SMART
AUTOMATION FOR ENHANCED LIGHTING THROUGH REMOTE CONTROL SYSTEMS IN COAL MINING
AREAS
Rizqi
Pratama1, Muhammad Fachri Maulana2, Aan Ardyantoro3
PT. Putra Perkasa Abadi, Indonesia
[email protected], [email protected], [email protected]
The coal mining
industry faces significant safety challenges due to hazardous working
environments and manual monitoring processes, particularly involving Tower Lamp
units. These activities expose employees to risks, including harsh weather and
operational incidents, leading to potential accidents and financial losses.
This study proposes an intelligent safety control system employing real-time
remote monitoring technology to mitigate these risks. The system enables
centralized control of Tower Lamps, reducing manual interactions, improving
energy efficiency through automated lighting adjustments, and enhancing
workplace safety. The methodology includes designing and implementing a
monitoring system with remote control capabilities supported by real-time data
analysis. Expected outcomes include reduced work accidents, optimized lighting
management, and streamlined operations, showcasing a scalable model for broader
industrial applications. This technological innovation demonstrates a practical
solution for improving safety and operational efficiency in coal mining
environments.
Keywords: coal mining industry, employee safety, remote control, smart technology, tower lamp
Corresponding Author: Rizqi Pratama
E-mail: [email protected]
INTRODUCTION
The coal mining industry has
a high level of accident risk, especially related to the use of heavy equipment
and uncertain environmental conditions
PT. Putra Perkasa Abadi uses
heavy equipment with high needs when carrying out mining operational
activities. A good mechanical tool maintenance management process is one of the
main demands for maintaining productivity. Employee safety is an important
factor in operational activities because if safety is neglected, the
possibility of accidents is very high. The coal mining industry has a close
relationship with the activities of its workers. However, there is a problem
that is always inherent with mining work, namely that each type of work has
potential hazards and risks that can occur, such as losses for workers (minor
injuries to death) and companies (labor losses, costs, working hours, and
others)
Employees are in direct
contact with the equipment when performing mechanical tool maintenance. This
increases the potential for accidents because many hard objects can contact the
body. In the event of an accident to an employee, potential death can occur.
Therefore, a good system is needed to minimize the potential for accidents. In
addition to direct contact with the appliance, exposure to hazardous areas is a
factor that can cause accidents
By presenting intelligent
technology that functions as remote monitoring, the frequency of labor
interaction with hazard exposure can be reduced. This reduces the value of
hazards and risks that will occur. Manual monitoring of Tower Lamp is an
activity that requires high interaction from the mining workforce. The
unpredictable environmental conditions around TL units can increase workers'
risk of incidents and near-misses.
Therefore, this project must
be carried out in line with PPA's commitment to PT Putra Perkasa Abadi's
Integrated Management System Policy, which focuses on accelerating the data and
information digitization process. This project aims to reduce the frequency of
labor interactions with hazard exposure. With the existence of a real-time
remote monitoring system, it is hoped that exposure to hazards and accident
risks in the monitoring activities of TL units can be reduced.
The project aims to develop
an intelligent technology-based safety control system that reduces manual labor
interaction with Tower Lamp in coal mining areas. This system allows remote
control to improve energy efficiency and reduce the risk of work accidents,
especially in adverse weather conditions. Operationally, the system is designed
to improve the effectiveness of Tower Lamp's data management through automated
data collection, more accurate analysis, and centralized monitoring. The system
also addresses refueling delays due to shifting Tower Lamp locations with more
precise refueling scheduling, reduced downtime, and improved fuel efficiency.
From the safety aspect, the system is expected to reduce the physical
interaction of workers with the Tower Lamp during maintenance, enable early
detection of problems, and improve overall work safety.
Several recent studies have
highlighted the significant safety risks of manual monitoring in the coal
mining industry. For instance, research by Ari Wibowo
The formulation of the
problem that became the focus was how to develop a safety control system based
on intelligent technology to reduce manual interaction of workers, improve
energy efficiency, and reduce the risk of accidents in mining. The project
hypothesis estimates that the implementation of intelligent control systems is
able to significantly reduce the risk of work accidents and improve energy
efficiency through timely and on-demand lighting control. This result is
expected to create a safer and more productive working environment in the coal
mining industry.
METHOD
This
qualitative research investigates the implementation of a smart safety control
system for Tower Lamps in coal mining areas, focusing on its potential to
enhance safety and operational efficiency. The study seeks to understand how
this technology reduces manual intervention and its associated risks. The
research examines employees at PT Putra Perkasa Abadi who are directly involved
in Tower Lamp operations, with purposive sampling employed to select
participants most affected by the system. This targeted approach ensures that
data reflects the operational realities of those using the smart system
Data
collection includes structured interviews, direct observations, and analysis of
documentation. Employees provide qualitative insights into their experiences
through interviews, while observational data captures the real-time
functionality of the smart monitoring system. System logs and reports serve as
supplementary data sources, enabling triangulation. The study's research
procedure starts with a baseline assessment of manual operations, followed by implementing
the smart monitoring system. Post-implementation observations and interviews
evaluate its effects on operations
Data
analysis involves thematic evaluation of qualitative inputs from interviews and
observations, complemented by descriptive analysis of system-generated data.
This mixed-method approach ensures a comprehensive understanding of the
system’s impact on safety and operational efficiency. The findings from the thematic
analysis are corroborated with real-time data from system logs to draw robust
conclusions about the benefits of the smart monitoring system. This approach
integrates qualitative and quantitative insights, providing a nuanced
understanding of the technology's implementation and effects.
RESULTS AND DISCUSSION
Implementation
of Improvement Ideas
Submission
of Permit for the Implementation of Smart Monitoring Installation and Use on
Tower Lamp Units
Implementation of Smart Monitoring Installation in A2B
Units and Support Units
The installation will be
done for 14 days, from July 14, 2024, to July 31, 2024. Installation is done on
Atlas Copco Tower Lamp units B6 +G and V5+ series. At this stage of Smart Monitoring
installation, it begins with P5M from the ICT Team. Furthermore, coordinate
with the Base Control Team regarding the movement of Tower Lamps in the field
to the workshop. If the Tower Lamp is already at the Workshop location, the ICT
Team can go to the Workshop location where the unit is located to carry out the
installation process. Coordination related to permits to plant supervisors is
carried out to convey the estimated work of the Smart Monitoring installation
on the unit because the unit will be placed back to its original position. The
installation position of Smart Monitoring on the Tower Lamp unit is as follows:
a.
Unit Tower
Lamp seri B6+G
The
above explains the installation of Smart Monitoring placed on the box panel at
the top of the controller, which is connected to several sensors needed to
transmit data from the Tower Lamp sensor.
b.
Unit Tower
Lamp seri V5+
The implementation of the Smart
Monitoring installation on the Tower Lamp unit, which was carried out from July 14, 2024, to July 31, 2024, can
be carried out optimally without any problems. The process of sending monitoring data through Smart
Monitoring is carried out with LTE network media, and for the location of the
Tower Lamp, GPS installed outside the cabin is used.
After
the installation is completed on all Tower Lamp units, Smart Monitoring is
continued to monitor Tower Lamps in real time.
Implementation
of the Use of Smart Monitoring for Monitoring Tower Lamp
The implementation of Smart Monitoring for
Tower Lamp monitoring is carried out to make it easier for employees to find and collect data on Tower Lamp so
that time and work can be done optimally.
At this
stage, the fuel man and the supervisor can
find out the location of the Tower Lamp by opening the monitoring dashboard so
that it does not take much time to refuel. Admins and supervisors can also
report and monitor digitally. Digital monitoring can be seen in the figure as
dashboard monitoring and monitoring HM unit data through the OFA (OnBoard
FleetSafe Assist) application.
The breakdown
data conditions of the units, as shown in the figure, can be displayed on the
dashboard of each Tower Lamp.
Results
of Improvement Ideas
In the previous explanation, the stages
in implementing the change idea have been explained, so the results of the improvement idea, which will
be explained later in this sub-chapter, are related to changes in Tower Lamp
data monitoring activities. The
following are the conditions
before the change related to the process flow of monitoring data
monitoring activities and filling Tower Lamp fuel:
a.
The
condition of the unit's cabin before the installation of Smart Monitoring
The
figure explains the layout of the conditions before the installation of Smart
Monitoring on units where repair actions still need to be implemented.
b.
The data input process and unit monitoring
for the service schedule are done manually.
The
figure explains the admin's process of entering HM-related data from the Tower
Lamp unit through two stages of the input process. The supervisor and mechanic will
inspect the tower lamp unit and manually input the results of the unit
inspection through the tower lamp inspection form using form paper. Then, the
mechanic reported the inspection form file to the admin to continue the input
process by the admin to SS6. The admin inputs data through the PPA
Team application obtained from mechanics through forms, so the possibility of
data input errors and forms being scattered or lost is very high. The process
requires approximately one hour, determined by the number of units ranging from
manual data input by mechanics to data input on the PPA Team application.
Fuel refueling
activities are still constrained, and there is the potential for incidents.
The
picture above explains the obstacles to refueling activities because the
location of the Tower Lamp cannot be reached, which causes unsafe conditions.
This can result in high-frequency incidents between workers with many Tower
Lamps. After the idea of improvement can be implemented, the provision of Smart
Monitoring for monitoring on the Tower Lamp unit is carried out, the process related to
the flow of the input process and monitoring activity data on the Tower Lamp
that is currently running is as follows:
a. Reports and data
monitoring are done through the OFA dashboard in real time.
Reporting and monitoring data related to
Tower Lamp can be done through the OFA dashboard in real-time. Because of real-time data input by
Smart Monitoring, errors in data input and during the data reporting process
can be minimized.
Figure 11.
Tower Lamp data report display on the OFA dashboard
Data reporting
by admins related to HM and fuel levels in real-time through the OFA dashboard.
The display of the Tower Lamp data report on the OFA dashboard, as shown in the
image, can be accessed by the admin and monitored directly by the management
team.
Figure
12.
Tower
Lamp location map
The
figure provides information related to the location of the Tower Lamp with
color indicators, namely red for off condition, green for running condition, and
yellow for key on condition. The Tower Lamp location map is beneficial in finding the location and
determining the priority of the Tower Lamp that will be refueled. Another
function of the Tower Lamp location map is that remote shutdown control can be
carried out so that potential incidents can be prevented and employees can
confirm and make repairs for access to the Tower Lamp.
b.
Reduction in the frequency of potential incidents on
employee interactions with Tower Lamp
Figure 13.
Declining Worker Interaction Activity Graph
Worker interaction activities with Tower
Lamp are often intense and have the potential to result in work accidents. With
the Smart Monitoring technology, it can be seen in Figure 3.20 that there is a
decrease in interaction between employees and Tower Lamp because it can be
monitored in real-time
through their respective devices, so potential hazards in the field can be
prevented.
c. Tower
Lamp monitoring and control via OFA dashboard
Figure 14.
Monitoring display and control of Tower Lamp
via OFA dashboard
The
figure explains the Tower Lamp monitoring display, which includes HM, fuel,
battery capacity, engine condition, emergency, Clipsal, key, temperature, and
remote shutdown control, which includes device key and engine status.
The
supervisor can monitor the breakdown, HM unit, fuel, and location. The
information received can be accessed in real time so that repair actions and
calculations of HM units can be according to existing data.
1. Information
Received by Plant Supervisors Quickly and Accurately
Plant supervisors can obtain accurate
information related to the unit's condition in real-time, allowing the
Supervisor to give instructions to the mechanics quickly and precisely. Because
the instructions obtained from the supervisor are delivered more quickly, mechanics
can quickly make repairs to the unit.
2. Report
to the Head Office and the Person in Charge of Operations
Management can monitor operational data accurately
and under the conditions in the field.
Standardization
Device
component standards
The
breakdown of the components of the Smart Monitoring device is outlined in the
following table:
Table 1. SS6 Monitor Bracket Component
Detail Table
|
Description |
Picture |
Sum |
Specifications |
Excess |
|
GPS Antenna: |
|
1 |
- Color:
Black - Voltage:
3 V~5 V - Frequency:
1575.42 MHz - DC
current (Max): 10 mA - Polarization:
Circular (RH) - LNA
Gain (without cable): 28 dB - Typ.
Operating Temperature: -45 ~+85 ℃ - Storage
Temperature: -50 ℃~+90
℃ - Cable
length: 3 m / 118 inch - Package
Weight: 57 g |
Ease of Installation: With the presence of magnets,
these antennas can be easily mounted on metal surfaces without the need for
additional tools. The magnetic design allows the antenna to be easily removed
and moved without damaging the surface of the mounting site. Weather Resistant Design: The magnetic GPS antenna design is resistant to
various weather conditions and objects that can cause damage, such as water,
dust, and so on. |
|
LTE Antenna |
|
1 |
- Temperature
Range : -55 s/d +155 ℃
(PE Cable -40~+85℃) - Vibration
: 98 m/ (10~2000Hz) - Frequency
Range : DC-12.4 GHz (semi-rigid cable DC-18 GHz) - Insertion
Loss : 0.15 dB / 6 GHz - Withstanding
Voltage 1000 V r.m.s at sea level - Working
Voltage : 335 V r.m.s at sea level - Insulation
Resistance : 5000 M - Durability:
500 (cycles) - Contact
resistance: Center Contact 3 m, Outer Contact 2.5 m - Voltage
Standing Wave Ratio: Straight flex cable 1.10+0.02f, Semi-rigid cable
1.07+0.018f Right angle, flex cable 1.20+0.03f, Semi-rigid cable 1.17+0.02f,
RG174 Electrical Characteristics - Capacitance
(Pf/M) : 101.05 - Impedance
(Ohm) : 50 - Velocity(%):
66 - Shielding
Effectiveness (>dB) : 10 - Max.
Oper. Voltage (VMS) : 1500 - Max.
Oper. Frequency (MHz) : 1000 - Operating
Temp. (*C) : -20 to 80 |
§
Ease of Installation: With the presence of magnets, these antennas can be easily mounted on
metal surfaces without the need for additional tools. The magnetic design
allows the antenna to be removed and moved easily, without damaging the
surface on which it is mounted. §
Weatherproof Design: The magnetic GPS antenna design
allows it to be resistant to various weather conditions and objects that can
cause damage, such as water, dust, and so on. |
|
SS6 module (product name still discussed) |
|
1 |
- Microprocessor
Xtensa Dual-Core 32 Bit LX6 - Freq Clock up to
240 MHz -
SRAM 520 kB -
Flash memory 4 MB -
11b/g/n Wi-Fi transceiver -
Bluetooth 4.2/BLE -
48 pin GPIO -
15 pin channel ADC (Analog to Digital Converter) -
25 pin PWM (Pulse Width Modulation -
2 pin channel DAC (Digital to Analog Converter) -
LTE-TDD B34/B38/B39/B40/B41 -
LTE-FDD B1/B3/B5/B8,GSM/GPRS/EDGE 900/1800 MHz -
Operation temperature: -40 ℃
~ +85 ℃ -
USB to TTL uploader -
Input power 12 V – 28 V VDC conversion to max 5 v DC -
Include 4x Relay 12 V – 2 A -
Data logger storage up to 16 GB -
J9 Include RTC DS3231 SMD |
§
Ease of Installation: designed for ease of use, with a simple programming interface and an
intuitive development environment (IDE). §
Open Source:
Open-source, both hardware and software, allows for easy modification and
customization. §
Rapid Prototyping: Plug-and-play features and a large number of ready-to-use libraries make
it possible to quickly prototype and test ideas. § Good Interoperability /
Compatibility: Wide
compatibility with a wide range of sensors and actuators and support for a
wide range of communication protocols makes integration with other devices
easy. |
|
Input Cable 1 |
|
2 |
-
AWG 24 cable (6 cores) -
Voltage Rating = Maximum 300 Volt -
Temperature Rating = 80 °C -
Outer sleeve diameter : 5.0 mm -
Inner cable sleeve diameter : 1.3 mm -
Cable copper diameter: 0.511 mm -
Number of fibers : 11 fibers |
§ International Standards: Using standard
cables that are widely known and used internationally facilitates
communication and understanding of cable sizes. §
Intuitive Numbering System: AWG sizes provide an intuitive numbering system
where smaller numbers indicate larger wire diameters, and vice versa. This
makes it easy to select the right cable size for a particular application. §
High-Quality Materials: AWG cables are often made from high-quality
materials, such as pure copper or aluminum, which provides durability and
reliability in the long run. §
Good Insulation Capacity: AWG cables are equipped with good insulation, which
protects the cables from physical damage and electrical interference, and
improves safety and performance. |
|
Input Cable 2 |
|
1 |
-
Cable NYYHY -
double isolation -
Size = 5 x 2.5 mm -
Voltage Capacity: 300/500 V |
§ High Flexibility: Fiber copper conductors provide
high flexibility, making it easy to install especially in areas with many
bends or tight spaces. §
Environmental Resistance: PVC insulation provides resistance to moisture,
weather, and certain chemicals, and has good flame retardant properties,
reducing the risk of fire and improving the safety of use. §
Multifunctional Use: This cable can be used in a variety of applications, including permanent
and temporary installations, both indoors and outdoors. |
Standard
Devices and Wearing Power Monitor SS6
Figure 15.
Power Path Simulation
Smart Monitoring Tower Lamp Module
This figure
shows a connection diagram for a machine monitoring system using monitoring
devices connected to various sensors and relays. The following diagram explains
the components. Main Components:
1.
Monitoring Devices (GG-Transformers)
a)
A central unit that
collects data from various sensors and sends it to the monitoring system.
b)
There are several
ports for sensor and relay connections.
2.
GPS
a)
GPS antenna used
for position tracking.
b)
Connect directly to
monitoring devices.
Sensor and
Relay Connectors :
1.
Using Vention brand
USB type C cables with lengths of 2 meters and 3 meters.
2.
Black 4.5 mm Conduit
Pipe for wrapping USB cables.
CONCLUSION
With
the optimization of real-time monitoring of operational data at PT Putra
Perkasa Abadi at the Adaro Indonesia job site through installing Smart
Monitoring devices, it is hoped that operational activities will be more
effective and efficient. This technology allows real-time monitoring of the
Tower Lamp through the OFA dashboard, making it easy to access location data,
fuel level, and engine status, thereby reducing time and the potential for
manual data input errors. This implementation also improves efficiency and
safety by speeding up the data collection process, reducing incidents during
refueling, and lowering the intensity of workers' physical interaction with the
Tower Lamp. In addition, checking the Tower Lamp becomes smoother and more
efficient, minimizing wasted time and allowing for seamless unit transitions.
Other advantages include real-time reporting capabilities, better monitoring,
reduced operational time and costs, and improved data accuracy, making it
easier for field supervisors and head office to provide quick improvement
instructions. Switching from paper forms to digital devices supports data input
efficiency and more sustainable work practices. In contrast, digital validation
reduces HM validation time by operational supervisors, allowing units to
operate earlier and improving overall time efficiency.
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© 2024 by the
authors. It was submitted for possible open-access publication under the
terms and conditions of the Creative Commons Attribution (CC BY SA) license (https://creativecommons.org/licenses/by-sa/4.0/). |