Page 58 - Vol 28 Issue 29 2019

mining equipment maintenance

Predictive Maintenance for

Productive Mining

By Angela Kerr

he mining industry operates returns. Its earlier 2015 report estimates vibration sensors specifically designed
in some of the harshest and the economic impact of sensors, those for operating equipment are being
Tmost remote parts of the world, used for predictive maintenance on the introduced and deployed. These advanced
requiring equipment that is as reliable worksite to better manage operations sensors detect low frequency vibrations
and efficient as possible. Robotics and and equipment, will range from and impacts that fall outside normal
semi-autonomous equipment only add $200 billion to $900 billion by 2025. ranges and provide real-time alerts that
to the maintenance complexity. When Vibrations as Early Warnings help maintenance teams react before
breakdowns occur, whether for the latest serious faults occur or equipment fails
technologies or for tried and tested tools, Some equipment vibrations are normal, completely.
they are time-consuming and expensive, but those outside the accepted range Vibration monitoring not only helps
resulting in lowered productivity, lengthy signal impending equipment failure. predict impending equipment failure, but
delays and an increased risk of injury. To For example, if a bolt or tie-down has also alerts maintenance teams to changes
minimize such disruptions and expenses, loosened or a belt, gear, bearing, drive in operating parameters that may affect
mining operators are turning to predictive motor or other component is worn, how the equipment operates. For example,
maintenance to prevent breakdowns vibrations will be different than if all bearings on rotating machinery, such as
before they happen, keeping equipment components are new. Measuring the pumps and conveyor lines, gradually wear
functioning at optimal performance levels. frequency or amplitude of vibration down, harming performance. Vibration
provides an early warning that something
Historically, mining companies have is about to go wrong. monitors can detect the subtle variations
relied on scheduled maintenance to that signal degradation so repairs can be
keep equipment operating properly. Previously, machine condition-monitoring made before operations are seriously
Predictive maintenance systems improve programs were not able to detect and affected. This is also true for draglines
on this by monitoring equipment communicate vibrations and impacts. and other equipment, where changes
while it’s in use. Also called condition However, that standard is changing as in vibration frequency over time (when
monitoring, this method
relies on sensors that,
once placed on multiple
pieces of equipment,
capture data needed
to help maintenance
teams anticipate failure.
Knowledge of potential
failure then allows them
to make necessary
repairs regardless of the
maintenance schedule. As
a result, the maintenance
team can better focus
its efforts, minimize
unscheduled downtime,
increase equipment
effectiveness and enhance
both personnel and
environmental safety.
In 2018, a McKinsey Global
Institute report listed
predictive maintenance
as one of the mining
operations activities Machine conditioning monitoring system
with the highest rate of

58 | AFRICAN POWER Mining & Oil Review Vol 28, Issue 29, 2019 Celebrating 10 years of excellence