasks
Determining the optimum fleet size:

1. Create a copy of the Base Waste Contract haulage system, press F2 and rename it to Workshop Fleet
Size.
2. Make a copy of the base haul cycle and rename it to Workshop Haul.
3. In Workshop Haul, change the pit ramp distance to 2000m. Remember to change both the forward and
reverse segments of the pit ramp.
4. Configure the rest of this haul system to have the same loader, truck, material and roster templates. Make
sure you save this haul system after you have selected the appropriate items.
5. Do a Full Simulation calculation and note the number of trucks.
6. Now determine the optimum number of trucks for the contractor's fleet. Click Optimisation.
7. Select the Fleet Size radio button and click OK.
8. Plot a graph of the fleet size versus the marginal cost.
9. Compare the optimum with the truck match determined in the full simulation previously calculated in this
workshop.
10.Export the Results Table by selecting File > Export.

11.Click Browse and choose a name and location for the file. Make sure the Excel File (.XLS) radio button
is selected.
12.Click OK.
13.Open your results file in MS Excel and examine the data.
2.9.3 Questions
1. What is the marginal cost of assigning one more truck than the optimum?
2. Why are the marginal economics important, and not just the average cost?
3. What is the optimum fleet size?

2.10 Fleet comparison
Key concepts: Haulage systems

The contractor wants to investigate the cost benefits of moving to larger equipment for the waste removal
contract. A new haulage system is going to be configured for the larger equipment. New truck and loader
templates will be created.
2.10.2 Tasks
Creating a new haulage system for fleet comparison:

1. Add a new haulage system called Workshop Comparison. This will have the Tutorial Roster, Tutorial
Waste and Base Haul Route from the Basic Waste Contract haulage system.
2. Create a new template for both the truck and loader.
3. Complete the details of the larger equipment items for the contractor below:
Description Shovel Truck
Name Komatsu PC3000-6 Komatsu HD1500-7 (Cont

Retard)
Type Hydraulic Shovel Rear Dump Trucks
Capacity 16.0 cu.m heaped 144.2 tonne payload
Availability 90% 85%
Capital Cost $2 000 000 $1 300 000
Residual Value 10% 10%
Life in Hours 35000 35000
Life in Years 8 8
Depreciation type Straight line Straight line
Depreciation Rate 15% 25%
Total Operating Cost $222.73 $163.50

4. With this equipment, each bucket cycle takes 30 seconds. Also, for the trucks, the spot time at the loader
is 30 seconds. The spot time at dump is 30 seconds and the dump time is 30 seconds.
5. Select the Total Operating Cost check box to enter the operating cost.
6. Compare the discounted average cost for the equipment fleet above with the equipment fleet used in the
Basic Waste Contract. In determining the discounted average cost, use the optimum truck fleet size for
each option.
2.10.3 Questions
1. Which equipment fleet would you recommend the contractor purchase?
2. What factors affect this decision?

2.11 The equipment database
Key concepts: User-defined equipment

The equipment database contains a large range of trucks and loaders used in surface mining operations. The
data supplied in the equipment database represents standard equipment and has been verified by the
appropriate manufacturer. For equipment not in the database or that has been changed, the user is able to
set up their own equipment items.
2.11.2 Tasks
Creating user-defined equipment in the user database:

1. Access the equipment database by selecting View > Equipment Database or clicking Equipment
Database on the toolbar.
2. Use the Type, Manufacturer and Class drop-down lists to view the truck and loader data stored in the
database for each equipment type.
3. Create a user-defined equipment item by copying a standard item of equipment and giving it a new name.
4. To copy an item from the standard database to a user database, select Edit > Copy Equipment. Rename
your copy of the Komatsu HD785-7 to My Mines 785-7.
2.11.3 Question
1. What role would user-defined equipment have at your operation?

2.12 Importing a haul cycle
Key concepts: Importing a haul cycle from a text file

In a previous workshop, we created a haul cycle by manually typing the required details for each segment. In
Talpac, you can also import this data directly from a text file. In turn, this text file can be automatically
generated in another system, such as a design package or a fleet monitoring/dispatch system.
The text file import facility in Talpac can be quite sophisticated, and in this workshop only a small portion of
the functionality is used. For more advanced requirements, refer to the help documentation or contact Runge.
2.12.2 Tasks
Importing a haul cycle:

1. Navigate to the Talpac\Tutorials directory.
2. Open the Test XYZ Space.txt file in a text editor (for example, Notepad). This file represents the
coordinates of a haul route.
3. Close the file after inspection.
4. In Talpac, add a new haul system called Workshop Import.
5. Select File > Import > Import Haul Cycles from a Text File from the menu bar.
6. Click Add and create a new template called Tutorial.
7. Click Browse and find the file Test XYZ Space.txt.
If Text XYZ Space.txt is not initially displayed, select All Files (*.*) from the drop-down list
next to the File name field.
8. Select the Space check box as the field delimiter character. If other field delimiter check boxes are
selected, deselect them.
9. Leave the First Import Line as 1, and also leave the Comment Character as !.
10.Click Next Line twice so that line 3 of the file displays in the viewer.
11.Set the Import Data Type radio button to X,Y,Z co-ordinates.
12.Enter appropriate field numbers for the entities:
X coord - 2
Y coord - 3

Z coord - 4.
13.Ensure all other field numbers are set to 0. This means that you are accepting the defaults displayed for
those fields.
14.When complete, select the Reverse all segments, setting load to "Empty" check box.
15.Click OK.
16.Inspect the results in Talpac. Check that the haul cycle Import Test Haul 1 has been imported.
2.12.3 Questions
1. Why is the new haul cycle called Import Test Haul 1?
2. How can this feature be used in your situation?
3. How else can the import facility be used?

2.13 Talpac options
Key concepts: Project options, Customising Talpac, Project management, Feedback, Project properties

There are many variables and options used in Talpac that are not contained in any of the templates that we
have looked at so far. There are also a number of ways to customise Talpac - this workshop will guide you
through these features.
2.13.2 Tasks
Accessing Talpac's options:

1. Select File > Data File Management and view the information available.
2. Click View the list of Templates and examine the options available.
3. Click Close.
4. From the menu, select Help > About Talpac and click the Send a suggestion link to automatically
generate an email to Runge's support desk to provide feedback.
5. The following are the main items accessed from the View menu:
Project Options
Used to access travel options, loading options, cost data options and bucket construction ratings.
Customise Talpac
Used to access general options, distribution defaults, set colours and currency options.
Project Management
Used to view all haulage systems in this project, create new haulage systems and run simulations on
all haul systems.

2.13.3 Questions
1. When should you change the options settings?
2. How can you tell the location of the current user database?
3. How can the project manager interact with mine planning?

2.14 Calibrating Talpac
2.14.1 Why calibrate?

Talpac is a proven tool for conducting haul simulation using the numerous input parameters that impact truck
and loader fleet performance. Variations in material characteristics, operating conditions, equipment changes
and mine operating procedures can all have an impact on fleet performance. Calibrating Talpac to match
actual productivities ensures that the results from the simulations reflect the individual conditions of your
operating environment, letting you calculate and report with confidence in the results.
2.14.2 How to calibrate
Calibrating Talpac:
1. Open your project in Talpac and verify that the correct Haul Cycle, Loading Unit and Truck Types are
selected.
2. Click All Parameters in the Talpac Data Entry screen and print the list of parameters. This print-out lists
all of the data being used in your Talpac project, whether default values or data that you have entered.
3. Gather performance data from your mine site for the key parameters. Possible sources of data include:
Truck and loader on-board performance monitors
Mine fleet dispatch and monitoring systems
Manufacturer-supplied specifications for the equipment at your site
Pit and dump plans displaying elevations along the haul route
"Time and Motion" field studies
Production records - for example, truck counts, belt weightometers, surveyed volumes.
4. Run some test simulations and compare the results to real-world performance data from your site. Ideally,
the performance data will be for a whole shift for a particular haulage system (otherwise, a few repetitive
timings of a particular haulage system can be used). Adjust the model as necessary to ensure that the
Talpac results are in line with actual performance data.
Some of the common adjustments that you might make are:
Type of data to adjust Adjustment description
User Equipment If equipment specifications are significantly different to the data in the
Talpac database, create "User Equipment" in Talpac with the actual
specifications and performance curves
Truck Travel Time Compare measured travel times segment by segment with those in the
Haul Cycle Report
Vary the rolling resistances in the Haul Cycle
Vary the Travel Time Correction Factor

Type of data to adjust Adjustment description
Truck Cycle Time Set calculation mode to Quick Estimate (rather than Full Simulation) to
eliminate variability in parameters during calibration
Check truck queuing and loading time (and number of trucks)
Check truck spotting time and first bucket pass delay
Truck Productivity Vary the non-operating shift delays and operating shift delays (roster
template) to achieve the actual working hours
Set truck availability to 100% for the calibration exercise
Loader Productivity Ensure that the number of passes to fill truck reflect actual data
5. Re-calibrate at frequent intervals.
2.14.3 Points to consider

Here are a few points to consider when gathering the calibration data for your site.
Material characteristics
What is the In Situ Bulk Density and how is it measured?
What swell factors are included in the data - In Situ into the Bucket, In Situ into the Truck?
How well does the loader dig? What is the Bucket Fill Factor?
Seasonal variations in material characteristics (for example, wet weather, snow).
Is there "carryback" of sticky material in the empty trucks?
Working roster
What are the site values for hours/shifts/day for each day of the week?
What are the site values for lost days per year (for example, weather, industrial, public holidays)?
Are there delays that do not occur every shift (for example, blasting, equipment relocation, power outages)?
What is the average operating time per shift (operator in the equipment, equipment in operating condition)?
What are the average operating delays per shift (for example, loader waiting for dozer clean-up, moving
large rocks)?
Equipment physicals
What equipment models are being used on the calibration haul?
Do they differ from the Manufacturer's Handbook Specifications and, if so, what are the revised
specifications (and the performance curves, if relevant)?

Changing tyre size, engine power or gear ratio requires a revised set of truck performance
curves.
Was all equipment purchased at the same time (differences in operating life will result in variations in
performance)?
Has the equipment been maintained in accordance with the manufacturer's recommended maintenance
schedule (poorly maintained trucks may not perform in accordance with the manufacturer's performance
curves)?
Haul route
What are the segment distances and grades?
What operating conditions may affect equipment performance?
Do seasonal variations affect the haul route and truck performance (for example, wet weather, fog, snow,
dust storms)?
What speed restrictions apply (for example, for safety, tire heating management)?
What is the productivity of the truck drivers?
Real-world performance data - truck

Actual haul profile and speed limits
Best estimate of rolling resistance for each haul segment
Actual number of trucks assigned to the loader
Actual truck travel times (empty and loaded) for each segment of the actual profile, including truck loading,
spotting, dumping and queuing times
Actual truck payload and empty truck weight.
Real-world performance data - loader

Loading regime (single-sided or double-sided)
Actual number of loader passes to fill truck
Actual time waiting for trucks
First pass bucket delay.
Real-world performance data - fleet

Actual number of working hours per shift
Actual probability distributions for truck travel time, truck dumping time, truck availability, bucket payload
and bucket cycle time.
'Representative' real-world performance data

Fleet performance on a particular haulage system can vary over time due to several factors, including:
Weather conditions
Diggability at the loader face (blast performance)

Haul road conditions
Truck driver performance
Loader operator performance
Condition of the equipment
Traffic density (night shift versus day shift)
The number of trucks assigned to the loader.
Most users build one Talpac model for their site, so real-world performance data (for
calibrating Talpac) is ideally representative of the long-term averages of the variables
mentioned above.

3 Answers
3.1 Workshop 1 - Talpac overview

1. What is in a TP7 file?
The TP7 file is the data file stored in your working directory that contains all of the data and settings for the
current project.
2. What are the five components of a haulage system?
Material, Roster, Loader, Truck and Haul Cycle.
3. What is a Talpac project?
A Talpac project is the collection of saved Haulage Systems that are in the same TP7 file.
4. Why would you want to print the ALL PARAMETERS sheet?
For reference and auditing. For example, it is useful to print this file to have as a backup of the important
Talpac configuration settings. This is haulage system specific.
5. What are the options available on the right-click of the mouse when a template name is
highlighted?
6. What types of Haul Segments can be used?
7. What is the difference between adding to a template list and editing a template?
Editing a template overwrites the data that already exists in the template. Adding a new template to the list
means that a new template is created, and so all the original templates still remain.

3.2 Workshop 2 - The material type
1. What is the loose density in the loader bucket?
1.83 t/m3 (see the image below).
2. How would you use your own site specific fill factors?
Change the Global Variables table.
3. What else will affect the filling of the bucket?
Fragmentation, operator experience, weather conditions, visibility, bucket geometry, material angle of
repose.

3.3 Workshop 3 - The shift roster
1. What are the total annual working hours for the loader?
4099 (see the image below).
2. What are the total fleet operating shifts for the year?
464 (see the image below).

3.4 Workshop 4 - Selecting a loader
1. What is the total operating cost per hour?
The total operating cost for each loader is $183.34/operating hour.
2. Why can the template name be different to the database equipment name?
You may want to model variations of the same basic equipment.
3. What does the default bucket payload represent?
The amount of material actually in the bucket, not the bucket capacity. The amount of material in the
bucket is calculated by the following equation:
Amount of Material in the Bucket = Bucket Size x Material Density x Bucket Fill Factor

3.5 Workshop 5 - Selecting a truck
1. What is the total operating cost per hour for the truck?
The total operating cost for each truck is $134.48/operating hour.
2. When would you use the different truck types in the same simulation?
If you were simulating a fleet that had more than one type of truck.

3.6 Workshop 6 - Setting up a haul cycle
1. When is a new segment required?
Whenever there is a change to the conditions which control velocity. Thus gradient, rolling resistance and
speed restrictions.
2. How many segments are required?
See the image below.
3. What other methods are available for constructing a haul route in Talpac?
Importing data from a text file.
4. What is the benefit of using real names for segment titles?
So the user can visualise, and hence validate, the haul cycle data.
5. What is the relationship between final and maximum speeds for segments?
The maximum speed (specified in the Max km/h column) is the maximum speed reached over the
complete segment; the final speed (specified in the Final km/h column) determines at what speed the
truck finishes the segment.

3.7 Workshop 7 - Production analysis
1. Why is it useful to have different calculation types?
Mine planning requires different scenarios and options to be investigated. This means that different
functionality is required. As well, this is useful to calibrate the model in Quick Estimate (deterministic)
mode first.
2. What is the vertical height difference that the load is being elevated through?
60m.
3. Why can you get different results in successive runs?
Due to the stochastic distributions used in simulation.
4. How long does it take to reach the production target?
307.35 days in Quick Estimate mode; slightly different in Full Simulation mode.

3.8 Workshop 8 - Incremental analysis and results table
1. What is the key information?
Key information is what you need to see, and so depends on the purpose of the simulation. In this
instance, cost, time, productivity, fleet size and length of haul would be key.
2. How many variables are available for inclusion in the results table?
250.
3. When should you consider purchasing another truck?
In year six, to ensure that a truck is ready for year seven. But what else should be considered?

3.9 Workshop 9 - Fleet size optimisation
1. What is the marginal cost of assigning one more truck than the optimum?
Assuming the optimum is six trucks, $2.64/bcm for truck seven.
2. Why are the marginal economics important, and not just the average cost?
Average costs disguise the impact of individual truck assignment.
3. What is the optimum fleet size?
The run with the lowest fleet discount cost.

3.10 Workshop 10 - Fleet comparison
1. Which equipment fleet would you recommend the contractor purchase?
The larger fleet is the pure cost choice, but is this correct?
2. What factors affect this decision?
Cost of capital, changes to working hours, flexibility of contract.

3.11 Workshop 11 - The equipment database
1. What role would user-defined equipment have at your operation?
You can set up the specifications for the truck and loader that exactly match your configuration, rather
than relying on the standard data.

3.12 Workshop 12 - Importing a haul cycle
1. Why is the new haul cycle called 'Import Test Haul 1'?
Set by the variable on line 2 of the import file. Otherwise, it will be imported and called the same as the
import file name.
2. How can this feature be used in your situation?
For example, from the mine design package, a string can be digitised which represents the haul route. This
string can then be exported to a text file as a series of X, Y, Z points. From there it can be imported
directly into Talpac.
3. How else can the import facility be used?
To import complete haul systems.

3.13 Workshop 13 - Talpac options
1. When should you change the options settings?
Only after consideration of what they are doing. It is also suggested that if these are changed, then make
sure that changes are properly recorded. The ALL PARAMETERS print outs and user-defined reports in the
Results Tables are two good ways of doing this.
2. How can you tell the location of the current user database?
Under View > Project Properties the location and name of the current user database displays.
3. How can the project manager interact with mine planning?
Can make the analysis of multiple simulations easier and more straight forward.

4 Talpac commands
4.1 Embedded buttons

Button Function Button Function
Project Options All Parameters
Loading Analysis Project Manager
Fleet Planner Optimisation Calculation
Incremental Analysis Calculate Full Simulation or

Quick Estimate
Edit Haulage System Edit Material Template
Edit Loader Template Edit Roster Template
Edit Truck Template Edit Haul Cycle

4.2 Toolbars
Button Function Button Function
Save View Project Manager
Print Help
Print Preview Insert haul segment
Truck and Loader database Delete haul segment
Edit Haulage System Paste copied or cut segments in

reverse
Edit Material Reverse all haul segments
Edit Roster Undo change
Edit Loader Redo change
Edit Truck Export haul cycle
Edit Haul Cycle

4.3 Function keys
Key Function Key Function
F1 Help F9 Run Quick Estimate
F2 Edit F10 Run Full Simulation

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1 About this tutorial 1

2 Background to worked example 3

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION ii

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION iii

Calculation of tyre TKPH or TMPH ratings for use in tyre selection.

Estimation of fuel usage.

1.1 Conventions used in this document

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 1

This indicates general advice and useful information.

This indicates additional information about the topic or procedure.

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 2

Caterpillar 992K Front End Loaders (12.20 m3 bucket)

Komatsu HD785-7 Rear Dump Trucks (94 tonne payload).

2.1 Talpac overview

2.1.1 Technical description

Talpac data structure

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 3

Starting the tutorial:

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 4

Project Title: Waste Haulage Tutorial

Secondary Title: Workshops

Prepared For: Talpac Training

Prepared by: (enter your name)

Company Name: (enter your company).

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 5

Selecting the required measurement units:

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 6

Viewing details about the haulage system components:

Roster and material information

Cash flow options

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 7

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 8

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 9

5. Close the Haul Cycle dialog box.

2. Right-click the highlighted name and select Edit.

3. Rename the haulage system to Basic Waste Contract.

5. Click OK on the toolbar.

2. What are the five components of a haulage system?

3. What is a Talpac project?

4. Why would you want to print the ALL PARAMETERS sheet?

6. What types of Haul Segments can be used?

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 10

2.2.1 Technical description

Setting up the material type:

2. Call the new template Tutorial Waste.

4. The waste has an insitu bank density of 2.20 tonnes/bcm.

Description Swell factor

Bank to Loader Bucket 1.20

Bank to Truck Tray 1.25

6. Click Edit Global Fill Factors.

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 11

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 12

2. How would you use your own site-specific fill factors?

3. What else will affect the filling of the bucket?

COMPANY CONFIDENTIAL AND PROPRIETARY INFORMATION 13

2.3.1 Technical description

Scheduled lost shifts

Unscheduled lost shifts

Non-operating shift delays

Operating shift delays.

Setting up the shift roster:

Description Duration Type

Crib (meal) break 30 minutes Non-operating