Condition Monitoring of Shovel Equipment Impacts Profitability Ppt

8/14/2019 Condition Monitoring of Shovel Equipment Impacts Profitability Ppt

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CONDITIONMONITORING OFSHOVELEQUIPMENT

IMPACTSPROFITABILITY

BY: GEORGEKREDEL- TIMKEN

& JUSTINPOPE KGHM INTERNATIONAL

SEPTEMBER25, 2012


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ROBINSONNEVADAMININGCO. SUCCESSSTORY

March 2009:Timken approaches Robinson about a proof of concept trial of a new

online condition monitoring system on their primary shovel

September 2009:Proposal delayed due to lack of funding

November 2009: Catastrophic failure of the shovels hoist pinion results in 1 week of unplanned downtime and lost

production

December 2009: Initial hardware installation

January 2010: System operational

February 2010: System identifies a slowly developing problem with the left boom point bearing

March 2010: Data closely monitored

April 2010: Bearing removed and inspected during normal outage.

Damage inspected by Timken bearing service engineer.Bearing was reinstalled but monitored until replacement was available.

May 2010: Root cause problem identified.

August 2010: Bearing replaced during normal outage.


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Hoist motor and gearbox 6 vibration, 2 shock pulse, 1

speed

Crowd motor and gearbox

1 vibration, 2 shock pulse, 1

speed

Swing motors and

Gearboxes

3 vibration, 1 shock pulse, 1

speed, each

Boom points

2 shock pulse

BUCYRUS495 MONITORINGPOINTS


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A system alarm identified a slowlygrowing problem with one of the

boom point sheave bearings not

long after the bearing had been

replaced during a routine

maintenance cycle.

Data analysis by a Timken project

manager indicated likely bearing

damage.

RNMC Success Story Problem

RNMC SUCCESSSTORY#1


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RNMC SUCCESSSTORY: DATATREND


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The bearing was removed forinspection.

Damage analysis identified light

damage to the outer race and

rollers, known as false brinelling.

Damage was light enough that thebearing was still serviceable.

The bearing was reinstalled, but

monitored closely for worsening

damage.

Success Story - Result

RNMC SUCCESSSTORY: RESULTS


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Subsequent investigationdetermined that the likely cause of

the damage was improper bearing

storage techniques used before

bearing installation.

A new storage procedure wasdeveloped to eliminate

the problems root cause.

E v e n th o u g h th e b e a rin g wa s re m o v e d e arly , i t s t i l l

p ro v e d th a t we c a n s e e th e

a n o m a ly in th e b e a rin g a t a

very early fai lure stage.

Wh e re I s e e th e v a lu e in th is

f in d is th e id e n t i f ic a t io n o f a

s t o r a g e p r o b l em t h a t w e h a v e s in c e re v is e d , wh ic h

w i l l s a v e m o n e y f o r t h e l i f e

o f th is p ro je c t.

- C ary B runs on of R obi ns on

M i ni ng

Success Story Root Cause

RNMC SUCCESSSTORY: ROOTCAUSE


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ONLINEINTELLIGENCESYSTEM- OVERVIEW

Features

Modular Condition MonitoringSystem with logic based hardwareand software.

Measures Shock pulse, vibration andother variable inputs.

Utilizes graphical driven andhierarchal software

Designed to take the right data at theright time


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SYSTEMHARDWARE

Hardware Technical Data

Monitoring Channels: up to 32

RPM / Digital Inputs: 4

Digital Outputs: 6

Onboard Storage: 2GB SD Card

LAN interface: Ethernet TCP/IP, 10/100

Mbps


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SOFTWARE- CONDMASTER

FeaturesEasy to use graphical overview

Multi-level data triggering and alarming

Slow-speed technology


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INTELLIGENTDATAFLOW

Measuring Logic

-Time based

-Conditional

-Triggered

-RPM

Alarm Logic

-Absolute level

-Trend

-Criteria based

(standard/flexible)

-Band alarm

OK

Storing Logic

-Time based

-Value level

-Value change

-When alarm

MeasurementTasks

Vibrati

on

Unit

Vibrati

on

Unit

Bearin

g Unit

Bearin

g Unit

Timken


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ustomer or TimkenMonitoring enter

ontrol Room

nternet

Cell

modem

Cell

modem

Network ConfigurationNETWORKCONFIGURATION

Wireless

carrier

Wireless

carrier


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Central Control

Center

Mine 2

Internet

DataCenter

Mine 1

Cellular

Ethernet

Mine

Ethernet

Customer Control

Room

Dragline

Wireless

Ethernet

Wired

Ethernet

ShovelHaul Truck

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1. Measure when in operation

2. Measure when there is relatively stable speed

3. Measure when the hoist is loaded

4. Only when lifting

5. Filter out randomly high readings

OBTAINING RELIABILITY & REPEATABILITY


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1. Collect data only when hoisting up.

2. Collect data under specified loads.

3. Collect data when rpm is in range.

In this setup we

only want to

collect data if the

shovel is

hoisting up.

We would also

like to monitor

motor amperage.

If the amps falls

within a set

parameter then

the unit will

collect the data

at that time.

The unit needs

an RPM input in

order to collect

vibration

measurements,here we can

specify at what

RPM we want

the data

sampling to

occur.

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Stable RPM

verification

In this particular setup, the maximum rpm

fluctuation can only be 2%. Any activity thatoccurs out of this range will not be recorded.

If rpm meets set criteria, data will then be

sampled

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Check load condition

>10 tons is OK

End users can specify

at what load the data

will be sampled at.

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Check if lifting

DI

1=Lifting

The system can connect to a

PLC/DCS control unit and verify what

direction the hoist is moving, so that we

are only sampling data during the hoist

up motion.

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Swing Drives

High probability of bearing damage on lower swing drive

SUCCESSSTORY#2


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LOWERSWINGSHAFT BEARING FAILED AND THE SHAFTDROPPED AGAINST THE HOUSING


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SWING LOWER SHAFT AFTER REMOVED FROM THE DRIVE


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OUTER RACE DEFECT ON LOWER SWING BEARING


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Success Story #3

Hoist Drive 2012

Large Increase in shock pulse readings in January on

the hoist drum pinion


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SPECTRUM SHOWS VIBRATION ON THE BEARING OUTERRACE OF BOTTOM BEARING


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SPECTRUM SHOWS VIBRATION ON THE BEARING OUTERRACE ON THE TOP BEARING


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HOIST BOTTOM PINION BEARING WHEN REMOVED FROMSERVICE INJULY2012 SPALLED OUTER RACE


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QUESTIONS

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Condition Monitoring of Shovel Equipment Impacts Profitability Ppt

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