OPTIMISING PM INTERVALS PAUL KRANS: PHU BIA MINING. Balikpapan 16 th October 2018/Bangkok 18-19 th October 2018
OPTIMISING PM INTERVALSPAUL KRANS: PHU BIA MINING.
Balikpapan 16th October 2018/Bangkok 18-19th October 2018
Preventative maintenance optimisation
Reviewing oil analysis data to fine tune
preventative maintenance intervals
Why optimise preventative maintenance?
More Less
Risk versus reward equation
Risk
Reward
It is all about finding the balance point
The oil analysis evolution
Monitor equipment
health
Look for unfavourable
conditions
Study wear metals that are
being generated
Look for trends
Optimise preventative maintenance
practices
Preventative maintenance intervals
Most equipment owners will adhere to the OEM recommendation
Caterpillar state the regular oil sampling should be used to optimise oil drain intervals for a given piece of equipment
Can we extend, or should we reduce preventative maintenance intervals?
What is ideal?
A cold, 3,500 metre altitude mine site
Tribology staff working with the LIMS
A condition report from our own laboratory
The Phu Kham 777D fleet
Iron, chrome and lead soot and TBN were studied for the engines
Iron, copper and lead and particle sizes (6µ and 14µ size) for:
• steering fluid
• Transmission
• Diff and final drives
• Front wheel bearings
We chose the following criteria to analyse
Iron ppm versus hours
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
0 100 200 300 400 500 600 700 800
Fe (
Iro
n)
PP
M
Hours on oil
TBN versus hours
4.00
5.00
6.00
7.00
8.00
9.00
10.00
11.00
0 100 200 300 400 500 600 700 800
TB
N (
alk
ylin
ity)
Hours on oil
ISO particle count versus hours
12
14
16
18
20
22
24
26
0 500 1000 1500 2000 2500
6 M
icro
n I
SO
co
un
t
Hours on oil
Maintenance cost savings
• Extended the hydraulic and steering oil drain
intervals to 4,800 hours
• Routine preventative maintenance costs reduced by
more than US$300,000 for the fleet
• 27.8 hours increased availability valued close to
US$800,000 annually
• The total cost saving of more than US$1 million was
realised
• Optimising preventative maintenance and other
initiatives saw the availability of the 777D fleet
increase from 91.65 to 95.45 per cent the following
year
Questions?