innovative maintenance systems and practice on longwalls

Innovative Maintenance Systems and Practice on Longwalls

Robert Langford – Engineering Manager

Longwall 201222nd & 23rd August 2012

Just because you have a big one

You won’t impress anyone if you

can’t keep it up



• Designing our longwall equipment better.

• Development of a maintenance program for new

equipment.

• Appropriate mine maintenance strategy.

• Condition monitoring

• Innovations in maintenance practice applicable to

longwalls.

Optimising Condition Monitoring 20th & 21st August 2012

0

20

40

60

80

100

1 2

Reactive Maintenance

Preventive Maintenance (FTM)

Predictive Maintenance

Proactive MaintenanceTypical Maintenance

Benchmark Maintenance

Mai

nte

nan

ce P

ract

ices

Per

cen

tage

Source -Ron Moore

Planning & Scheduling

Root Cause Defect Elimination

Maint Strategy Implementation


Administrative Controls


PPE


Bad Design


Improved Engineering• Fit for purpose.

• Learn from our mistakes.

• Improved communication between OEM’s and

miners.

• Continuous improvement.

• Appropriate use of technology.


Maintenance program for new equipment


Mine Maintenance Strategy

• OTF, Operate to Failure

• FTM, Fixed Time Maintenance

• CBM, Condition Based Maintenance

• DO, Design Out

Understanding Failure Mode(s)• Describe the Failure Mode

– What causes the component to no longer perform the function for which it was intended

– Describe modes that are reasonably likely

– “What Fails due to Why”

• Is the Failure Characteristic Understood ?

– Infant Mortality

– Random Failures

– Wear Out

• Is there a history of failures ?

– On site with this component, or

– Same equipment at other sites, or

– Similar equipment else where.

D

E

C

Failure Characteristic

A

B

F



Maintenance tasks:Valid

Failure Mode ?

Park Tasks without Valid Failure Modes.

Record as“No Scheduled Maintenance”

No

List & Describe Failure Mode(s)

Identify & Analyse Consequences of

Failure Mode

Determine the Acceptable Limits

(Share Best Practice)

Identify Corrective Action

Yes

Determine Appropriate Maintenance Policy

Group Tasks By:• Frequency• Trade Type• Physical Location

Generate New Checksheets

ReviewComponents to ensure all likely Failure Modes

have been included

Condition Monitoring



Condition MonitoringWe need to:

• understand the failure we trying to predict

• identify a strategy that is appropriate to the failure mode

• identify a reliable indicator

• action & our review results

• understand that CM doesn't work for all failure modes or circumstance

PF Interval

Conditio

n o

f th

e ite

m

100%

Time in service

Moment of first damage

Moment of 1stpossible detection

Failed

*

*

*

F

P

PF interval

inspection

inspection

Having some knowledge of the PF interval helps make a sensibledecision about the Condition MonitoringInspection frequency. Suggestion:Inspection Frequency = ½ PF interval


When is it wrong to use CM

• When it doesn't tell you anything useful

• When you don’t understand the results

• When you don’t tell the person doing or interpreting the results about changes

• When it adds to the cost of the operation for no operational improvement

• When it you don’t use the results



Innovative Maintenance Methods or Practices

• Thermography

• Audio

• Hydraulic return flow monitoring

• On line refractometry

• Reticulated lubrication oil systems


Innovative Maintenance Methods or Practices

• Maintenance Management Practices

• Education of the Workforce

• Partnering with OME’s

• Intelligent use of Contract Partners

Innovative Maintenance Systems and Practice on Longwalls

Robert Langford – Engineering Manager


innovative maintenance systems and practice on longwalls

Technology

innovative maintenance systems

failure modes

results

practice

equipment

dont

component