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Auto lube in practice Exxaro Grootegeluk Coal Mine is situated 25 km from Lephalale in South Africa’s Limpopo province, this open-pit mine employs 1 800 people and produces 18,6Mtpa of thermal and semi-soft coking coal using a conventional truck and shovel operation. Grootegeluk has the world’s largest beneficiation complex where 7 600 tonnes per hour of run-of-mine coal is upgraded in six different plants.
The Grootegeluk fleet of dump trucks operating on the mine is fitted with the latest technology to ensure continuous operation and reliability of their fleet. Flosolve (Pty) Ltd. recently supplied and installed the Graco Dyna-Star 10:1 hydraulic pump on one of the Euclid EH3500 diesel electric dump trucks. The Dyna-Star supplies grease to the adjustable injectors lubricating the bearings on the Euclid dump truck. The pump uses the existing low pressure hydraulic power source on the Euclid to lubricate itself delivering longer life and increased reliability. The versatile pump system is designed for both injector and progressive divider block systems.
During normal operation of the fleet the Euclid dump trucks are subjected to excessive vibration as a result of their harsh operating environment, this vibration has in the past caused competing pump systems to fail. The Graco Dyna-Star hydraulic piston pump has an innovative design and is vertically orientated in order to eliminate the design “flaw” observed in old pump systems; this vertical orientation ensures continuous operation of the pump and the greasing system on the vehicle.
The Graco Dyna-Star reservoir is manufactured out of a thick 12 gauge steel and is powder coated ensuring better durability. The Dyna-Star reservoir has a 50% greater capacity which means less refill cycles and longer machine availability. “After 1000 hours we are very happy with the overall perfor- mance of the Graco Dyna-star, the system has an excellent design; where previous systems have leaked oil the Dyna-star is still clean. The service and back-up we have received from Flosolve has been very good, their open door philosophy is great, we really feel like family when we contact them. If the Graco Dyna-star continues to perform as expected the Dyna-star will definitely be the hydraulic pump of choice on all our dump trucks.” Buks Swanepoel - Exxaro Grootegeluk Coal Mine.
Flosolve’s venture into centralized greasing systems dates back to the early 1990’s and they have since been a leading supplier of fluid and lubrication equipment to Southern Africa.
AngloAmerican is one of the world’s largest mining companies. In one of their South African open coal mines, they use the Hitachi Electric Mining Shovel EX3600. Designed to operate 24/7, a shutdown of the machine will seriously impact the mine’s productivity. To maintain its efficiency and reduce service and maintenance, an automatic lubrication system is vital to keep the bearings and bushings running.
The machine was fitted with a factory-installed auto lube system but unfortunately the reservoir was too small, causing the operator to have to stop the machine often to refill the reservoir with grease. This obviously decreased the efficiency of the machine. AngloAmerican and Graco distributor Flosolve came up with a superior customized solution based on two Graco Electric Dynastar grease pumps.
The new reservoir that was created can store up to 900 kg grease; nearly five times more than the factory fit reservoir. This increased the running time of the system to 500 hours before a refill was necessary.
12 LUBE MAGAZINE NO.136 DECEMBER 2016
One Electric Dynastar greases the boom, while the other one greases the rest of the machine. The pumps run every three minutes for maximum one minute. In case a pump cannot reach the needed pressure in one minute it will give a visual and audible alarm to the GLC4400 controller in the cab. This immediately warns the driver that there is a problem with the lube system.
Thanks to the bigger grease tank and the feedback from the pump to the controller, AngloAmerican can run their Electric Mining Shovel more efficiently. The reduced service time increases productivity and saves money.
Reliability when you need it Other features of the Graco ElectricDynastar made it an excellent choice for Anglo American. Thanks to the Tube-Tube-Fill and Vent Path, no additional external hoses are needed which could break during operation and result in the machine shutting down.
The harsh conditions in the mine means that the pump has to be rugged and durable – the drive is a particularly critical link. The Graco Advantage Drive™ consists of high quality, hardened steel helical gears sealed to keep contaminants out for longer lasting performance. It has been field-proven for over ten years to be the longest lasting drive in the industry. Warranty claims on the Advantage Drive over the past five years have only been 0.2%.
Furthermore, the Advantage Drive is lubed for life, which increases the running time of the whole machine. The motor control of the EDS allows the pump’s speed and current to be adjusted. This helps to protect the power circle of the Electric Mining Shovel and makes adjustment easy. The built-in LEDs quickly indicate if there is any failure and help to make a first troubleshooting.
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The high pressure Electric Dynastar is capable of 5,000 psi (344 bar) with a maximum output of 18 cubic inches (295 cc) per minute. This model maintains its high performance levels even in temperatures as low as -40°C. If the application demands high flow, there is an Electric Dynastar model capable of providing 3,500 psi (241 bar) with a maximum output as high as 25 cubic inches (410 cc) per minute.
LINK
www.graco.com
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