HAZEMAG

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ENGINEERING

Member of

I-MOSTIntegrated Monitoring Optimisation & Support Technologies

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Integrated Management and Engineering Systems.

Monitoring and Analysis of operation trends and performance.

Optimisation of the equipment and process performance.

Support to site through an expert group.

Using leading edge Technologies and Tools

Integrated Monitoring Optimisation & Support Technologies

What is I-MOST?

With a wide range of products and services under one roof, IMS Engineering has over the years redefined the one-stop shop model when it comes to the provision of application-specific comminution and separation solutions specially adapted to suit an array of processing applications. Our specialist machinery is backed up by our in-depth knowledge of the industry, coupled with strong backup support from various leading global technology partners.

Our approach has always been to offer novel and, if need be, tailor-made technologies that speak directly to customer needs. To further reinforce our one-stop model, we have introduced IMost – a smart analytics platform which allows equipment owners to monitor their mission-critical assets remotely. A key talking point of the new analytics platform is that it can be easily integrated into existing platforms.

At the heart of IMS Engineering’s success over the years has been the three key pillars – innovation, engineering excellence and performance. With the inception of IMost, we are further bringing this reputation to life. As equipment owners fight to reduce operational costs and maximise efficiencies, IMost can provide significant cost savings and operational efficiencies. But how?

IMost utilises several sensors installed to your processing equipment. Through a series of data acquisition and networking protocols, information is continually captured, analysed and reported for process improvement via predictive insights and actionable dashboards. More importantly, these indicators arm equipment owners with insights they need to run reliable and efficient plants.

ENGINEERING

Principals of the system

Maintenance, Service, Training

EstablishExisting Kpi

SetBenchmarks

InstallMonitoring

System

Collect Data

Process

Analysis of Data

Equipment/Components

IdentifyIssues &

Improvements

OperationsOptimisation,Max Product

Cost Reduction

Set Up,Component Life,

Reliability

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Why remote monitoring

Controlling cost and expenses has always been the biggest challenge faced by many maintenance managers, and in a world where there is pressure to do more with less, IMost definitely changes the face of preventative maintenance. The reasoning behind the analytics platform is to catch failures prior to them occurring – that’s the optimal zone where you get the maximum value out of data analytics.

IMost allows fleet managers and owners to remotely manage their preventative maintenance regime by monitoring crucial parameters such as wear and tear, as well as scheduled service and repairs. It also detects any trouble areas, such as hydraulic pressure, bearing temperature or lubrication issues, thus preventing catastrophic failures, reduce the actual cost of repairs and potential downtime. Its ability to predict breakdowns and monitoring maintenance compliance and performance enables higher fleet lifecycle efficiency.

Why Remote Monitoring

Traditional methods of monitoring and control using

PLCs and SCADA systems are well established in the

mining industry.

These traditional technologies were designed for a

world of central command and control, tailored for the

production environment – not necessarily suited to the

new world of business imperatives such as:

■ Increased plant availability

■ Reduced environmental impact

■ Reduced operating costs

■ Reduced manpower resources

■ Increased green credentials

Remote Management

■ One feature that allows even greater optimisation

of running cost is remote access to the monitoring

system

■ From the central location:

• Series of remote stations are connected to the

same network

• User can set limits on set points

• User can set alarm thresholds

• Actions can be carried out in real time

• User can access information on the remote

device

With IMost, plant managers can now gain incremental improvement in Overall Equipment Efficiency and get additional productive hours and subsequently more tonnes out. The system assesses your machinery’s performance, including potential improvements, such as optimising the equipment’s energy efficiency or throughput. Additionally, customers can now coordinate their maintenance effort so much better – the whole process behind it, from planning to ordering of parts and getting the machine back up and running.

In a nutshell, the introduction of IMost allows your plant to operate at its optimum and most profitable at all times. Information from the analytics platform can be integrated into existing control room systems in real time, while it can be accessed remotely, anywhere, around the clock, on any device, allowing you to keep the finger on the pulse of your business from wherever you are. From mobile optimised views, through to SMS and email notifications – whether you have a smart phone, tablet, laptop or desktop – critical information is at your fingertips always.

Key benefits of IMost:

■ Access to the online portal, anytime and anywhere

■ Manage services and equipment

■ Manage inventory

■ Troubleshoot problems and optimise performance

Monitoring, analysis and diagnosis:

■ Real-time analysis and interpretation of critical performance data

■ Real-time, fact-based, root cause analysis or machine performance

■ Operational insights applied to your processes

For improved performance:

■ Reduced downtime

■ Enhanced output

■ Increased safety

Available anywhere, anytime:

■ Remote monitoring

■ Accessible via any device

■ Can be integrated with existing operational systems

What do we do with the extracted info?

■ Generate simple, clean, graphical automated reports Daily / Weekly / Monthly

■ Data will provide insight into:

• Failure Predictions

• General Equipment Condition

• Trending Component Life

• Scheduling Replacement

• Maintenance team investigation / action points

• Plant Utilisation

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Key areas for measurement

Compression Crushing:

■ Lubrication oil flow

■ Lubrication Supply, Return & Tank Temperatures

■ Lubrication & Hydraulic Pressures

■ Lubrication & Hydraulic Tank Levels

■ Gap settings

■ Stroke

■ Liner Wear

■ Gap calibration frequency

■ Crusher Feed level

■ Crusher power draw

■ Main motor vibration (optional)

■ Crusher throughput (optional)

■ Horizontal shaft bearings temperatures (optional)

■ Spherical bearing grease level (optional)

■ Spherical bearing temperature (optional)

■ Oil condition monitoring (optional)

■ Vortex blower pressure (optional)

■ Cooler efficiency (optional)

■ Pump efficiency (optional)

Impact Crushing:

■ Main motor power draw

■ Rotor speed

■ Bearing temperatures

■ Bearing vibration

■ Gap setting

■ Main motor vibration (optional)

■ Crusher throughput (optional)

Kawasaki Crusher

Hazemag

Allair

■ General data logging of jig parameters

■ Alarm logging in the event of a fault/failure

■ Low pressure

■ Low bed depth measurements

■ Nuclear density gauge settings

■ Actual bed density

■ Compressed air

■ Filter system differential pressure

■ Inlet stargate speed

■ Jig bed vibrations

Alljig

■ General data logging of jig parameters

■ Alarm logging in the event of a fault/failure

■ Low bed depth measurements

■ Low hutch water

■ Hydraulic oil levels

■ Air vessel pressure

■ Blower status

■ Blower output pressure

■ Low and high product levels in jig hopper

■ Hutch overload sensor ( jig is filled to high with material will cut out)

■ Rotary vale errors

■ Poppet valve stroke

Allflux

■ General data logging of allflux parameters

■ Alarm logging in the event of a fault/failure

■ Low water level

■ Low or no feed level

■ Hydraulic oil levels

■ Course chamber bed level

■ Middlings chamber bed level

■ Dart vale activation and stroke count

■ Pinch valve activation

Allgau

■ General data logging of allgauss parameters

■ Alarm logging in the event of a fault/failure

■ Low water level

■ Low or no feed level

■ Hydraulic oil levels

■ Magnetic coil status

■ Magnetic coil temperature

■ Magnetic coiling cooling fans

■ Spray bar water pressure

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■ Belt coverage

■ Volume output

■ Objects per second

■ Ejection pressure

■ Service air pressure

Sensor Sorting

■ Main motor power draw

■ Screen stroke

■ Screen operating speed

General Kinematics

Screening

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Examples of Condition Monitoring Components

Liner Wear Rate Wear rate to be determine between gap calibrations

Liner Replacement Planned liner replacement based on crusher motor power drawn and gap setting

Crusher Internals Rate of temperature rise of lubrication oil return temperature compared

Lubrication Pump Flow rates of lubrication pumps at specific oil and ambient temperatures

Oil Cooler Temperature difference across oil cooler

Drive System Higher no load power could be due to bearing problems

Operation Productivity Analyse plant productivity from crusher power drawn trends

Energy Efficiency Analyse unnecessary crusher motor starts

Oil Analysis Analyse lubrication oil for suspended contaminants wear debris

Vibration Analysis Analyse crusher internals and drive system for baring wear, misalignment and imbalance

Instrumentation Trends would highlight inaccurate or faulty instruments

System Data Analysis

Pre-Set waring levels Can provide immediate feedback on equipment systems that are operating outside normal limits.

Quick response, reduced failures and better use of resources

Component life cycle Measure of wear and KIP to extend component life & rescue breakdowns

Equipment start up / Run-in Correct process for equipment start up & run-in to extend life.

Analysis of Power draw and CSS trends could offer useful guidance during the crusher run in phase after major component replacement

Power trends Analysis of Power draw and CSS trends could offer useful guidance on performance, feed and process efficiency

Maintenance plan Monitoring provides accurate maintenance planning

Equipment utilisation Analysis of key factors such as power draw provide actual equipment utilization versus production for analyzing plant productivity

Instrumentation Trends would highlight any drop in instrumentation accuracy or faulty instrumentation

Analysis

Service Module Cost Reduction

PlantUtilisation

PlantAvailability

ReducedBreakdowns

ProcessOptimisation

Safety

Set-Up / Start-Up 3 3 3 3

Maintenance 3 3 3 3

Inventory / Maintenance planning

3 3 3

Operation monitoring 3 3 3 3 3 3

Process optimisation 3 3 3

Critical system trends 3 3 3 3 3 3

Benefit summary of monitoring system

ENGINEERING

IMS Engineering (Pty) Ltd10 Derrick Road, Spartan Kempton Park, 1620, South Africa

Postal Address: P.O. Box 8003, Edleen, 1625 +27 11 571 6700

+27 11 970 3200

imse@imsgroup.co.za www.imsengineering.co.za

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