{"id":5291,"date":"2024-10-16T11:52:16","date_gmt":"2024-10-16T09:52:16","guid":{"rendered":"https:\/\/www.yellotec.co.za.dedi2118.jnb1.host-h.net\/usd-1000000-savings-on-a-primary-crusher\/"},"modified":"2024-10-16T11:52:16","modified_gmt":"2024-10-16T09:52:16","slug":"usd-1000000-savings-on-a-primary-crusher","status":"publish","type":"post","link":"https:\/\/staging.yellotec.co.za\/?p=5291","title":{"rendered":"USD$ 1,000,000 savings on a primary crusher"},"content":{"rendered":"\n
\"Atten2<\/figure>\n\n\n\n

<\/p>\n\n\n\n

Optimizing Lubrication Management with Advanced Predictive Maintenance.<\/h2>\n\n\n\n

Previously, traditional predictive maintenance tools failed to detect early bushing damage in a primary crusher, resulting in a catastrophic $1,000,000 failure. To enhance their lubrication management, the customer integrated Atten[2]\u2019s OilWear S sensors<\/strong> after a thorough assessment of predictive maintenance technologies.<\/p>\n\n\n\n

Before this, lubrication cycles took over a week, requiring sampling, lab analysis, and decision-making. With the new sensors, real-time monitoring now streamlines maintenance, reduces downtime, and improves equipment health.<\/p>\n\n\n\n


Download Case Study
<\/a>
\"PrimaryCrusherCaseStudyDownload\"<\/p>\n\n\n\n

CHALLENGES:<\/h5>\n\n\n\n
    \n

  • Short time interval from start of damage to catastrophic machine failure<\/p><\/li>\n\n\n\n

  • Damage difficult to detect with conventional monitoring technology<\/p><\/li>\n\n\n\n

  • Possible mistakes during oil sampling<\/p><\/li>\n\n\n\n

  • Long response time of the lab<\/p><\/li>\n<\/ul>\n\n\n\n

    SOLUTION:<\/h5>\n\n\n\n

    Given this customer\u2019s needs, Atten[2] recommended the installation of OilWear S sensors. The ISO code display and real-time particle shape classification enabled quick decision-making:<\/p>\n\n\n\n

      \n
    •  The lubrication management cycle went from one week to one or two days, reducing risks in sampling, reducing lab and labour costs, and thus increasing machine lifetime.<\/li>\n\n\n\n
    • The sensors also optimized asset management and prevented a catastrophic failure that would have shut down the mine production. <\/li>\n<\/ul>\n\n\n\n
      SEQUENCE OF FAULT DETECTION<\/h5>\n\n\n\n
      \"Screenshot<\/figure>\n\n\n\n

      <\/p>\n\n\n\n

      May 20th, 2021<\/strong><\/p>\n\n\n\n

      \u201cBaseline\u201d of primary crusher operation was set to an ISO code 22\/20\/19, as seen in the box, the average data before the failure began.<\/p>\n\n\n\n

      \"Screenshot<\/figure>\n\n\n\n

      <\/p>\n\n\n\n

      May 22nd, 2021<\/strong><\/p>\n\n\n\n

      At the precise moment when the values showed a notable deviation, increasing beyond the normal ISO code (24\/23\/21), an increase in sliding wear was detected.<\/p>\n\n\n\n

      Armed with this information and mindful of the previous catastrophic bushing failure, the operator conducted on-site inspections, leading to the discovery of a fault in one of the bushing.<\/p>\n\n\n\n

      * Note: The increase in fatigue wear (natural wear) is not in itself an abnormality that requires attention!<\/p>\n\n\n\n

      \"Screenshot<\/figure>\n\n\n\n

      <\/p>\n\n\n\n

      May 23th, 2021<\/strong><\/p>\n\n\n\n

      The graph shows a sustained upward trend in the ISO code (25\/24\/22). Similarly, the classification of particulate matter indicates a continuous increase in cutting and sliding particles.<\/p>\n\n\n\n

      To stabilize the crusher\u2019s performance, several corrective actions were implemented, including partial lubricant changes, enhanced lubrication practices (such as lifting and balancing the bushing with additional oil supply), reducing the machine\u2019s operating speed, and maintaining frequent filter replacements.<\/p>\n\n\n\n

      \"Screenshot<\/figure>\n\n\n\n

      <\/p>\n\n\n\n

      June 06th, 2021<\/strong><\/p>\n\n\n\n

      Thanks to continuous monitoring, an issue with a bushing was detected, associated with the presence of cutting and sliding particles deviating from normal operating parameters. Without Atten[2]\u2019s imaging technology and shape analysis, detecting this damage in time would have been impossible or very difficult. The ability to provide reliable measurement results even with high oil viscosity and strong bubble formation in lower ISO classes, compared to con-ventional particle counters, is another key advantage that enables early damage detection under harsh conditions as given here with this particular crusher.<\/p>\n\n\n\n

      Prompt actions were taken to rectify the situation, allowing production to proceed as planned. On June 6th, 2021, corrective measures were implemented during the scheduled plant shutdown, replacing the bushing. After the crusher\u2019s startup process, it returned to its established \u2018normal line\u2019 of operation, indicated by the ISO code (22\/20\/19). During the monitoring period, a bell-shaped curve in fatigue particles was noted, a typical phenomenon linked to the machine\u2019s startup phase.<\/p>\n\n\n\n

      CUSTOMER \u0301S BENEFITS<\/h5>\n\n\n\n

      An unexpected failure in this type of machine significantly impacts the mine\u2019s operation, leading to substantial production losses. Atten2 technology played a crucial role in early fault diagnosis, allowing timely decisions and actions to prevent a catastrophic breakdown. This proactive approach not only extended the machine\u2019s lifespan until the next planned shutdown but also helped the mine avoid potential failure-related costs amounting to USD$1,000,000<\/strong>.<\/p>\n\n\n\n

      \"Screenshot<\/figure>\n\n\n\n
      \"Screenshot<\/figure>\n\n\n\n


      <\/p>\n\n\n\n

      This same event occurred years ago at the primary crusher, resulting in the customer reporting losses and expenses of approximately one million dollars. This includes direct costs of production hours and expenses associated with the shutdown.<\/p>\n\n\n\n

      <\/p>\n","protected":false},"excerpt":{"rendered":"

      Optimizing Lubrication Management with Advanced Predictive Maintenance. Previously, traditional predictive maintenance tools failed to detect early bushing damage in a primary crusher, resulting in a catastrophic $1,000,000 failure. To enhance their lubrication management, the customer integrated Atten[2]\u2019s OilWear S sensors after a thorough assessment of predictive maintenance technologies. Before this, lubrication cycles took over a […]<\/p>\n","protected":false},"author":3,"featured_media":6294,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[3],"tags":[40],"class_list":["post-5291","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-case-studies","tag-oil-analysis"],"_links":{"self":[{"href":"https:\/\/staging.yellotec.co.za\/index.php?rest_route=\/wp\/v2\/posts\/5291","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/staging.yellotec.co.za\/index.php?rest_route=\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/staging.yellotec.co.za\/index.php?rest_route=\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/staging.yellotec.co.za\/index.php?rest_route=\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"https:\/\/staging.yellotec.co.za\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=5291"}],"version-history":[{"count":0,"href":"https:\/\/staging.yellotec.co.za\/index.php?rest_route=\/wp\/v2\/posts\/5291\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/staging.yellotec.co.za\/index.php?rest_route=\/"}],"wp:attachment":[{"href":"https:\/\/staging.yellotec.co.za\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=5291"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/staging.yellotec.co.za\/index.php?rest_route=%2Fwp%2Fv2%2Fcategories&post=5291"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/staging.yellotec.co.za\/index.php?rest_route=%2Fwp%2Fv2%2Ftags&post=5291"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}