The advantages of predictive maintenance as a means to improve the availability of centrifugal slurry pump at Ergo City Deep Plant
- Authors: Martinus, Aroon
- Date: 2018
- Subjects: Mining machinery - Maintenance and repair , Pumping machinery - Maintenance and repair , Plant maintenance - Management
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/284823 , uj:30776
- Description: M.Phil. (Engineering Management) , Abstract: Condition monitoring is the process of monitoring a parameter of condition (vibration, temperature etc.) in machinery in order to identify a significant change which is indicative of developing fault. It is a major component of Predictive Maintenance. The use of condition monitoring allows maintenance to be scheduled, or other actions to be taken to prevent failure and it consequences. Predictive Maintenance helps the organization to predict equipment failure before a catastrophic failure can occur. The purpose for implementing Predictive Maintenance in industry is to increase productivity, decrease maintenance costs and downtime, and also to increase safety. In this study, Predictive Maintenance was implemented as a means to improve the availability of a centrifugal slurry pump, and conclusions were made on whether it is a better method than reactive maintenance to minimize equipment downtime and maintenance operation costs. Centrifugal slurry pumps are used in many applications such as in the mining, chemical and in the industrial plants. Ergo City Deep Plant uses centrifugal slurry pumps to pump slurry from its City Deep pumping station to Elsburg pumping station over a distance of about 50 km. Due to unplanned breakdowns, the pumps are not operating at peak efficiency point, and as a result the plant does not meet its monthly production target. Before the implementation of Predictive Maintenance, no planned maintenance strategy was done on the pumps. Ergo City Deep Plant used reactive (breakdown) maintenance, which had escalated the maintenance operating costs year on year. Reactive Maintenance methods result in huge unplanned costs as well as overheads if the budget for maintenance is exceeded in order to restore the pump into working order. Hench in this study, Predictive Maintenance by using Condition Monitoring techniques was used to improve the availability of a centrifugal slurry pump. From the field data the pump availability increased by Predictive Maintenance. The research field data resulted in decrease in downtime and equipment failures, and also reduced maintenance costs. It was concluded that Predictive Maintenance is a better maintenance method than reactive maintenance.
- Full Text:
- Authors: Martinus, Aroon
- Date: 2018
- Subjects: Mining machinery - Maintenance and repair , Pumping machinery - Maintenance and repair , Plant maintenance - Management
- Language: English
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/284823 , uj:30776
- Description: M.Phil. (Engineering Management) , Abstract: Condition monitoring is the process of monitoring a parameter of condition (vibration, temperature etc.) in machinery in order to identify a significant change which is indicative of developing fault. It is a major component of Predictive Maintenance. The use of condition monitoring allows maintenance to be scheduled, or other actions to be taken to prevent failure and it consequences. Predictive Maintenance helps the organization to predict equipment failure before a catastrophic failure can occur. The purpose for implementing Predictive Maintenance in industry is to increase productivity, decrease maintenance costs and downtime, and also to increase safety. In this study, Predictive Maintenance was implemented as a means to improve the availability of a centrifugal slurry pump, and conclusions were made on whether it is a better method than reactive maintenance to minimize equipment downtime and maintenance operation costs. Centrifugal slurry pumps are used in many applications such as in the mining, chemical and in the industrial plants. Ergo City Deep Plant uses centrifugal slurry pumps to pump slurry from its City Deep pumping station to Elsburg pumping station over a distance of about 50 km. Due to unplanned breakdowns, the pumps are not operating at peak efficiency point, and as a result the plant does not meet its monthly production target. Before the implementation of Predictive Maintenance, no planned maintenance strategy was done on the pumps. Ergo City Deep Plant used reactive (breakdown) maintenance, which had escalated the maintenance operating costs year on year. Reactive Maintenance methods result in huge unplanned costs as well as overheads if the budget for maintenance is exceeded in order to restore the pump into working order. Hench in this study, Predictive Maintenance by using Condition Monitoring techniques was used to improve the availability of a centrifugal slurry pump. From the field data the pump availability increased by Predictive Maintenance. The research field data resulted in decrease in downtime and equipment failures, and also reduced maintenance costs. It was concluded that Predictive Maintenance is a better maintenance method than reactive maintenance.
- Full Text:
Reliability analysis to optimise dump trucks in a platinum mining environment : a case for Mogalakwena mine
- Mbeki, Comfort Jacqueline Bathabile
- Authors: Mbeki, Comfort Jacqueline Bathabile
- Date: 2017
- Subjects: Earthmoving machinery - Maintenance and repair , Mineral industries - Equipment and supplies , Reliability (Engineering) - South Africa , Mining machinery - Maintenance and repair
- Language: Englsh
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/242852 , uj:25061
- Description: M.Phil. (Engineering Management) , Abstract: The mining industry is faced with declining profits due to the fall of commodity pricing in recent years. The decline in profits resulted in mining companies looking for ways to reduce operational costs especially relating to heavy mining equipment maintenance costs in order to gain a competitive advantage. Diversified miners such as the Anglo American Group have sold loss making assets in efforts to sustain the business. Mogalakwena Mine is the largest open-pit platinum mine in the world. The mine has the largest population of dump trucks in the platinum market and has experienced an increase in equipment failure. The purpose of this research is to investigation the nature and cause of failures in the dump trucks using the Komatsu 930E Series as the population over a 24-month period. The objective of this research is to determine the international best practices in maintenance that can assist in the optimisation of equipment life and reduce the cost of maintenance. This research is a case study that uses the full population of trucks to investigate applied maintenance strategies in Mogalakwena Mine. In addition, a framework of FMECA is used to determine the criticality of common failures. The research study reviews literature on maintenance strategies and its approaches. The theory around preventive maintenance, corrective maintenance, predictive maintenance and reliability-centred maintenance is also reviewed. Furthermore, the concept of reliability, reliability parameters and reliability analysis is evaluated placing emphasis on the methods used to conduct reliability analysis on mining equipment. The results from the research study show a significant increase in downtime and unscheduled maintenance although machine availability remains within acceptable the level set by the mine. Further to this, preventive maintenance, corrective maintenance and condition-based maintenance strategies are been utilised by the mine.
- Full Text:
- Authors: Mbeki, Comfort Jacqueline Bathabile
- Date: 2017
- Subjects: Earthmoving machinery - Maintenance and repair , Mineral industries - Equipment and supplies , Reliability (Engineering) - South Africa , Mining machinery - Maintenance and repair
- Language: Englsh
- Type: Masters (Thesis)
- Identifier: http://hdl.handle.net/10210/242852 , uj:25061
- Description: M.Phil. (Engineering Management) , Abstract: The mining industry is faced with declining profits due to the fall of commodity pricing in recent years. The decline in profits resulted in mining companies looking for ways to reduce operational costs especially relating to heavy mining equipment maintenance costs in order to gain a competitive advantage. Diversified miners such as the Anglo American Group have sold loss making assets in efforts to sustain the business. Mogalakwena Mine is the largest open-pit platinum mine in the world. The mine has the largest population of dump trucks in the platinum market and has experienced an increase in equipment failure. The purpose of this research is to investigation the nature and cause of failures in the dump trucks using the Komatsu 930E Series as the population over a 24-month period. The objective of this research is to determine the international best practices in maintenance that can assist in the optimisation of equipment life and reduce the cost of maintenance. This research is a case study that uses the full population of trucks to investigate applied maintenance strategies in Mogalakwena Mine. In addition, a framework of FMECA is used to determine the criticality of common failures. The research study reviews literature on maintenance strategies and its approaches. The theory around preventive maintenance, corrective maintenance, predictive maintenance and reliability-centred maintenance is also reviewed. Furthermore, the concept of reliability, reliability parameters and reliability analysis is evaluated placing emphasis on the methods used to conduct reliability analysis on mining equipment. The results from the research study show a significant increase in downtime and unscheduled maintenance although machine availability remains within acceptable the level set by the mine. Further to this, preventive maintenance, corrective maintenance and condition-based maintenance strategies are been utilised by the mine.
- Full Text:
Life cycle management for mining machinery
- Authors: Barkhuizen, W. F.
- Date: 2008-11-18T09:00:16Z
- Subjects: Mining machinery - Maintenance and repair
- Type: Thesis
- Identifier: uj:14723 , http://hdl.handle.net/10210/1728
- Description: M.Ing. , Until very recently reactive maintenance was still used in the mining industry. Equipment failures occurred without warning and resulted in catastrophic breakdowns and large production losses and maintenance cost. As a result, the mining industry turned to preventative maintenance that focused on changing parts before they fail. Although preventative maintenance was an improvement over reactive maintenance practices, equipment reliability did not necessarily improve. Next came predictive diagnostics, which monitored the health of components within assemblies, and thereby predicting the life expectancy of assemblies through vibration analysis, infrared thermography, lubrication and oil analysis and ultrasonic detection. However, the level of success could not be achieved. Many hours and a lot of money are spent in developing and implementing a maintenance management system, but without the correct approach, efficient maintenance might not be achieved. The overall objective of this dissertation is to introduce a logical approach to managing the maintenance of mining equipment over the economical life of the equipment. This concept can be defined as Life Cycle Management. The research included in this dissertation is partially aimed at developing the Life Cycle Management program for P&H MinePro Services A division of Joy Global (South Africa) (Pty) Ltd. The dissertation also includes case studies on the P&H Mining Equipment (Blast Hole Drills) and their alliance partners (LeTourneau Front-end Loaders). The dissertation focuses on the cradle to grave approach of maintenance for mining machinery, referred to as the Life Cycle Management of Mining Machinery.
- Full Text:
- Authors: Barkhuizen, W. F.
- Date: 2008-11-18T09:00:16Z
- Subjects: Mining machinery - Maintenance and repair
- Type: Thesis
- Identifier: uj:14723 , http://hdl.handle.net/10210/1728
- Description: M.Ing. , Until very recently reactive maintenance was still used in the mining industry. Equipment failures occurred without warning and resulted in catastrophic breakdowns and large production losses and maintenance cost. As a result, the mining industry turned to preventative maintenance that focused on changing parts before they fail. Although preventative maintenance was an improvement over reactive maintenance practices, equipment reliability did not necessarily improve. Next came predictive diagnostics, which monitored the health of components within assemblies, and thereby predicting the life expectancy of assemblies through vibration analysis, infrared thermography, lubrication and oil analysis and ultrasonic detection. However, the level of success could not be achieved. Many hours and a lot of money are spent in developing and implementing a maintenance management system, but without the correct approach, efficient maintenance might not be achieved. The overall objective of this dissertation is to introduce a logical approach to managing the maintenance of mining equipment over the economical life of the equipment. This concept can be defined as Life Cycle Management. The research included in this dissertation is partially aimed at developing the Life Cycle Management program for P&H MinePro Services A division of Joy Global (South Africa) (Pty) Ltd. The dissertation also includes case studies on the P&H Mining Equipment (Blast Hole Drills) and their alliance partners (LeTourneau Front-end Loaders). The dissertation focuses on the cradle to grave approach of maintenance for mining machinery, referred to as the Life Cycle Management of Mining Machinery.
- Full Text:
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