implementing sustainable lubrication improvementss3.amazonaws.com/zanran_storage/ · •sag mill...
TRANSCRIPT
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Implementing Sustainable Lubrication Improvements
Darryl GrayMatthew Grant
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Starting Point- Turning This into This
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Overview
• Background on Xstrata/EHM
• Starting Point
• Lubrication Process Improvement
• Benefits to EHM
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Xstrata plc
• A major global diversified mining group • Headquartered in Switzerland • Listed on London & Zurich Stock Exchanges
• Top 20 in FTSE 100; S&P Europe 350 Index• Market capitalisation approx US$45 billion• Employs 43,000+ people worldwide
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Ernest Henry Mining
•Located in NW Queensland, approx. 40km north of Cloncurry
•Copper/gold operation
•Employs over 580 people
•Began commercial production in 1998
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•Open pit operation- final dimensions 1.3km x 1.3km x 570m deep•Produces 11 million tonnes of ore per annum•Seeking to extend operations past the scheduled completion of open cut in 2010
Ernest Henry Mining
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EHM Concentrator
•Processes 11 million tpaof ore
•Produces approx. 115,000 tonnes of copper and 120,000oz of gold annually
•Single-line plant
•Employs around 90 people
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EHM Concentrator
Major Equipment
•Gyratory crusher•Conveyor System•SAG Mill•Ball Mill•Vertical Grinding Mill•Flotation Circuit (rougher and 3-stage cleaning process)•Concentrate and Tailings Thickeners•Pressure Filter
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Starting Point
• Lubrication-related failures common (30-40 hours per year @ $2000/minute)
• SAG Mill Gearbox replaced/overhauled on average every 12-16 months (cost around $500K plus up to 5 days downtime)
• Contamination levels (particles and water) off the scale
• Inappropriate lubrication management practices
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LPIT Process
• Lubrication Process Improvement Teams (LPIT) were formed across Xstrata NQ in 2004
• Driven by central maintenance department with assistance from lubrication consultant
• Involvement from reliability engineers and lubrication technicians
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LPIT Process Overview
1. Document the “AS IS”
2. Plan & Consolidate
3. Employ Resources
4. Manage and Review
5. Optimise and Re-Plan
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1- Document “AS IS”
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Lubrication Audit- 2004
Following areas were identified as requiring significant improvement:
1. Lubricant Application2. Lubricant Storage and Handling3. Contamination Exclusion and Removal4. Structure, Support and Education of Staff
(including sampling practices)
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Lubrication Application- Use of (old) single-point Auto-Grease Lubricators
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Lubrication Handling-Poor Handling of 1000L Pods
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Lubrication Handling-Poor Handling of 1000L Pods
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Lubrication Handling-Poor Filter Storage
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Lubrication Handling-Poor Housekeeping
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Lubrication Handling-Dispensing Facility/Use of 205L Drums
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Lubrication Handling-Waste Oil
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Contamination Management-Incorrect Breathers
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Contamination Management-Water Ingress
As a further example of contamination management- during the audit, the Ball Mill Fixed Bearing oil circuit was contaminated with water, reaching levels of 27,000ppm and emulsifying
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Contamination Management-Poor Mill Seals
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Oil Sampling- Incorrect Sample Points/Techniques
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Education, Structure and Support of Staff
• No full-time lubrication technician or reliability staff
• Use of three different labs for oil sample analysis
• No written lubrication standards
• No lubrication training
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2- Plan and Consolidate
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Set Standards-Cleanliness Targets
• Cleanliness Target for Gearboxes 19/17/14 (ISO:4406-1999)
• Cleanliness Target for Hydraulics 18/15/12 (ISO:4406-1999)
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Set Standards-Contamination Control
• Portable kidney loop filters available to achieve the ISO targets on compartments
• Permanent kidney loop filters on all bulk lube tanks
• Water and Particle Contamination eliminating breathers fitted to all dispensing tanks, pods and drums.
• Oil dispensing manifolds fitted with (5µm Absolute Filters at Dispensing - Minimum)
• Inlet and outlet filters fitted to bulk lube installations (pods and tanks)
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Set Standards- Oil Sampling and Analysis
• Oil sampling and analysis on all critical equipment with lube compartments
• Test criteria defined for each compartment type
• Live sample points fitted to all fixed and mobile lube compartments
• All people involved in taking oil samples trained
• Key maintenance people to complete oil analysis and interpretation training
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Specifications Before (14/08/04) Present (6/10/04) TargetShell Omala F460 VG 493 484 460ISO Cleanliness >28/#/# 23/18/15 17/15/12Particle Size Distrib. (%)
(<10um) 84 96 80(10-20um) 12 3 20
(>20um) 4 1 0No. Particles of (>4um) 1,900,000 60,000 970Est. Life Extension 1 2.5-3.0 5.0 -6.0Water (Crackle or FTIR) <0.1 <0.1 Below SaturationFiltration (Nominal) 20um 20um On Target <20umOffline Filtration Trolley No No YesMachine Proactive Servicing - Seals, ect
No Start The Norm!
Measure and Compare with Targets
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Lube Process Improvement Team
•Team Leader- Darryl Gray
•EHM Concentrator Maintenance Team
•Support from Maintenance and Central Engineering (Glen Croft)
•External Specialist Support (Wayne Dearness)
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Training and Personnel Support
• All maintenance personnel to undertake 2-day lubrication and contamination management course
• All supervisory and management personnel to undertake 1-day lubrication course
• Key staff to undertake oil analysis and interpretation course
• RCM• RCA
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3- Employ Resources
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Employ Resources-People
• Full-time Reliability Officer
• Full-time Lubrication Technician
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Alfa Laval Centrifugal Filter
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Alfa Laval Centrifugal Filter
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Alfa Laval Centrifugal Filter
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Alfa Laval Centrifugal Filter
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Alfa Laval Centrifugal Filter
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Alfa Laval Centrifugal Filter
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Portable Kidney Loop Filtration Trolleys
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Mill improvements-Kidney Loop Filters
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SAG and Ball mills oil cooler (580C to 450C)
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SAG and Ball Mills heat exchangers
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Desiccant Breathers-First Trial
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Desiccant Breathers-Second Trial
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New Breathers
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New Breathers/Fill Points
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Mill Improvements- New System
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1000L Pods
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Lube storage shed
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Lube storage shed
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Lube pumps
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Lube pump
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Dispensing valves
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Oil Storage Tanks
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New Sample Points
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Cost- Setup
$354,000Total
$5,000Wear particle counter
$127,000Oil storage tanks
$50,000Lube storage facility
$52,000Alfa Laval centrifugal filter
$120,000Filter systems fitted to all lube systems and gearboxes
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Cost- Ongoing
$120,000Reliability Officer
$272,000Total
$10,000Training
$16,000Running Costs (Filters, Breathers etc)
$120,000Lubrication Technician
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4- Manage and Review
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SAG FLT 1-8-04SAG FLT 12-1-05
CRUSHER 30-9-04 SAG FLT
Contamination Control-Alfa Laval
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Contamination Control-Alfa Laval
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Contamination Control-Water
17-7-04Sag Fixed1-2-05
17-7-04Sag FLT1-2-05
18-12-04Ball Fixed1-2-05
11-7-04Ball FLT1-2-05
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Contamination Control-Water
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OIL TYPE Shell Tellus 68
DATE 17/12/2004 21/12/2004 31/12/2004 6/01/2005 12/01/2005 20//01/05 29/01/2005
> 4 um Count 33396 19304 1541 37802 4727 7908 911
> 6 um Count 14502 7255 316 10737 1270 670 186
> 14 um Count 230 160 23 1107 140 13 13
Water Content ppm 130 85 169 122 144 115 78
ISO - 4406 22\21\15 21\20\15 18\15\12 22\21\17 19\17\14 20\17\11 17\15\12
CONCENTRATE FILTER HYDRAULIC POWER UNIT
Particle Size Analysis
05000
10000150002000025000300003500040000
17/12/2004 21/12/2004 31/12/2004 6/01/2005 12/01/2005 20//01/05 29/01/2005
> 4 um Count> 6 um Count> 14 um CountWater Content ppm
Filtering Buggy installed 17/12/2004 Filtering Buggy reinstalled 6/01/2005
Filtering Buggy removed 31/12/2004 100ltrs of oil added 20/01/2005
Quantifying Impact-Early Days
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Quantifying Impact-Early Days
0
5000
10000
15000
20000
25000
30000
35000
40000
coun
t PPM
20 Jan 05 31 Jan 05 25 Mar 05 22 Jun 05 7 Jul 05 14 Jul 05 20-jul-05
Ball Mill Floating Bearing E332LU008 Trend
4 micron6 micron14 MicronWater
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Quantifying Impact-SAG Mill Floating Bearing
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Quantifying Impact-Ball Mill Fixed Bearing
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Quantifying Impact-Vertical Grinding Mill
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Quantifying Impact-Larox Filter
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Finishing Point
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Quantifying Impact-Contamination (SAG Mill Floating Bearing)
284842,39618/16/1231/8/06
3,8407,680122,88024/20/1930/10/04
Particles/mL(>14µm)
Particles/mL(>6µm)
Particles/mL(>4µm) ISO Codes
Sample Date
Contamination Removed:>4µm: 98.1%>6µm: 93.7% Equivalent to 59kg/day of particles>14µm: 99.3%
Estimated Life Extension: 526%
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Quantifying Impact-Downtime
2004- 40 hours lubrication-related downtime
2005- 30 hours lubrication-related downtime
2006- 3 hours lubrication-related downtime
2007- 118 minutes lubrication-related downtime
Estimated saving: $3.2million in 2006
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Quantifying Impact- Mill Gearboxes
• Each gearbox replaced only once since 2004 (for upgrade purposes rather than failure)
• Currently 18 months in service with no indication that replacement/overhaul will be necessary in the near future.
• Expectation is to at least triple life, possibly extend to 5-6 years.
• Estimated saving- $300-400k pa
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Quantifying Impact-Oil Consumption
• Since 2005, lubricant and sealant consumption has decreased by approx. 18%.
• Saving- approx. $40k in 2007
• Achieved through fewer changes of oil-based on condition rather than time, use of oil storage tanks for mills
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Return on Investment
Expenditure on improvements since 2005:• Setup: $354,000• On-going: $624,000• Total: $978,000
Savings since 2005:• Downtime: $6,500,000• Gearboxes: $1,000,000• Consumables: $65,000• Total $7,565,000
Return on Investment: 780%
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5- Optimise and Re-Plan
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Future Plans
• Senior Reliability Engineer- Sept 07• Maintenance Engineer- Jan 08• New Portable Kidney Loop Filter• New Alfa Laval• Contamination Control Improvements• Improved KPI Reporting• Review/Formalisation of Lubrication
Standards
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Conclusion
• Lubrication improvements, in order to be sustainable, involve significant work and financial commitment
• The benefits outweigh the costs by a significant margin
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Questions