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MinMach-HomePage01

MinMach-HomePage01

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Published by miningnova2
To operate successfully in a competitive world catastrophic failures need to be prevented. This can be achieved by implementing a balanced approach which covers all phases of the life cycle of equipment.
To operate successfully in a competitive world catastrophic failures need to be prevented. This can be achieved by implementing a balanced approach which covers all phases of the life cycle of equipment.

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Published by: miningnova2 on Oct 26, 2009
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01/13/2011

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ELSEVIER
ht. J. Pres. Ves. & Piping 61 (1995) 329-347
0308-0161(94)00114-6
Elsevier Science LimitedPrinted in Northern Ireland030%016!/95/$09.50
COST-EFFECTIVE PREVENTION OF EQUIPMENT FAILURE INTHE MINING INDUSTRYERNST DREYERTest & Analysis Section/Mechanical Engineering Department,Anglo American Corporation of South Africa Limited45 Main Street, Johannesburg, South AfricaABSTRACTTo operate successfully in a competitive world catastrophic failures need to be prevented.This can be achieved by implementing a balanced approach which covers all phases of thelife cycle of equipment.To gain maximum benefit, the effective prevention of failures should involve a team ofpeople ranging from the supplier to the maintenance personnel on site. Initially, the logicand main elements of the approach are discussed, whereafter the practical implementation andbenefits are illustrated by means of two case studies comprising, respectively, a bucket wheelexcavator and a main ventilation fan.INTRODUCTIONPremature failures in the mining industry are expensive not only because of the high repaircosts involved but primarily as a result of the cost of lost production.This has been theexperience of the gold, coal and diamond operating divisions of Anglo American Corporationof South Africa Limited. The paper outlines efforts that can be made to reduce the numberand extent of failures hence reducing the risks of catastrophic failures and their expensiveconsequences.
329
 
330E. Dreyer
The approach to be discussed does not rely on a single activity or person, nor is itlimited to a single phase of the equipment life cycle.In fact, as various persons have aninfluence on the operational success of equipment all parties involved should be co-optedduring the implementation of such a failure prevention philosophy.Potential role players arethe0supplier who designed the equipment.0project engineer who specifies the operational requirement.0operator who controls the production rate.0maintainer who ensures the operational availability.0failure analyst who determines the cause of failure.What is meant by cost-effective prevention of failure? The aim of this approach isfirstly to minimise the probability of failure by ensuring that the equipment is adequatelydesigned. Secondly, regular inspections make provision for the early detection of faultsbefore catastrophic failures develop and thirdly, the life cycle loop is closed by incorporatingthe experience gained into in-house standards which are to be used during future designaudits or equipment specification.MAIN ELEMENTS OF THE APPROACHAlthough the equipment referred to in the text will be mainly capital equipment of amechanical nature, the main elements of the approach to be discussed are applicable to allcapital equipment in production based industries.The life cycle of capital equipment in the mining industry can be simplified bydividing it into three phases namely0procurement0operation0decommissioningas shown in figure 1. To prevent operational failures cost-effectively, it is necessary tointroduce a balanced approach which addresses he activities of all three phases of the typicallife cycle. Overemphasis of a specific activity such as, for example, finite element analysis,cannot compensate for the neglect or absence of other activities such as routine inspection.As an input to the overall process the operational requirement must be an accuraterepresentation of what is expected from the equipment, not only in terms of function but alsoregarding expected fatigue life, reliability as well as standards to be used in design andmanufacturing. After a suitable supplier has been selected the proposed design needs to beaudited. This also applies to design modifications after operational failure has beenexperienced. The main aim of design audits is to ensure that the operational requirement hasbeen translated accurately into the design and that the equipment will perform its intendedduty successfully for the duration of the required operational life. Guidance can be obtainedfrom international and in-house standards referred to in the operational requirement. Adesign audit may be concluded by the specification of recommended routine inspectionintervals.
 
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