Fluid contamination is a leading cause of slower performance, erratic operation, lost productivity, higher operating costs and catastrophic failure of Machines. This video, “Fluid contamination – The Silent Thief,” details the importance of following strict procedures and guidelines to keep your engines and components clean so you can maximise machine productivity and component life.
Mobile mining equipment hydraulic systems are typically exposed to very high solid particle ingression rates. A mine was experiencing premature component failure on its excavator due to high particle contamination. In the first 27 months of operation, costs included four variable speed piston pump replacements ($20,000 per exchange, $34,000 new), three swing motor replacements, two drive motor replacements, numerous servovalve repairs or replacements, 42 hydraulic hose-related problems, and 16 instances of contamination sensors requiring cleaning. The oil was highly contaminated, yielding excess oxidation after 2,255 service hours and needed to be replaced. Other associated costs included excessive unplanned equipment downtime, more than 39 hours, and unplanned maintenance costs.
The machine was not operating reliably and was approaching the end of the warranty period. The goal was to eliminate premature pump and servovalve failures, minimize costly component repairs or replacements, and increase the overall productivity of the operation. The shovel is the critical piece of equipment in the mining process. When the shovel is down, several haul trucks are also down and no coal is being produced.READ MORE
You Just Found Yours
Revolutionise the Way you Think about Oil
All Lubricants are the same right? Just select the the cheapest oil of the right viscosity grade and the rest is history. Right…? Wrong!
Not all lubricants are created equal. I am a great fan of Synthetic Lubricants. They are well worth their salt, as the savings that they produce go way beyond the cost of the lubricant. However there is more to a lubricant than just it’s Base Oil.
Some lubricant blenders such as Revolution Oil have taken it further by sourcing cutting edge additive technology, which is unmatched in today’s market, giving lubricants a film strength 4 times greater than any other on the market and an extended oil life factor of at least 2 and in some case 24 times. Among these benefits are a raft of others.READ MORE
Injector failures is something that is not always monitored. We have a failure, decide whether it is a warranty case or not and book it to the breakdown cost subjected to the machine. However, there is a hidden cost compiling from each machine’s injection system that is not measured. Every machine has a specific load it can carry and it has to carry that load at a specific time interval over a distance. If the machine has a loss of engine performance, it effects the production capability of the machine and therefore a loss in production over time. We therefore have to cases, a ‘catastrophic’ failure of the injection system and the functional failure of the injection system.
With the ‘functional’ failure the injection system can no longer operate at its designed specifications. This causes a loss of engine performance, higher fuel consumption and an irregular spray pattern which can ultimately lead to breakdown.
I obtained my bachelor’s degree in education at North West University in 2008. After five years of teaching experience I made a career change into the mining sector as a contractor. For two years I dealt with foreman, engineers and condition monitors within the mining industry. As a salesman I constantly had to think out of the box to find specific solutions to problematic issues my clients encountered and through this I gained a lot of experience on different applications. During this time I found that the greatest machine failures within the market were caused by surface degradation enhanced by contaminants and dirt ingress. This is where my passion for efficient contamination control systems grew stronger as I found that there is a need within our market for these type of systems.READ MORE
AGA Siguiri mine is a multiple open-pit oxide gold mine in the relatively remote district of Siguiri, around 850km northeast of the country’s capital, Conakry. The area has significant potential for gold mining and has long been an area of traditional artisanal mining. The gold processing plant treats about 30,000t daily.
AGA Siguiri mine holds an 85% interest in Siguiri, with the remaining 15% held in trust for the nation by the Government of Guinea. Headquartered in Johannesburg, South Africa, AngloGold Ashanti has 20 gold mining operations in 10 countries, as well as several exploration programs in both the established and new gold producing regions of the world.
Goedgevonden is situated 7km south of Ogies, a small town to the west of Emalahleni (formerly Witbank) in Mpumalanga.A trial mini pit was started at Goedgevonden in May 2003, and since then has been producing at a rate of 1,200,000 tonnes per annum run of mine (ROM) coal by contractors.
The Filtration of bulk diesel supply on Sishen Mine has been on ongoing quest for many years. Clean diesel is crucial on this mega-mine, not only to keep the operation running but also to prolong the lifespan of the multi-million rand equipment.
The bulk of Kumba’s iron ore production comes from Sishen mine, located in South Africa’s Northern Cape Province near the mining town of Kathu. Opened in 1947, Sishen mine is Kumba’s flagship operation and one of the largest open-pit mines in the world. It operates 24/7 and in 2013 produced 30,9 million tonnes (Mtpa) of iron ore.
FloSolve proudly installed the PALL filtration system on the Tellus 68 Hydraulic oil tank at Anglo Thermal Coal Greenside Colliery during October 2013. This installation was prompted as a result of the corrosive effect that the had on their mobile machines working underground.
The goal was extending the lifespan of the hydraulic components on the machines and the solution was to exceed the Anglo Ashanti ISO4406 standard of 13/10 cleanliness level.
The diesel at Anglo Thermal Coal Isibonelo Colliery was tested after a single pass through the PALL 619 20″ filtration systems and the results were impressive. Upstream of the filters a cleanliness level of 15/11 was recorded. Downstream of the filter after a single pass the cleanliness level achieved was 9/8.
BHP Billiton’s Hotazel Manganese Mines (HMM) Mamatwan is located in the Kalahari Basin in the Northern Cape Province and produces manganese ores and integrated ferroalloys. HMM is one of the largest single producers of manganese ore in the world.
Manganese is an indispensable element in the manufacturing of steel, which in turn is an essential material in many industries including construction and transportation. Its use in the steel making process results in increased strength, resistance and machinability.