CONDITION MONITORING OF SHOVEL EQUIPMENT IMPACTS PROFITABILITY

BY: GEORGE KREDEL - TIMKEN & JUSTIN POPE KGHM INTERNATIONAL SEPTEMBER 25, 2012

ROBINSON NEVADA MINING CO. SUCCESS STORY

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. 2

BUCYRUS 495 MONITORING POINTS

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

RNMC SUCCESS STORY #1 RNMC Success Story Problem

A system alarm identified a slowly growing 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: DATA TREND

RNMC SResult UCCESS STORY: RESULTS Success Story The bearing was removed for inspection. Damage analysis identified light damage to the outer race and rollers, known as false brinelling. Damage was light enough that the bearing was still serviceable. The bearing was reinstalled, but monitored closely for worsening damage.

RNMC SUCCESS TORY: ROOT CAUSE Success Story RootS Cause

Subsequent investigation determined that the likely cause of the damage was improper bearing storage techniques used before bearing installation. A new storage procedure was developed to eliminate the problems root cause.
Even though the bearing was removed early, it still proved that we can see the anomaly in the bearing at a very early failure stage. Where I see the value in this find is the identification of a storage problem that we have since revised, which will save money for the life of this project.
- Cary Brunson of Robinson Mining

ONLINE INTELLIGENCE SYSTEM - OVERVIEW

Features Modular Condition Monitoring System with logic based hardware and software. Measures Shock pulse, vibration and other variable inputs. Utilizes graphical driven and hierarchal software Designed to take the right data at the right time

SYSTEM HARDWARE
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

SOFTWARE - CONDMASTER
Features Easy to use graphical overview Multi-level data triggering and alarming Slow-speed technology

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INTELLIGENT DATA FLOW

Measurement Tasks
Vibrati on Unit Vibrati on Unit Bearin g Unit Bearin g

OK Measuring Logic -Time based -Conditional -Triggered -RPM

Unit

Timken

Storing Logic -Time based -Value level -Value change -When alarm

Alarm Logic -Absolute level -Trend -Criteria based (standard/flexible) -Band alarm

Network Configuration N ETWORK C ONFIGURATION

Control Room

Wireless carrier

Customer or Timken Monitoring Center

Internet

Cell modem

Mine 1

Central Control Center

Wireless Ethernet

Data Center

Internet

Mine

Dragline
Wired Ethernet

Ethernet

Mine 2
Cellular Ethernet

Customer Control Room

Shovel

Haul Truck

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OBTAINING RELIABILITY & REPEATABILITY

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

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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.

We In this setup we The unit needs would also only want to in an RPM input like to monitor collect data if the order amperage. to collect motor shovel is falls vibration If the amps hoisting up. measurements, within a set here we can parameter then specify at what the unit will RPM we want collect the data the data at that time. sampling to occur.

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If rpm meets set criteria, data will then be sampled

In this particular setup, the maximum rpm fluctuation can only be 2%. Any activity that occurs out of this range will not be recorded.

Stable RPM verification

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>10 tons is OK
End users can specify at what load the data will be sampled at.

Check load condition

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Check if lifting

DI 1=Lifting
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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.

SUCCESS STORY #2
Swing Drives High probability of bearing damage on lower swing drive

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LOWER SWING SHAFT BEARING FAILED AND THE SHAFT

DROPPED 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 OUTER

RACE OF BOTTOM BEARING

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SPECTRUM SHOWS VIBRATION ON THE BEARING OUTER

RACE ON THE TOP BEARING

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HOIST BOTTOM PINION BEARING WHEN REMOVED FROM SERVICE IN JULY 2012 SPALLED OUTER RACE

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QUESTIONS

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