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Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving

Nov 11, 2014

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Tod Findlay, Asset Reliability Manager, Yancoal Technology Development delivered this presentation at the 2013 Longwall Conference.

Longwall Conference is the optimal place for the industry to come together to discuss the latest advances in the industry, swap experiences and learn from the best operators in the business.

For more information, please visit: http://www.longwallconference.com.au/2013
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Page 1: Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving
Page 2: Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving

YTD’s asset management philosophy follows the principles of the British Asset Management Standard, PAS 55.

It’s a requirement of this standard to establish, document and maintain an asset management plan for the maintenance of an asset throughout its life cycle.

The aim of this plan is to achieve the asset management strategies and deliver the asset management objectives of the business.

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Page 3: Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving

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An RCM analysis is a time consuming and costly process.

It should only be carried out on complex assets that are critical to achieving the organisation’s business objectives.

Assets of low criticality or complexity can utilise other techniques for establishing their maintenance plans.

The criticality and complexity of each asset should be determined, and an appropriate method chosen.

Due to the criticality and complexity of the NGC LTCC system, an RCM analysis was chosen as the technique to determine the most appropriate maintenance tasks.

Page 5: Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving

In an effort to determine the most suitable RCM analyst, YTD assumed a spectators role in two different service provider’s RCM sessions that they were conducting for other clients.

Both of these companies carried out the RCM analysis in accordance with the requirements of the SAE International standard, JA1011, Aug 2009

Both companies displayed different strengths and weaknesses, however YTD considered Reliability Success PTY LTD to be the most suitable fit for our business. The principal analyst and Managing Director of Reliability Success is Daryl Mather.

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The RCM analysis on the NGC, LTCC system was scheduled to take place over 3 months. This included;

RCM training for all participants

Shearer RCM

Coal clearance RCM

Shields RCM

Monorail RCM

Electrical system RCM

Pump station RCM and

Finalisation of all RCM reports

The actual process took 6 months to complete.

We underestimated the time required to complete each RCM session.

Page 7: Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving

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RCM analysis on different types of equipment should not be scheduled back to back. The RCM process is mentally draining and it is easy for the participants to lose focus. Scheduling a break between the sessions is essential.

If the RCM is on new equipment it should be carried out after conceptual design is completed, but before the detailed design is locked in. This will allow any design changes that arise from the RCM process to be incorporated into the final design of the equipment.

Page 8: Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving

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The correct mix of participants is critical to achieving a successful RCM. If people with the appropriate knowledge are not available then the RCM should be deferred until they are.

OEM product specialist

Mine electrician

Mine fitter

Mine operator

Mine process engineer

It is important that all participants in the RCM session have undertaken RCM training. This will ensure that no time is wasted during the analysis explaining

what the process is all about.

Page 9: Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving

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Nominating the functions the organisation want the asset to perform is one of the most critical parts of the preparation process for an RCM.

Identifying these functions prior to the start of the RCM session will not only save time but will also reduce the risk of missing any.

It is a good idea to have the stakeholders of the business sign off on the list of functions prior to commencing the RCM sessions.

To control all hydraulic fluid under pressure

To transmit ranging arm height to the Shearer compact

To transfer power from the CST input spline to the output spline

605 functions identified in total

Page 10: Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving

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This is “The circumstance in which the physical asset or system is expected to operate” (SAE JA1011, AUG 2009)

Identifying these prior to the start of the RCM session is essential.

Once again, have the stakeholders of the business sign off on the operating context that has been established

Ventilation

Ambient temperature

Cross grade

Material abrasiveness

Etc.

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Located away from the distractions of the mine

Facilitate easy access to additional information that might be required during the analysis

The RCM on the NGC, LTCC system was held at Peabody head office in Brisbane. A better location would have been at CAT head office in Beresfield.

YTD reviewed all delay data for the Austar LTCC system.

OEM complied a data base on all known failures of the equipment that were in service.

Facilitator compiled all available, relevant, generic failure data.

This failure data was adequate for the RCM

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The RCM analysis consist of the following steps (SAE JA1011, AUG 2009)

1. Determine the operating context and the functions the business wants the asset to perform

2. Determine how an asset can fail to fulfil these functions

3. Determine the causes of each functional failure

4. Determine what happens when each failure occurs

5. Classify the consequences of failure

6. Determine what should be performed to predict or prevent each failure

7. Determine if other failure management strategies may be more effective

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Every maintenance task that was derived from the RCM process has also had a task duration, resource requirement and Off line or On line status allocated to it to enable the total maintenance workload to be established.

1730 1730 2303 1730 2303 1730

5713 5713 6052

13011

6127 6172

Year 1 Year 2 Year 3 Year 4 Year 5 Year 6

Man Hours

NGC, LTCC system 6 Year Mechanical Maintenance Workload Map

Production workload Non Production workload

Page 26: Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving

The production and maintenance schedule for the NGC, LTCC system was manipulated so that both the required production hours and maintenance workload were achieved.

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Page 27: Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving

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The mine’s maintenance work force numbers and shift allocations were structured to achieve the identified maintenance workload within the derived production and maintenance schedule.

Maintenance crew

4 x fitters

1 x electrician

3 x miners (TA’s for fitters)

1 x maintenance supervisor.

Production crews

1 x fitter

1 x electrician

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The requirement for specialised service providers to manage specific components of the maintenance workload were also identified. Functional Safety systems proof testing

Oil and grease analysis

Wear surveys

Vibration analysis

Service contracts can be negotiated for these services with both parties having a full understanding of the specific workload.

Hastings Deering (Australia) Limited are one of the major service providers that are working closely with NGC to supply these specialised services. To date, HDAL’s commitment to achieving this component of the maintenance strategy has been excellent.

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Design requests are another output that can result from the RCM process

These can be suggested changes to the design of the equipment that can be incorporated in the final design if it is newly manufactured.

If it is not new equipment design, changes can be made during the next major overhaul.

Design changes can also include requests concerning training, procedures, etc.

Page 30: Tod Findlay, Asset Reliability Manager, Yancoal Technology Development - Reliability Centred Maintenance and Longwall Top Coal Caving

Maintenance strategy is focused on maintaining the functions of the machine the business requires it to perform. This has resulted in a reduced preventative maintenance workload by removing task that do not support the business objectives.

All areas of the maintenance strategy have factual data to back up the decisions that have been made. This means the strategy is easy to audit and review Justify maintenance hours

Justify maintenance manning

Justify Maintenance task or lack of.

On new equipment, it has enabled input into the design of the equipment that will reduce functional failures. i.e. Design out maintenance.

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