Saraji Train Load Out Automation
A Best-In-Class Train Load Out Automation Solution
Pipar's Train Load Out automation system at Saraji utilises multi-beam lidars alongside traditional industrial automation sensors to provide a reliable, performant loading system capable of operating unsupervised. This system pushes the limits of "old-school" clamshell train loading, maximising wagon volumes while increasing payload accuracy and minimising spillage.
The Challenge
In 2021, BMA approached Pipar to deliver a holistic transformation of the Saraji TLO, built in the 1970s. They wanted increased performance, reduced train loading times, reduced overloads, and a highly reliable, robust system.
The Approach
Following a comprehensive investigation into the operations of the current train load out (TLO), the Pipar team designed a system utilising state of the art sensor technology paired with intelligent decision-making to create an Advanced Loading Control System.
The first steps involved creating a fully modelled simulation to test and validate the Pipar software, along with hardware placement, long before going on-site. This simulation exemplified usage of both digital twins (as shown below) and smart algorithms, ensuring that the solution being built could be physically installed, automatically controlled and remotely managed.
When the team reached site, sensors were installed and used to observe loading data over a 1 month collection period, ingesting real world data and identifying site-specific edge cases. The site commissioning that followed transferred the operations to automated loading under supervision while retaining both a fallback PLC control system utilising traditional sensors, as well as manual loading functionality as a further back-up.
The transition to fully-automated loading was seamless with the new system loading to the level of a trained operator within the first 10 wagons. The Advanced Loading Control System was then further tuned throughout commissioning to optimise performance which resulted in the system exceeding all stretch KPIs.
Pipar continues to work with BMA in supporting and upgrading their automated train loading systems. This includes the systems at the Peak Downs, Caval Ridge, and Saraji mine train load outs.
The Point of Difference
The Pipar engineers who design, develop, and simulate our control systems are the same engineers who commission our systems on site. This deep, intrinsic understanding of the control systems means that commissioning is fast, efficient, and minimises impact on site operations.
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