Professional Documents
Culture Documents
UNIDAD VI
Monitoreo regular de los sntomas de los equipos para determinar su condicin de funcionamiento interviniendo solamente cuando es necesario
Captar los sntomas de la maquinaria o equipo. Variacin del Sntoma vs. Condicin de la mquina. Identificacin del problema en base al anlisis del sntoma.
Mxima vida til de componentes de una mquina o equipo. Incluye ventajas sobre el Mantto. Preventivo Reduce prdidas de produccin Elimina necesidad de inspeccin programada Reduce horas extras de mantenimiento Reduce paradas imprevistas Aumenta confiabilidad y disponibilidad de equipos.
M.Sc Alberto Ochoa Torres 6
TECNICAS DE MPD
Anlisis Vibracional Anlisis Ferrogrfico Termografia Ensayo de Ultrasonido Anlisis Acstico Pruebas Radiogrficas Anlisis Espectogrfico de aceite Ensayos No destructivos, etc..
M.Sc Alberto Ochoa Torres 7
PRUEBA DE VIBRACION
PRUEBA DE ULTRASONIDO MEDICION ULTRASONICA DE EJES HASTA 4.5 MTS, PARA DETECTAR FISURAS, RAJADURAS, O GRIETAS INTERNAS.
PRUEBA DE ULTRASONIDO
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11
12
13
14
V (vertical)
A (axial)
H (horizontal)
3 2 1
M.Sc Alberto Ochoa Torres 15
CRITICIDAD : Equipos que sean muy importantes para el proceso. CONDICION ACTUAL ROI : costo de monitoreo de condicin vs. Costo potencial de averas, prdida de produccin y reparaciones
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METODOS DE MONITOREO
Instalacin Fija : con tendido de cables centralizados en registradores o microprocesadores (Siderurgia, refinera, procesos qumicos, etc.). Indicadores porttiles : Dispositivos de medicin y registro.
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Los datos medidos y registrados deben analizarse, marcar su tendencia,interpretarse y luego deben tomarse decisiones (acciones correctivas): Entrada de datos Anlisis de datos, muestras o valores comparativos Conclusiones y toma de decisiones Planificar accin correctiva
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20
Maintenance Engineering
Actual Program
Up-today the area of responsibility for Maintenance Engineering includes all fixed plant equipment related with production plants like Crushing, Grinding, Flotation, Pipeline and Port Installations. This activities include Condition Monitoring, Quality Control, Wear Pattern Determination, Oil Contamination Control and Failure Analysis. The condition monitoring program considered Critical equipment since production and safety point of view. Moderate & low criticality equipment were inspected on demand.
Maintenance Engineering
Condition Monitoring
Vibration Analysis
More than 250 pieces of equipment under the program. Analysis for requirement. Non-Critical equipment under on-demand
Maintenance Engineering
Lab Oil Analysis
Condition Monitoring
More than 125 pieces of equipment under the program. About 160 samples by month. Analyzed in Ferreyros Lab. Lima Non Critical equipment under on-demand analysis.
Cu ppm
Cr ppm
Na ppm
Mg ppm
Sn ppm
Cu ppm
Fe ppm
Cr ppm
Pb ppm
Al ppm
Si ppm
Mo ppm
Na ppm
31-Oct-01
12-Nov-01
Mo ppm
Mg ppm
20-Nov-01
Pb ppm
Al ppm
Si ppm
27-Nov-01
Fe ppm
3-Dic-01 10-Dic-01
Sn ppm
10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0
Maintenance Engineering
Condition Monitoring
Temperature Trending
More than 250 pieces of equipment under the program.
Non Critical equipment under on-demand analysis. Help to diagnose lubrication problems on bearings, misalignment, etc.
Maintenance Engineering
Condition Monitoring
US Thickness Measurement
There is no an specific program. Use T-Mike EL for measuring. We inspect spools, tanks and cells on demand. Help to schedule structural replacement or reinforcement before they fail.
A B C D E F G H I J K L M N O P Q R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
2.00-3.00 6.00-7.00
3.00-4.00 7.00-8.00
36.00 34.70 17.80 13.60 34.10 31.00 29.80 28.30 23.90 17.80 26.10 19.20 31.60 33.90 28.90 22.00 18.80 12.60
COLUMNA # 1
Maintenance Engineering
Condition Monitoring
Water Analysis and Corrosion Control
Monthly water analysis work together with ROCSA (NALCO)
Actual Corrosion of the system 1 mpy (Under control) Monthly inspection of the operation of the system and parameter like Ph, ORP, Conductivity.
Thermographs: The AFE is still pending for approval. Budgeted money was delayed to this year due Project Budget curtail.
Motor Current Analysis: Software is no running well. Second priority by the Analytical Ferrography On Site Oil Tests Thermograph Motor Analysis moment.
Check on demand structural components using: Visual Inspection Visual Dye Penetrant Magnetic Dye Penetrant Fluorescents Dye Penetrant
We are verifying the alignment after each mechanical repair and as per vibration analysis results.
The program will consider more than 50 equipments for this verification.
100.0
50.0
0.0 0.000 1.000 2.000 3.000 4.000 5.000 6.000 7.000 8.000 9.000 10.000
y = -7.3224x + 160.12
M-Tons
Maintenance Engineering
Wearing Trending and Shutdown determination Primary Crusher Concaves Wear Trending
Trend the liner wearing pattern and advice the estimated liner change to Maintenance Planning and Operations. Critical Thickness Variation
160.0 140.0 120.0 100.0
15,000.0 20,000.0 25,000.0
80.0 60.0 40.0 20.0 09/16/01 11/05/01 12/25/01 02/13/02 04/04/02 05/24/02
10,000.0
5,000.0
y = -0.0041x + 113.64
5000
15000
25000
Points 17_20
Maintenance Engineering
Failure Analysis
Active participation in solving problems like: SAG Mill cannon failure report and control Pipeline failure weld and supervision in the construction of new spares (In progress) WIRTH pump gear pitting problem. (In Progress) FALK gear reducer failure and claim (Favor to CMA) Etc.
Maintenance Engineering
Problems affecting our Performance
System : Our Database and our system need an auditory by expertise. Need additional on-site training for managing the Database. Need to schedule our activities using JdE and to complete the interface to transfer our work request. Standardize the Lube Oil Databases. Improve oil change control and oil standardization. Kirk-off a lubrication crew if it will exist.
Maintenance Engineering
Problems affecting our Performance
Personnel : Lack of personnel to fulfill our objective. Growing responsibilities are not allowing us to complete our scheduled activities. Training and Certification program is mandatory for this kind of activity. (Attached proposal) Evaluate if leader could work on 4 x 3 basis.
Maintenance Engineering
Problems affecting our Performance
Infrastructure: Poor Technical Information On-site require Implementation of technical library. Thermo graphic technique should be implemented soon. Higher space for our laboratory or small shop. One additional truck to cover a large extension area. No color printer for our reports. (just lost)
Maintenance Engineering
How we could contribute to Mine
Additionally to improve and standarize the oil analyisis program and the VIMS parametres monitoring. We would like to share and apply the MaIntelligence Monitor Software as an standard database for Condition Monitoring of the Mine equipment. This will also allow a full access for the information contained by other supervisors. Mobil Laboratory should be defined and review looking for the best option for CMA.
Vibration:
Take vibration in rotating equipment like drills electric motors and compressors, gear reducer in shovels
Maintenance Engineering
How we could contribute to Mine
Airborne Ultrasonics:
UT Flaw detection
Inspect structural chassis, axles, beams for Haul trucks, shovels and drills during overhaul program.
Laser alignment
Align using precision alignment components for trucks and shovels.
Maintenance Engineering
How we could contribute to Mine
Other activities:
Thermo graphic inspection of sub-stations, Haul truck MCI, high tension lines, electric motors and tires. Wear control of liners. Material quality control . Quality tests of fuels. Support failure Analysis and warranty claims.