An automated method to determine dynamic pump efficiencies in deep-level mines

Abstract

Deep-level mines use dewatering systems that are responsible for the removal of underground water. A dewatering system consists of a series of dewatering dams and pumps. Dewatering pumps are responsible for pumping water from lower-level dams to upper-level dams. The water is moved through pumps and pipes until it reaches the mine's surface. Due to harsh conditions under which dewatering pumps operate, their efficiencies deteriorate rapidly. Research revealed a gap in literature pertaining to quantifying dewatering pump efficiencies in deep-level mines, considering the data challenges faced by the industry. The challenges relevant to this study were found to be missing data that occur due to limited instrumentation or communication issues, static data challenges due to faulty instrumentation issues or communication issues, and inaccurate data such as negative values. This study followed a data analysis approach to develop a methodology through which the data challenges were addressed. The data analysis process revealed that pump discharge flow rate, discharge pressure and power consumption readings were critical to the accuracy of efficiency measurements. A unique and automated method was developed through which dewatering pump efficiencies can be quantified despite the challenges. The developed method was tested on two case studies. The case studies are from a deep-level gold mining group in South Africa. Results from both case studies highlighted the data challenges and thus the importance of having a data quality monitoring system. From the results, it is also clear that, despite the data challenges, pump efficiency is quantifiable. The solution was automated to require minimal human intervention and can also help mines reduce the cost associated with hiring external contractors who conduct efficiency audits. The solution can also help enhance labour productivity. The developed method can be applied to any deep-level mine that uses dewatering pumps.