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MANTENIMIENTO PREDICTIVO

UNIDAD VI

M.Sc Alberto Ochoa Torres

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MANTENIMIENTO PREDICTIVO (MPD)

Monitoreo regular de los síntomas de los equipos para determinar su condición de funcionamiento interviniendo solamente cuando es necesario

M.Sc Alberto Ochoa Torres

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CARACTERISTICAS DEL MPD


Captar los síntomas de la maquinaria o equipo. Variación del Síntoma vs. Condición de la máquina. Identificación del problema en base al análisis del síntoma.

M.Sc Alberto Ochoa Torres

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COMPARACION DEL TIEMPO VS. EL DESGASTE

M.Sc Alberto Ochoa Torres

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BENEFICIOS DEL MPD

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Máxima vida útil de componentes de una máquina o equipo. Incluye ventajas sobre el Mantto. Preventivo Reduce pérdidas de producción Elimina necesidad de inspección programada Reduce horas extras de mantenimiento Reduce paradas imprevistas Aumenta confiabilidad y disponibilidad de equipos.
M.Sc Alberto Ochoa Torres 6

TECNICAS DE MPD


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Análisis Vibracional Análisis Ferrográfico Termografia Ensayo de Ultrasonido Análisis Acústico Pruebas Radiográficas Análisis Espectográfico de aceite Ensayos No destructivos, etc..
M.Sc Alberto Ochoa Torres 7

PRUEBA DE VIBRACION

M.Sc Alberto Ochoa Torres

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PRUEBA DE ULTRASONIDO MEDICION ULTRASONICA DE EJES HASTA 4.5 MTS, PARA DETECTAR FISURAS, RAJADURAS, O GRIETAS INTERNAS.

M.Sc Alberto Ochoa Torres

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PRUEBA DE ULTRASONIDO

M.Sc Alberto Ochoa Torres

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VERIFICACION DE ALINEAMIENTO CON RAYO LASER

M.Sc Alberto Ochoa Torres

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M.Sc Alberto Ochoa Torres

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MEDICIÓN CON VIBROTIP:
BOMBA DE AGUA CONDENSADOR DE AMONIACO

M.Sc Alberto Ochoa Torres

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MEDICIÓN CON SENSOR DE ACOPLE MAGNÉTICO:
MOTOR PRINCIPAL INSPECTOR BOTELLAS VACÍAS

M.Sc Alberto Ochoa Torres

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PUNTOS DE MONITOREO CON VIBROTIP

V (vertical)

A (axial)

H (horizontal)
3 2 1
M.Sc Alberto Ochoa Torres 15

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QUÉ MAQUINAS DEBEN INCLUIRSE EN EL MONITOREO?

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CRITICIDAD : Equipos que sean muy importantes para el proceso. CONDICION ACTUAL ROI : costo de monitoreo de condición vs. Costo potencial de averías, pérdida de producción y reparaciones

M.Sc Alberto Ochoa Torres

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MONITOREO DE CONDICION DE EQUIPOS
Decida que desea monitorear, por máquina. Los primeros 4 ó 5 ítems son, por lo general, las condiciones más significativas a monitorear : - Temperatura - Vibración - Estado del aceite - Características eléctricas - Presión - Flujo - Tensión y esfuerzo - Mov. y desplaz. mecánico - Estado de los componentes metalúrgicos - Sónica - pH y conductividad
M.Sc Alberto Ochoa Torres 17

METODOS DE MONITOREO

Instalación Fija : con tendido de cables centralizados en registradores o microprocesadores (Siderurgia, refinería, procesos químicos, etc.). Indicadores portátiles : Dispositivos de medición y registro.

M.Sc Alberto Ochoa Torres

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EVALUACION DEL MONITOREO

Los datos medidos y registrados deben analizarse, marcar su tendencia,interpretarse y luego deben tomarse decisiones (acciones correctivas):  Entrada de datos  Análisis de datos, muestras o valores comparativos  Conclusiones y toma de decisiones  Planificar acción correctiva

M.Sc Alberto Ochoa Torres

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ANTECEDENTES A NIVEL MUNDIAL
MANTENIMIENTO PREDICTIVO

M.Sc Alberto Ochoa Torres

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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

Most powerful tool for rotating machinery

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

17-Dic-01 24-Dic-01 31-Dic-01 15-Ene-02 22-Ene-02 6-Feb-02

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
Data Trending and Analysis

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

0.00-1.00 4.00-5.00 8.00-9.00

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1.00-2.00 5.00-6.00 9.00-10.00

2.00-3.00 6.00-7.00

3.00-4.00 7.00-8.00

Maintenance Engineering Condition Monitoring
Airborne Ultrasonic
Equipment inspected on-demand, we use as a additional analysis tool when vibration is no effective due to low rotating speed
Help to diagnose lubrication problems on bearings Program need to developed and implemented.
Brg/Unit 21 19 17 15 13 11 9 7 5 3 1 dB 15.70 FECHA 5-Feb 6-Feb dB Reengrase general Reengrase general Reengrase general Observaciones

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

Reengrase general Se regulo limpiador

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.

Maintenance Engineering Condition Monitoring - Non developed techniques
Under original Predictive Maintenance Philosophy, the following techniques should be a 100% implemented: Analytical Ferrography : Predictive Technique for oil Analysis that help to identify problem before the component is destroyed. On-Site Oil Test: It will allows 3 minutes test to analyze viscosity, ISO Cleanness and Iron Content. Special filter under warranty. Analyzer calibrated under warranty.

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.

s

Maintenance Engineering Quality Control
NDT Testing - cracks detection

Check on demand structural components using: Visual Inspection Visual Dye Penetrant Magnetic Dye Penetrant Fluorescents Dye Penetrant

Maintenance Quality Control Engineering
UT Welding or Base Material cracks detection
Check on demand structural and welding components using UT flaw detection We have dual or single probes and straight and/or angular techniques for the inspections. Also check critical section in Mill shell.

Maintenance Quality Control Engineering
UT Bolt elongation control
Check under program about 3,856 critical bolts for Mills on a six month basis. 1,288 SAG Mill Critical bolts 856 Critical Bolts by each Ball Mill (2,568) The Trommel bolts are checked on monthly basis. We keep the history of each bolt to observe loosening, retightening and decide its change.

Maintenance Quality Control Engineering
Laser Alignment
A proactive program will be implemented since May 2,002

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.

Maintenance Quality Control Engineering
Other instruments that we have for quality control:
Brinell tester (BHN) Rockwell C Tester (HRc) Thermocouple with trending software

Shore A hardness tester (for plastic, PU, HDPE)
Humidity, Dew point sensor Torque wrench calibrator for 1-3/4, 1-7/8, 2” Laser tape for dimensional verification Painting thickness measurement.

Maintenance Engineering Oil Contamination Control and Life extension
Oil dirty and water removal
This is a 1,200 gph filtration equipment designed to remove the water contamination due to its vacuum chamber and its 6 & 3 μm pre and post filter. It will allow to extend the Mills oil life when a unexpected oil contamination occurs. This year we safe 10 hours SAG mill shutdown and 60 cylinders of oil during February.

The equipment is intensively used by Pipeline and Crusher too.

Maintenance Engineering Wearing Trending and Shutdown
determination SAG & Ball Mill Liners Profiling
Trend the liner wearing pattern and advice the estimated liner change to Maintenance Planning.
We will be part of the advisory committee headed by Metallurgy for the new design of the Liner Profile for next campaigns.
200.0 161.2 (100%) 150.0
Area (in2)

145.9 (90.5%) 124.6 (77.3%) 107.3 (66.6%) 98.4 (61%)

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

Tons processed vs. Date

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

0

5000

10000 Points 5_8

15000

20000 Points 9_12 Linear (Point 1_4)

25000

-

Point 1_4 Points 13_16

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.

PROBLEMS AFFECTING OUR PERFORMANCE
Up to March, 1st 2002

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)

HOW COULD WE CONTRIBUTE TO MINE
Up to March, 1st 2002

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:

Monitor roller bearings using the airborne US technique.

UT Flaw detection
Inspect structural chassis, axles, beams for Haul trucks, shovels and drills during overhaul program.

Inspect using visible or fluorescent dye penetrant for cracks or discontinuities

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.