Life Cycle Management of mining machinery

Transcription

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2 Life Cycle Management of mining machinery Keith E. Meyers, P.E. Manager Mining, Mineral Processing & Cement SKF Slide 1 SKF Mining, Mineral Processing & Cement

3 Content 1. Life Cycle Management (LCM) 2. LCM example of Pro-Active Reliability Maintenance 3. LCM example with OEM 4. Summary

4 1 Life Cycle Management Mining, Mineral Processing & Cement Slide 3 21 November 2013

5 Mining and mineral processing Slide 4 21 November 2013

6 Common mining industry needs Improve productivity and profitability Improve worker health and safety Improve the environment

7 Life cycle on an asset Health & Safety Environment Productivity

8 Percentage of Life Cycle Costs Costs across the asset life cycle 60% 50% 45% 40% 35% 30% 20% 10% 3% 12% 5% 0% Specification Design & Develop Manufacture & Commission Operate, Monitor & Maintain, Decommission Repair

9 Life Cycle Management A strategy to maximize the productivity and reduce the Total Cost of Ownership (TCO) of machinery over the entire operating life cycle Health & Safety Environment Productivity

10 Measure productivity with Overall Equipment Effectiveness OEE = Availability x Utilization x Process Efficiency (%) Availability TH DT 100 TH TH = Total hours DT = Downtime hours Utilization TH DT SH TH DT 100 SH = Stand-by hours AP TH DT SH Process Efficiency 100 RC Source: Mining Equipment Reliability, Maintainability and Safety D.S. Dhillon AP = Actual production (tons per annum) RC = Rated capacity (tph)

11 Benchmarking

12 Impact of reliability

13 Total Cost of Ownership (TCO) Installation service Replacement price Replacement service Downtime Maintenance Energy Inventory Disposal Logistics/delivery Price TCO with original solution Value of improved solution Price gap TCO with improved solution Longer service life Avoid replacement price Avoid replacement service Avoid downtime Reduced maintenance Price

14 Reliability Optimize with solutions that increase MTBR Mean Time Between Repairs (MTBR) Mean Time Between Failures (MTBF) Mean Time To Repair (MTTR) TH DT SH MTBF NF TH = Total hours DT = Downtime hours SH = Standby hours NF = Number of Failures MTBR MTTR Time MTBF

15 Different maintenance schemes Maximum efficiency Operator-Driven Reliability (ODR) Pro-Active Reliability Maintenance (PRM) Predictive maintenance (PdM) Preventive Maintenance Reactive/Corrective Minimum efficiency Run-to-Failure The goal is to maximum maintenance efficiency

16 Pro-Active Reliability Maintenance (PRM) Combines Predictive Maintenance Root Cause Analysis Reliability Improvement Problem Cause Solution Documentation Value

17 Functional Capability Define the PdM frequency and technology Consider the majority of failures are random, not time-based Setting a arbitrary PdM frequency (interval) may not be appropriate eg Every 3 months or 4 months Consider the Potential-Failure (PF) interval for the asset P Potential Failure Point where potential fault is identified F Functional Failure PF interval The PdM technology must detect the fault within the PF interval

18 Eight (8) recommended PdM technologies? 1. Vibration analysis 2. Lubrication analysis 3. Infrared thermography 4. Non-Destructive Testing (PT, MP, UT, etc) 5. Ultrasonic Airborne (UTA) 6. Motor Current Analysis 7. Corona Analysis 8. Visual Inspection

19 Idler Sound Monitor is new PdM device for conveyors Handheld sound monitor for detection of faulty conveyor idlers SKF Idler Sound Monitor Kit is tuned to the frequencies of the conveyor idlers. 5 to 40 khz Detects good idlers from bad idlers

20 OEE trend over 3 years with LCM for one cement plant Actual cement plant performance 100% 95% 90% Availability actual (2 months) Rate actual (2 months) Yield actual (2 months) 85% 80% 75% 87,0% 86,1% 84,0% OEE Actual (2 months) 6 per. Mov. Avg. (OEE) 6 per. Mov. Avg. (Availability) 6 per. Mov. Avg. (Rate) 70% 6 per. Mov. Avg. (Yield) 65% Overall Equipment Effectiveness increased 25 %

21 Original maintenance compared after working with LCM Actual plant maintenance performance Plant original maintenance After 3 years working with LCM Reactive Preventative Predictive Proactive Reactive Preventative Predictive Proactive Predictive Maintenance Root Cause Analysis Reliability Improvements

22 Life Cycle Management Life Cycle Specification Design and development Manufacture and test Install and commission Operate and monitor Maintain and repair Scope Consultants, producers and OEMs include the latest technology, knowledge and innovations into their project and machinery specifications. OEMs and Project Engineers use the latest design and develop methods and tool. Reduce development time and costs. Improve production and quality. Reduce warranty returns. Shorten commissioning time. Reduce costs. Improve worker skills Improve productivity and profitability, Improve Health, Safety, Environment Reduce maintenance costs. Improve safety. Reduce waste.

23 2 LCM example of PRM Mining, Mineral Processing & Cement Slide November 2013

24 RMS Velocity in mm/sec Problem Short conveyor pulley bearing life P/ST-P108 PULLEYS P/ST-P107 PULLEYS P108P P107P (01-Dec-08) Max Amp 1.31 Plot Scale P107P Frequency in Hz Spectrum from vibration analysis P108P Frequency in Hz Bearing life less than pulley lagging life

25 Solution- Improved sealing Sealed spherical bearing Excludes contamination At initial installation During operation Retain lubricant Extends service life

26 Sealed bearing in sealed housing Three barriers 1 2 3

27 RMS Velocity in mm/sec Satisfactory conveyor pulley bearing life P/ST-P108 PULLEYS P/ST-P107 PULLEYS P108P P107P (01-Dec-08) Max Amp 1.31 Plot Scale Frequency in Hz P107P Original P108P Frequency in Hz Spectrum after implementing solution With solution Bearing life longer than pulley lagging life Lowest TCO

28 3 LCM program in OEM Mining, Mineral Processing & Cement SKF Slide 27 SKF Mining, Mineral Processing & Cement

29 OEM had serious failure of stacker/reclaiimer Crack Broken bolts at retainer Page 1 of 5

30 Field measurements of vibration during operation Vibration data collected a key point on whole structure Page 2 of 5

31 Case 3 Bucket wheel excavator Operating Deflection Shape (ODS) analysis using vibration data Page 3 of 5

32 Vibration data used as input to Finite Element Analysis Excessive deflection / stress found in frame FEA modeled with increased ribs and brace Field repairs implemented Page 4 of 5

33 5 Summary Mining, Mineral Processing & Cement SKF Slide 32 SKF Mining, Mineral Processing & Cement

34 Life Cycle Management A strategy to maximize the productivity and reduce the Total Cost of Ownership (TCO) of machinery over the entire operating life cycle Health & Safety Environment Productivity

35 Optimizing the machinery Life Cycle Specification Consultants, Producers, and OEMs to specify the latest technologies and solutions for Projects. Maintain and repair Avoid maintenance and repairs with Pro-Active Reliability Maintenance to improve productivity. Design and develop Engineering services to deploy the latest analytical methods and techniques. Reduce development time and costs. Health & Safety Environment Productivity Operate and monitor Increase safety and more profitable operations with increased availability through condition-based maintenance. Manufacture and test Tools to validate design and manufacture. Reduce warranty claims and rework. Install and commission Optimized the installation process. Reduce commissioning time and costs. Ensure correct machine performance and asset management.

36 Success with Life Cycle Management Success depends on the right combination of Culture, Process and Technology

37 Thank You