OPERATIONS MANAGEMENT
METHODS OF EQUIPMENT REPLACEMENT Traditionally, there have been two methods of equipment replacement: Condition-based replacement, where components are replaced when they stop working, and time-based replacement, where components are placed consistently after a certain period of time. The introduction of predictive
monitoring technologies has introduced a third, more fluid option, where the condition of components is monitored to find the most appropriate point in time to replace it. Predictive maintenance through
real-time monitoring enables the collection and analysis of data to assess the condition of components and replace them before they break. This saves not only time and money, but also potential injuries. It also positively impacts the labour market, as the number of jobs related to predictive maintenance has increased tenfold over the last five years. One way in which this technology
can extend the life of mining equipment is the use and monitoring of high-performance synthetic lubricants, which can reduce the need for costly overhauls or replacements, even more than standard oils. Monitoring the condition of
lubricant and equipment wear through techniques such as oil analysis, vibration monitoring and thermography, can identify patterns of wear and degradation. This considers extreme conditions such as high temperatures and pressures during operation, which accelerate oxidation, diffusion and thermal fatigue. By identifying issues early, such
techniques reduce the risk of sudden failures and malfunctions that lead to safety incidents. “Mining doesn’t have the best track
record with safety and safety really does start with each one of us and the little decisions that we make,” said webinar speaker ExxonMobil lubricants field engineer Jonathan Leland. A company-wide cultural shift
appreciating the importance of predictive maintenance is key to extending the life of mining equipment, according to Leland. To obtain useful results analysing the
Predictive maintenance through
real-time monitoring enables the collection and analysis of data to
assess the condition of components and replace them before they break
Predictive maintenance is key to extending the life of mining equipment
status of lubricants, everyone in the company must take the same approach to sampling. “Quality sampling practices are the
foundation for oil analysis,” he said. “There are inconsistencies that can be driven just by how you take your sample that can skew your data.” A detail-oriented approach is
also vital. Although automated and predictive technologies have taken over much of the work that used to be entirely manual, operators can still monitor the results that come in and apply them to each unique situation. “Using data to recognise failures
and drive reliability initiatives is really helpful because you can detect small
failures as they start to happen with oil analysis,” said Leland. “If you’re not watching it closely or you’re not heeding those cautions and alerts that come into the lubricant analysis platform, you’re missing an opportunity to catch a failure about to happen.” Catching these failures allows
users to replace components before they break, minimising downtime, money spent on emergency parts and potential injuries from unreliable equipment.
For more information visit:
www.globaldata.com
www.engineerlive.com 17
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