IMEC 2011 Final Clientes

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1. Optimizing mining hoist maintenance decisions through blending oil analysis and hazard modelling Miguel Snchez Ca. Minera Doa Ins de Collahuasi, Chile Pedro Cancino, Dictuc Tribologia, Chile 2. Introduction This presentation discusses work carried out at Minera Collahuasi to improve the existing oil analysis program currently undertaken for hoist systems. Current practice for monitoring the health of equipment is by examining trends in readings obtained from condition monitoring. Such an approach does not guarantee that the full information-value contained in the readings is captured. 3. Methodology This paper reports a new approach that uses a statistical procedure, proportional-hazards modeling (PHM) to identify the key measurements that should be used to assess the true state of health of equipment. 4. Data Availability Within the mines computer maintenance management system (CMMS) from MINCOM ELLIPSE there are histories of hoist lifetimes. Costs associated with failure and preventive removals were also available. Oil analysis results from a fleet of 9 shovels were analyzed along with their respective failures and repairs over a six year period. 5. Life Cycle of a Component 6. Age Effect Life Cycle of a Component 7. Current Practice Normal 25 Cr Cu Fe Si Age Effect 8. Summary: Principle of CBM Optimization Age Data Condition- Monitoring Data Supplied by user Software engine Intermediate result Final result Maintenance Decision Hazard Model Transition Model Cost and Availability Model Remaining Useful Life Engineering Judgment 9. 1 1 1 ... ( ) n nz t z tt HAZARD t e Hazard Model Failures/op.hour Failures/km. Failures/cycle Failures/tonne Etc Contribution of age to hazard Contribution of condition information to hazard 10. Combined Data From All Histories / Data Cleaning Equipment System Interventions / Histories Installation Date Actual Component Life / Hours OEM Recomended Life / Hours Type of Events SH01 Hoist Middle Shaft Hoist Gear 09-may-00 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 14-abr-02 14.221,6 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 15-abr-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 04-nov-02 3.390,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 05-nov-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 6.086,9 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 48.578,3 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 15-jul-07 25.938,2 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 16-jul-07 0,0 30.000 B SH01 Hoist Oil Change 15-oct-09 12.691,0 OC SH01 Hoist Oil Change 22-nov-09 912,0 OC SH01 Hoist Oil Change 13-oct-10 7.800,0 OC SH01 Hoist Middle Shaft Hoist Gear 03-dic-09 13.402,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 04-dic-09 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 2.639,7 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 41.979,9 30.000 EF 11. Combined Data From All Histories / Data Cleaning Equipment System Interventions / Histories Installation Date Actual Component Life / Hours OEM Recomended Life / Hours Type of Events SH01 Hoist Middle Shaft Hoist Gear 09-may-00 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 14-abr-02 14.221,6 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 15-abr-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 04-nov-02 3.390,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 05-nov-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 6.086,9 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 48.578,3 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 15-jul-07 25.938,2 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 16-jul-07 0,0 30.000 B SH01 Hoist Oil Change 15-oct-09 12.691,0 OC SH01 Hoist Oil Change 22-nov-09 912,0 OC SH01 Hoist Oil Change 13-oct-10 7.800,0 OC SH01 Hoist Middle Shaft Hoist Gear 03-dic-09 13.402,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 04-dic-09 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 2.639,7 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 41.979,9 30.000 EF 12. Combined Data From All Histories / Data Cleaning Equipment System Interventions / Histories Installation Date Actual Component Life / Hours EOM Recomended Life / Hours Type of Events SH01 Hoist Middle Shaft Hoist Gear 09-may-00 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 14-abr-02 14.221,6 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 15-abr-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 04-nov-02 3.390,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 05-nov-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 6.086,9 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 48.578,3 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 15-jul-07 25.938,2 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 16-jul-07 0,0 30.000 B SH01 Hoist Oil Change 15-oct-09 12.691,0 OC SH01 Hoist Oil Change 22-nov-09 912,0 OC SH01 Hoist Oil Change 13-oct-10 7.800,0 OC SH01 Hoist Middle Shaft Hoist Gear 03-dic-09 13.402,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 04-dic-09 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 2.639,7 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 41.979,9 30.000 EF 13. Equipment System Interventions / Histories Installation Date Actual Component Life / Hours OEM Recomended Life / Hours Type of Events SH01 Hoist Middle Shaft Hoist Gear 09-may-00 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 14-abr-02 14.221,6 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 15-abr-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 04-nov-02 3.390,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 05-nov-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 6.086,9 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 48.578,3 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 15-jul-07 25.938,2 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 16-jul-07 0,0 30.000 B SH01 Hoist Oil Change 15-oct-09 12.691,0 OC SH01 Hoist Oil Change 22-nov-09 912,0 OC SH01 Hoist Oil Change 13-oct-10 7.800,0 OC SH01 Hoist Middle Shaft Hoist Gear 03-dic-09 13.402,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 04-dic-09 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 2.639,7 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 41.979,9 30.000 EF Combined Data From All Histories / Data Cleaning 14. Equipment System Interventions / Histories Installation Date Actual Component Life / Hours OEM Recomended Life / Hours Type of Events SH01 Hoist Middle Shaft Hoist Gear 09-may-00 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 14-abr-02 14.221,6 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 15-abr-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 04-nov-02 3.390,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 05-nov-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 6.086,9 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 48.578,3 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 15-jul-07 25.938,2 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 16-jul-07 0,0 30.000 B SH01 Hoist Oil Change 11-sep-09 12.691,0 OC SH01 Hoist Oil Change 15-oct-09 912,0 OC SH01 Hoist Oil Change 13-nov-09 7.800,0 OC SH01 Hoist Middle Shaft Hoist Gear 03-dic-09 13.402,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 04-dic-09 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 2.639,7 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 41.979,9 30.000 EF Combined Data From All Histories / Data Cleaning 15. Combined Data From All Histories / Data Cleaning Equipment System Interventions / Histories Installation Date Actual Component Life / Hours OEM Recomended Life / Hours Type of Events SH01 Hoist Middle Shaft Hoist Gear 09-may-00 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 14-abr-02 14.221,6 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 15-abr-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 04-nov-02 3.390,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 05-nov-02 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 6.086,9 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 30-oct-03 48.578,3 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 31-oct-03 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 15-jul-07 25.938,2 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 16-jul-07 0,0 30.000 B SH01 Hoist Oil Change 15-oct-09 12.691,0 OC SH01 Hoist Oil Change 22-nov-09 912,0 OC SH01 Hoist Oil Change 13-oct-10 7.800,0 OC SH01 Hoist Middle Shaft Hoist Gear 03-dic-09 13.402,0 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 04-dic-09 0,0 30.000 B SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 2.639,7 30.000 EF SH01 Hoist Middle Shaft Hoist Gear 01-ene-11 41.979,9 30.000 EF 16. Age Effect 17. How does data model hazard? significant covariates. EQUIPMENT FAILURE Age Effect Sample History History consists of: Beginning time Inspection results Ending time and reason 18. Combined data from all histories. 19. PHM Model for MSHG 20. Optimal Hazard Level Cp = Total cost of preventive replacement Cf = Total cost of failure replacement Cp = cost of manpower + cost of a new gear US$ 0.25 M Cf = cost of manpower + cost of a new gear + opportunity cost US$ 2.3 M 21. Decision Graph for MSHG of PA04 Z__00 = - 0.00997583*Iron + 0.14597734*Magnesium + 0.01593247*Molybdenum + 0.59406619*Nickel - 0.04483219*Sodium + 0.01527817*Zinc at 29582 hours or at 29788 hours. 22. Conclusion The case study demonstrates the value of using the PHM tech