The use of cutting-edge technology underpins the future of smart mining. However, it doesn’t matter how great equipment is; without good maintenance, running an efficient and profitable operation is impossible.
Every maintenance professional is all too familiar with the headache of unexpected asset failure and extended downtime. If only it were possible to continually monitor equipment performance and be alerted to any extraordinary vibrations, temperatures or out-of-parameter processes.
Enter smart monitoring sensors (smart meters), an easy-to-install gadget that does just that.
But before talking about the solution, let’s explore the problem in a little more detail.
Mining maintenance challenges
Whether discussing rotating equipment or pumps, the same forces are at work to cause damage, reduce efficiency and eventually lead to asset failure.
These forces are:
- Vibrations
- Processing heat
- Environmental heat
- Processing pressures
- Aggressive agents
All these challenges mean that maintenance teams are fighting a constant battle to monitor the effect of these forces, fix problems as they arise, and schedule maintenance tasks to extend asset longevity.
This tends to be carried out in one of three ways:
- Preventative – repairs and maintenance are carried out at predetermined intervals. These are decided by how long the equipment is expected to last between each care interval. The issue is that it doesn’t consider any of the above anomalies. Instead, it’s usually defined by the manufacturer’s guidelines and pre-purchase testing. However, every mining situation is different, meaning that this type of maintenance relies on data from external forces that could be completely different from what’s happening in real time
- Reactive – work is carried out when equipment fails. The biggest disadvantage of this is extended and unexpected downtime. Not only can this prove expensive, but it’s also an extremely unsafe practice
- Predictive – by far the best method, predictive maintenance means using historical data to determine the mean time before the failure of an asset. Work can then be pre-planned to allow for the best equipment longevity, therefore reducing costs and increasing safety
It’s quite obvious that predictive maintenance is by far the premium option. However, the sticking point is gathering the accurate data that allows for this. While a smart meter is not a silver bullet solution that will remove all the issues with plant maintenance, it is a viable tool that can overcome many of these challenges.
What is a smart meter and why does every mine need them?
A smart meter or sensor is a gadget fitted to various assets to monitor their performance. They collect this information 24/7, providing data about vibrations, temperatures, and pressures and sending alerts should an event exceed any predetermined levels.
These sensors work via Bluetooth, constantly monitoring and providing maintenance managers with the data necessary to accurately predict when and where care and repair occur.
Such knowledge means that:
- Asset shutdowns can be accurately pre-planned for multiple maintenance tasks to take place at the same time
- Maintenance managers are alerted to the early signs of equipment wear and tear, dramatically reducing the chances of unexpected failure
- Understanding equipment inefficiencies that equal increased power and/or water requirements (and, therefore, costs)
- Providing employees with safer working conditions.
Smart meters and sensors, such as Chesterton Connect, can be fitted to new equipment or retrofitted to those already used. Understanding equipment operation is the key to truly predictive maintenance and all the benefits this brings.
Reliability, cost savings and public perception are keys to profitability and shareholder confidence. While smart meters won’t solve all mining maintenance woes, their use helps remove many of the traditional issues.
Smart mining is the way forward – and smart meters are definitely going to play their part as the industry drives away from outdated maintenance methods and embraces the power of prediction.
The best solutions often come in the simplest packages. Chesterton Connect is one of those – a smart device that provides highly valuable data that can significantly impact the profitability and safety of a mining operation. And that’s the real reason that every mine needs to take advantage. Because if yours doesn’t, you can be sure your competitors are.
Chesterton can provide bespoke solutions to overcome many of your plant operation challenges. To explore these efficiency and money-saving options, contact one of our experts today, or for more information, go to chestertoncustomseal.com.au to know our range of Chesterton and Chesterton Customseal solutions.
This sponsored editorial is brought to you by Chesterton.
