Big Data, Signos Vitales y Mantenimiento

Centrado en la Condición
Educación Profesional
Escuela de Ingeniería UC

Prof. Eduardo Carvajal

ecarvajal@gmail.com

El uso de apuntes de clases estará reservado para finalidades académicas. La reproducción total o parcial de los mismos por cualquier medio, así como su
difusión y distribución a terceras personas no está permitida, salvo con autorización del autor.
 Contenidos
Módulo 7: Caso Estudio

• Sistema Vibración en línea Palas Eléctricas

• Real Time Condition Process Implementation
 Contenidos
Módulo 7: Caso Estudio

• Sistema Vibración en línea Palas Eléctricas

 Diagnostico (Monitoreo Manual)
Detenciones de 3 equipos
semanales
Exposición del personal a equipo
en movimiento
Sistemas tecnológicos actuales no
entregan diagnostico efectivo
Exposición del mantenedor a
cambios de componentes con
fallas
Cambios de componentes con el
doble de tiempo de detención por
ser imprevistos
Aumento de trabajos sub
estandar al realizar reparaciones
imprevistas con repuestos
disponibles en el momento
4
- Utilización de hh de la línea de
mantención para realizar las
inspecciones
- Perdida de productividad por
indisponibilidad moncon
- Aumento de imprevistos
- Costos elevados por cambios de
componentes imprevistos y
emergencias
- Incumplimiento de plan matriz
144 horas de indisponibilidad al
año por moncon
Inspecciones cada 500 horas que
imposibilitan el diagnostico Just
in time
 Comparación Monitoreo Manual vs Online
Cuadro comparativo situación actual vs Moncon online
Variable en análisis Moncon actual Moncon Online

Exposición de personal a
SI NO
equipo en movimiento

Detención de equipo SI, 3 veces a la semana por 2 horas de detención NO

Requiere de HH para Solamente 1
SI, 1 técnico predictivo y 2 eléctricos
inspección técnico predictivo
Monitoreo continuo 24/7 NO SI

Diagnósticos efectivos NO SI
- Costos de reparación elevados Se espera reducir
- Costos elevados por adquisición de componente en un 60% los
Impacto por imprevisto en
de emergencia imprevistos
transmisiones
- Exposición del personal a trabajos críticos anualmente
- Altas horas de indisponibilidad
Perdida de disponibilidad
4 horas por pala 0 horas
mes
Perdida de producción anual
1.728 Kton 5 0 ton
por indisponibilidad
 Comparativo Tecnologías Existentes
Características SKF Cadetech Emerson Joyglobal

software de velocidad variable y order tracking no si si si

software de velocidad fija con opcion de order tracking si no no no

Nombre de software @ptitude Siamflex mhm Prevail

Acelerometros si si si si
Cables de conexión (alambrico) si No (inalámbricos) si si
Acelerómetros inalámbricos si si no no
Tacometros con cable si no no no
Tacometro señal encoder de Pala no si si si
conocimiento software por personal predictivo si si no no
Kit de Montaje si si si si
Sistema instalado en otras Mineras Chilenas no si si si
Servicio Técnico (antes, durante y después) si si si si
Empresas con instalaciones en otros paises no se tiene información si si si
Servicio de asesoría si si si si

Considera Instalacion de equipos monitoreo en Palas No Si Si Si

Compra de software no no 30000 no
Costo del proyecto por Pala US$ 77797 97791 120000 206000
Costo Total por Pala US$ 77797 97791 150000 206000

6
 Análisis Flujo de Caja
Proyecto Monitoreo Online
Periodo de evaluación (US$)
2017 2018 2019 2020 2021 2022
$ -
inversión inicial
97.791
$ - $ $ $ $
Flujos generados $ 24.696
97.791 24.696 24.696 24.696 24.696

$ - $ - $ - $ - $
Flujo acumulado $ 25.689
97.791 73.095 48.399 23.703 993

PayBack (años) 4,0

Ult periodo con FA negativo 3

Valor Absoluto último FA
23.703
negativo
Valor del flujo de caja del
24.696
periodo siguiente

Consideraciones para el calculo del payback:

- Inversión inicial por una pala 97.791 US$

- Rendimiento promedio de pala 7.000 (Ton/Hrs)
- Detención mensual por moncon para una pala al mes 4 horas.
- Costo fijo aproximado por traslado de mineral 0,882US$
 Análisis fallas
De las fallas ocurridas y que afectaron principalmente a la flota, se tiene que con el sistema de
monitoreo online operativo se podría haber evitado por lo menos 7 fallas catastróficas las
cuales se resumen a continuación.

Equipo Falla Fecha falla Horas de detención

PA06 Desplazamiento eje de entrada hoist 24-03-2016 107
PA08 Transmisión hoist 14-06-2016 540
PA10 Desplazamiento de eje vertical virar trasero - derecho 02-01-2016 33
PA06 Cambio transmision hoist por falla 04-04-2016 677
PA10 Cambio tambor hoist por falla 27-03-2016 85
PA06 Cambio Transmision de empuje por falla 12-11-2016 100
PA09 Cambio eje salida hoist por falla 16-09-2016 77
Total 1619

Oportunidad

Cabe destacar que considerando un rendimiento de 7000 (Ton/hr) se tendría una perdida
de producción de 11.333 Kton

8
 Sistema de Vibración Palas
Ventajas:
• Detección de fallas.
• Permite un monitoreo constante.
• Permite tener un historial del comportamiento de los componentes.
• Sin pérdida de producción (Habilitando descarga Inalámbrica)
• Datos con carga
• Mayor control sobre mala utilización del equipo. (Operador se siente
observado)

Sistemas a Monitorear
• Transmisión de Levante. (Hoist)
• Transmisión de Empuje-Recoge. (Crowd)
• Transmisión de Giro. (Swing)
 Potenciales Aplicaciones
• Desbalanceo
• Desalineamiento
• Solturas
• Deformación de carcaza
• Fallas en Transmisión por Correas
• Fallas en Rodamientos
• Fallas en Engranajes

Datos de Cálculos
engranajes

Frecuencias de
engrane

Datos de motor Velocidades de giro y

condiciones del motor

Frecuencias de
Fallas.
Datos de Búsqueda de
rodamientos información
 Sistema de Vibración Palas
Componentes del Sistema
Sistema de Vibración Palas
 Sistema de Vibración Palas

24 Sensores instalados por pala

Sistema de Vibración Palas
Arquitectura IT de Instalación
Casos de Éxito
 Contenidos
Módulo 7: Caso Estudio

• Real Time Condition Process Implementation

 CONTENTS
• Introduction
• Definition of the elements
– Technology
– People
– Processes
• Results
• Expected Benefits
• Conclusion
18
Introduction

•The development of an online predictive strategy requires to establish a series of

previous definitions for a successful implementation and obtain the expected
returns on the investment.

•For such purpose, three variables need to be considered which have elements that
require to be defined and adjusted in accordance with the reality of each company.

•Such variables are: Processes, People and Technology, which shall work as gears.

•It is important to clearly define each one of these variables and evaluate which one
of them requires further development, since each one of these elements are
fundamental for a proper implementation of an online monitoring system.

19
 Technology People Processes

Survey of
Levantamiento Red de
Data Network
Datos Data
Colector
Collector
de Competencias
Personnel Interaction with
Interaccion con
OEM Interfaces
Interfaces OEM datos del personal
Competencies otras areas
other

Technology
 Listing of OEM Interfaces

Systems available in mobile equipment.

 Data Network

It is the information highway to transmit data in real time.

 Data Collector

On board computer that can connect to diverse interfaces and also capable of processing
and extracting information in order to transmit them afterwards to Databases
(Historians).
OEM Interfaces
OEM
TYPE OF EQUIPMENT BRAND MODEL INTERFACE FUNCTIONALITY

793C
Monitoring of all equipment sensors on board (engine,
CATERPILLAR 797A VIMS
suspension, drive, braking system, etc.)
797B
DDEC Monitoring of Diesel Detroit engine
TRUCK 830E STATEX Monitoring of traction motor
PLM Monitoring of suspension system
KOMATSU
CENSE Monitoring of Diesel Cummins engine
930E TCI Monitoring of traction motor
PLM Monitoring of suspension system
LOADER LETOURNEAU L1850 DDEC Monitoring of Diesel Detroit engine
Monitoring of all shovel sensors on board.
BUCYRUS 495HR MIDAS
Direct access to control systems.
SHOVEL Monitoring of all shovel sensors on board.
P&H 4100XPB CENTURION
Direct access to control systems.
KOMATSU PC5500 CENSE Monitoring of Diesel Cummins engine
854G Monitoring of all equipment sensors on board (engine,
WHEEL DOZER CATERPILLAR VIMS
854K suspension, drive, braking system, etc.)
Monitoring of all equipment sensors on board (engine,
VIMS
TRACK DOZER CATERPILLAR D11T suspension, drive, braking system, etc.)
GUARDIAN
Less variables available
21
 Data Network
• The various systems available for data transmission must be assessed together with the IT
(Information Technology) area.

• There are several technologies available in the marketplace, such as:

• Wi-Fi systems (Masterlink is a network available for systems with Dispatch)

• Wi-Max systems (for larger coverage areas)
• MESH systems

• The systems allow the construction of communication networks between pieces of

equipment and provide large coverage and robustness to the communications network.

• CMDIC uses two networks, a Wi-Max network (with Alvarion equipment) which provides
a good base for information transmission and Masterlink network.
Data Collector
In order to be able to retrieve information from the equipment it is necessary to have
computers on board that are capable of connecting to the various interfaces and also be able to
process and retrieve the information in order for them to be transmitted later to the data bases
(Historians).

OEM REMOTE
BRAND OEM INTERFACE
MONITORING SYSTEM
VIMS
Minestar
CATERPILLAR VIMS GUARDIAN
ET Product Link
KOMATSU VHMS KOMTRAX
CUMMINS CENSE RF Modem
BUCYRUS ROCKY MIDAS
P&H CENTURION Prevail
Layers of Real Time Monitoring : Scheme of Integration
of elements

Predictive Models / Advanced Process Control Pilot: Matrikon

Reports / SMS / e-mail To be defined

Integration of Information To be defined

Application Servers / Data Bases

Communication / Data Networks WiMAX: Alvarion

Current: Minecare, Prevail, Midas

Data Collectors / DCS Pilot: Matrikon

PLC / ECM / Sensor VIMS – PLM – CENSE –

TCI – DDEC – MIDAS –
CENTURION

24
People

 System Administrator
Responsible for the configuration and continuous development of the system.
 Specialty Engineer
In charge of validating the collected information and certifies its reliability.
He develops the rules and conditions of the monitoring to be set up in the
system.
 Predictive Technicians
Control of reportability of the systems on a daily basis and issue work orders in
accordance with the alarms and predictive models that reside in the platform.
 Processes
What will be subject to a real time condition monitoring?

It must be considered that real time monitoring requires a significant effort to maintain the perfect
operation of the systems, which translates into significant investments (Capital Cost) and monthly fixed
costs for maintenance
(Operating Cost). That is why we must be aware of the fact that what is going to be monitored in real
time must be the outcome of a process of analysis of failure modes and the evaluation of the operating
risk impact that such failures may have. For that purpose, there are documented techniques to carry
out this process, where RCM (Reliability Centred Maintenance) is one of the most well-known.
Definition
Definici ónof
dea Definition of
predictive monitoring Definici ón de
technology and
estrategia de
strategy tecnolog ía y equipos
Predictive monitoreo predictivo equipment

Development
Desarrollo of the
de la Estrategia Reactive and Preventive Deployment
Despliegue of
de the
la
Maintenance Strategy
de Mantenimiento maintenance
Estrategia de
(Identificaci
(Identification
ón deofmodos
failure de
modes
falla y strategy
and maintenance
estrategia strategy)
de mantenci ón)
Mantenimiento

Proactivo
Proactive
Continuous
Mejoramiento
Improvement
Continuo
(Removal of repetitive
(Eliminacion de fallas
failures ororedesign)
repetitivas rediseño)
 How will the maintenance areas interact with the information of real time monitoring?

It is required to establish a list of the current processes of mine maintenance and determine the
points where the
information from the real time monitoring systems is an actual contribution for maintenance
management.
Línea
Operative
Operativa
Line
Atencion
Site Camión
Lube
Terreno
Servicing Lubricador
Truck

Coordinación Coordination
Maintenance Mantención

Planificación
Planning Condición Equipos
Equipment Condition Confiabilidad
Reliability

Operaciones
Operations

Maintenance Coordination: Validation of information provided by operations and provides support for
prioritizing equipment servicing.

Planning: It is fundamental when prioritizing service and generating more effective plans.

Reliability: It contributes towards reliability analysis and failure analysis of the equipment.

Operations: It supports the monitoring of the Operating Practices and serves as the base to develop ODR (reliability- centred operator).
Minecare Application

The diesel engine models analyzed in this case study were the Caterpillar (CAT) 3516 and CAT 3524. The primary
metric used to predict engine failure was the exhaust temperature delta per cylinder bank, and data was collected only
while the engine was under maximum load. Eight cylinder banks were monitored on the CAT 3516, while four banks
were monitored on the CAT 3524 (two coupled V-12 engines).
Exhaust temperature data was collected only while the engine was under maximum load, forming the following trend
constraints:

Delta = +/-50 ° C between pairs of banks (Right -Left)

Operating Conditions

• Engine Load greater than 95%

• Engine Speed greater than 1700 RPM
• Payload greater than 300 tons for CAT 797 and 200 tons for CAT 793
Matrikom Application - FLEET OVERVIEW
Matrikom Application

Shovel Overview

Truck Overview
Matrikom Application

Matrikon monitoring graphics – Monitoring of exhaust temperatures for Cummins QSK78 engine
Benefits

• Impact maintenance management KPI’s that aim at enhancing safety of both

people and equipment.
• Reduce unit costs ($/hr - $/ton).
• Impact the reliability of the equipment by reducing unforeseen and
catastrophic failures in order to increase the equipment MTBF.
• As a result, an impact is made directly on equipment performance and the
expected availability on a consistent and sustainable form in time is achieved.
Benefits

Benefits

Safety
Unit Costs(USD$)
Reliability
Availability

Increased Useful Life Reduced Catastrophic

Safety
for Components Failures

•Analysis of major •Increased availability •Diminished people exposure

component conditions
•Increased MTBF
•Estimation of effective useful life •Control of equipmentcondition
•Reduced unit costs
(PF curve)
•Less Man-hrs for interventions •Planned works
•Optimum use of resources
 Conclusion
•Real time monitoring is a predictive tool that is fundamental for monitoring the
conditions of the equipment.

•The success of the implementation depends on technological variables, a clear

definition of processes and training of personnel.

•This type of strategies certainly contribute towards future challenges of the mining
industry, since it will be increasingly harder to find qualified personnel to control the
conditions of increasingly complex equipment used in the mining industry.

•The industry trend is moving towards the implementation of centralized monitoring

centres, thus, generating synergies between suppliers and mining companies to
control the condition of equipment.

•For that purpose, it will rely on remote assistance for diagnosis and troubleshooting
while connecting directly to the headquarters of the suppliers and/or mining
companies. 34
 Big Data, Signos Vitales y Mantenimiento
Centrado en la Condición
Educación Profesional
Escuela de Ingeniería UC

Prof. Eduardo Carvajal

ecarvajal@gmail.com

El uso de apuntes de clases estará reservado para finalidades académicas. La reproducción total o parcial de los mismos por cualquier medio, así como su
difusión y distribución a terceras personas no está permitida, salvo con autorización del autor.