Condition Monitoring of Shovel Equipment Impacts Profitability Ppt
Transcript of 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