Maintenance Management & Equipment

ESCO has wear parts service and installation experts working in key mining hubs in Brazil, Australia, the US and elsewhereESCO has wear parts service and installation experts working in key mining hubs in Brazil, Australia, the US and elsewhere

More so than initial sales of new equipment, which has a higher profile, the aftermarket in mines that focuses on delivering uptime is where the real long term benefits are realised, whether that be in the mill or in the mine itself. Trends include more comprehensive service agreements covering whole minesites; more sharing of machine monitoring data; and the use of more high-tech materials and solutions in key components to minimise service intervals. Fuel supply and delivery is a part of this, but is covered in another dedicated article in the November issue of International Mining.

Mine-site agreements

Goldcorp’s Minera Penasquito gold mine in Mexico has engaged Siemens to operate and maintain their crushing and conveying systems for five years. The Siemens Customer Services Division will perform all the services and also provide the personnel and equipment. The order has an estimated value of around €40 million, but is based on the output of the plant. Siemens has already supplied equipment and performed maintenance tasks for the mine, but is now responsible for round-the-clock operation and maintenance of the IPCC system at Penasquito, which uses sizer stations to crush overburden near the extraction site, which is then conveyed to waste stacking systems.

The Penasquito gold mine in Mexico has engaged Siemens to operate and maintain their IPCC systemsThe Penasquito gold mine in Mexico has engaged Siemens to operate and maintain their IPCC systems

Siemens uses a computer-aided maintenance system to increase the availability and reliability of the systems. The scope of services also includes round-the-clock repairs, as well as stock and spare part management. The customer also benefits from the flexible contractual arrangements. Payments during ongoing operations depend on the output of the plant, in a production-based contract. Key performance indicators, such as productivity, availability and environmental compatibility, are also taken into account.

SKF recently announced a five-year contract with LKAB worth around SEK60 million for maintenance services at its mines in Malmfälten, northern Sweden. The contract covers advanced condition monitoring, vibration measurements, remote monitoring services, and machine diagnostics for mills, conveyors, pumps, and fans both above and below ground.  “We have been a partner of LKAB for many years and this new agreement gives us additional enthusiasm to assist in preventing disruptions and breakdowns through our preventive maintenance solutions,” said Vartan Vartanian, President, SKF Industrial Market, Regional Sales and Service. “We focus on prevention and, where necessary, consult partners with expertise and experience that can further develop our maintenance process. SKF has extensive experience in systems for condition based maintenance and is an essential partner in our work,” commented Anders Kitok, Senior Vice President, Mining for LKAB.

SKF has also launched a new range of hydraulic seals to meet the hydraulic cylinder industry’s needs for improved performance. By consolidating the product offers from SKF and from the acquired companies Economos and Polyseal, SKF says it can now present a fully consistent range and catalogue of hydraulic seals, for both OEMs and the aftermarket, and in metric and imperial units. In addition, SKF has added four completely new products to the range as well. For the first time, SKF can supply a complete system solution, with all types of seals, to meet customers’ demand for system solutions. “This complete range of hydraulic seals enables SKF to support our global OE customers with a wider choice of solutions. Combined with the SEAL JET system for rapid production of machined hydraulic seals and our strength in problem-solving customized solutions, we can help in the full life cycle management of the customers’ hydraulic cylinder applications.” says Danny Zitting, Product Manager, SKF Industrial Fluid System Seals.

The launch introduces several new products in the range, such as the “S1S” polyurethane Ucup for heavy duty rod sealing systems and three new styles of polyurethane piston seals. SKF developed a new grade of SKF ECOPUR polyurethane material in conjunction with the new product designs. The material was improved for seal function in heavy duty applications with high system pressure and temperature. The new complete SKF hydraulic seals range includes thousands of standard articles from more than forty different designs of rod seals, piston seals, wipers, static seals and guide rings, plus a broad range of design and material choices for tailor-made solutions.

ABB recently won an order for a long-term service agreement (LTSA) to maintain and improve the performance of two installed ABB gearless mill drive (GMD) systems at the Freeport Climax molybdenum mine near Leadville, Colorado. The order was booked in June 2012. ABB is providing one single contact person – ABB’s Life Cycle Manager – who will coordinate all tasks related to the service agreement and work with a dedicated team to guarantee the availability of service staff when they are needed. The agreement covers scheduled maintenance services and remote diagnostic services including troubleshooting, ABB SupportLine, periodic maintenance report and condition monitoring. With these services ABB aims to help keep the systems running smoothly at all times and maximise their overall productive life. Condition monitoring will identify and minimise any potential equipment issue well before production problems occur, and remote diagnostic services will enable ABB service teams from anywhere in the world to quickly provide support via a secure remote connection.

Metso and Boliden have extended their services contract for Boliden’s Aitik mine in Gällivare, northern Sweden. The three-year extension includes the supply of mill-lining solutions and the preventive maintenance of the grinding circuit. It is a performance based cost-per-tonne agreement, where Metso is rewarded according to the output of the customer process.  “Signing a cost-per-tonne agreement with Boliden gives us a great opportunity to show our expertise and ability to provide complete mill lining solutions. Within the scope of the service partnership we will be responsible for planning the shut-down process related to the replacement of mill-linings to be as efficient as possible and have a direct impact in helping Boliden to maximise the output of their process” commented Simon Pelletier, SVP, Life Cycle Services of Services business line at Metso Mining and Construction.

“The challenges Boliden has tested us with have pushed Metso to combine our expertise in both services and capital businesses. This refined approach has resulted in new Life-Cycle Services contracts with Northland Resources and Russian Copper Company as well”, said Joao Ney Colagrossi, President of the Services business line at Metso Mining and Construction.

The most recent Aitik expansion project will increase the capacity of the mine to 36 Mt/y of ore. Metso delivered two AG mills to Boliden in 2007, which at 11.58 m by 13.72 m in diameter were the largest ever supplied by Metso at that time. The AG mills installed in Aitik are also to be lined using the new Metso Megaliner shell liner. This new concept liner helps to maximise the availability of large mills by utilising aninnovative design which offers more rapid replacement. Megaliner uses larger than average liners, yet these can still be placed with the same liner handlers used with many large AG mills. By using larger liners a smaller quantity of them is needed and Megaliner also has fewer attachment points compared with conventional liners, improving installation and removal time even further. It also improves worker safety during maintenance, as the liners are bolted into position from the outside of the mill, so workers do not need to stand in the ‘drop-zone’ of the liners.

Timken bearing technology can more than double the service life of wheel end rebuilds on mining haul trucksTimken bearing technology can more than double the service life of wheel end rebuilds on mining haul trucks

Representatives of Timken, together with KGHM International’s Robinson Nevada Mining Company (RNMC), gave a presentation at MINExpo 2012 on the success of their predictive maintenance system, focussing on the predictive maintenance and tools used to improve the reliability of dragline equipment at the RNMC mine, which mine managers say has helped avoid millions of dollars in unscheduled downtime over the past five years. RNMC approached Timken to provide condition monitoring and bearing maintenance training as well as bearing repair services for the open pit copper and gold mine near Ely, Nevada. Thanks the training offered by Timken, Robinson mine technicians have been collecting data on some of the mine’s most critical bearing applications and identifying problems before major problems with equipment occur. “Within two months of initiating the training program, Timken helped us find impairments in two bearings that could have caused catastrophic results if not detected,” said Cary Brunson, RNMC Mill Maintenance General Superintendent. “Without Timken’s training and reliability services support, these two events alone could have cost us in excess of $3 million each in unscheduled downtime, labour and parts.”

Timken offers a portfolio of condition monitoring solutions, including portable handheld devices, continuous monitoring devices, online systems and field reliability support services. Those support services range from vibration, infrared thermography and oil analysis to fan balancing, ultrasonic analysis and video-scope inspections.

Equipment monitoring

Emerson Process Management has entered into an agreement with P&H Mining Equipment to extend vibration monitoring to P&H mining shovels. Emerson’s onboard monitors will recognise excess vibration in key shovel components and notify operators in real time, enabling users to take corrective action in time to prevent unexpected shutdowns and possible damage. The global agreement covers continuous vibration monitoring of the hoist, crowd, and swing systems on P&H Centurioncontrolled shovels. Vibration monitoring will be offered on all new P&H shovels, and all existing Centurion controlled shovels can be retrofitted to include vibration monitors. Emerson has broadened the CSI 6500 system’s monitoring capabilities from rotating equipment to recognise and capture non-repetitive vibration in mining machines.

Vibration data captured online by permanently installed sensors and multiple CSI 6500 Machinery Health Monitors will be integrated with the onboard P&H PreVail Remote Health Monitoring System. The online data will also be continuously fed to Emerson’s AMS Suite predictive maintenance software, which works in concert with the PreVail system to spot potential operating issues. The PreVail system currently monitors key operating parameters such as motor currents, temperatures, and drive information. An onboard historical database enables troubleshooting of suspected problems and predicting future performance. Information from shovels operating anywhere in the world is transmitted through P&H’s MinePro network to its headquarters in Milwaukee for diagnostic and consultative support as needed. “Emerson and P&H see an impressive opportunity to make users aware of potential problems, and we’re investing together to make that a reality,” said Ron Martin, Vice President and General Manager of Emerson’s Asset Optimisation and Lifecycle Care business. “Our technology enables early and accurate detection of anomalies for users whose equipment operates round the clock in harsh, often remote environments.”

A screenshot from BMT WBM’s new Pulse TerraMetrix RS shovel monitoring solution, installed on machines at Teck, Codelco and Syncrude operations to dateA screenshot from BMT WBM’s new Pulse TerraMetrix RS shovel monitoring solution, installed on machines at Teck, Codelco and Syncrude operations to date

“Emerson’s AMS Suite and our PreVail monitoring systems fit together very well,” said Bob Hicks, Manager of Product Technology at P&H parent company Joy Global. “Both are designed to raise early warnings of potential trouble, but they cover different aspects of shovel operation. Emerson’s patented method of processing vibration data preserves peak amplitudes of stress waves emitted by deteriorating equipment. Our analysts find this information very helpful in trending and evaluating fault development.”

Infor, a leading provider of business application software, has released a cloudbased offering of its suite of applications for the equipment industry. The company states that deploying Infor applications in the cloud will help equipment companies “modernise their technology, reduce IT infrastructure, speed deployment, and create a lower total cost of ownership.” Infor will leverage IBM Power Systems, which is built on open standards to create a private cloud environment to run Infor applications with increased speed and agility.  “Infor is committed to helping our customers in the equipment industry drive efficiency not only through applications that improve business processes, but also through technology that helps reduce their IT budgets,” said Mark Wright, Infor Executive Vice President.  “Customers that choose to deploy Infor applications in the cloud will be able to take advantage of reduced costs, increased flexibility and easier upgrades, all with maintenance and support direct from Infor’s award-winning Xtreme Support Program.” Whether deployed on-premises or in the cloud, Infor Equipment helps customers centralise key information from production, sales, service, warranty, finance, and rental with a single, scalable business system to drive strategic and profitable operations. The delivery of a cloud offering of Infor Equipment follows Infor’s recent announcement of heavy investment in the industry, which includes a dedicated innovation centre and the formation of the Infor CAT Dealer Advisory Council.

BMT WBM, a subsidiary of BMT Group, has announced that it has secured a major contract with Codelco to deliver its PulseTerraMetrix RS machine health, production and payload management system. Pulse TerraMetrix RS has been deployed at the Chuquicamata mine in on shovels SHE 200 and 230, both of which are P&H 4100 models and according to BMT is already providing valuable production and machine operating data to mine personnel. The system can communicate in real time through the mine wireless mesh to a server located in the mine’s administration offices. Data is saved in a SQL database and is accessible through an advanced server analysis programme located on the mine’s intranet. This feature has enabled maintenance, training and production staff at Chuquicamata to easily access, process and analyse the data on a shift basis, to identify where production shortfalls arise and where further operator training is required.

BMT WBM originally developed the Pulse TerraMetrix RS system to manage machine health, production and payload measurement for the Canadian mining industry. The system is currently deployed by Syncrude in the Alberta oils sands and by Teck in British Columbia. Charles Constancon, Director of BMT WBM Canada comments: “The Pulse TerraMetrix system helps to overcome the accuracy issues commonly associated with shovel based payload monitoring systems. Previous calibration trials which were completed at several mine sites in North America confirmed that the system can repeatedly achieve accuracy levels of better than 5% error, 95% of the time, when compared against load scale data.”

Unlike other payload monitoring systems which apply electrical parameter estimation techniques to approximate the payload, BMT WBM says that the Pulse TerraMetrix system employs a robust, custom designed loadcellbased device. The location of the loadcell in the immediate loadpath of the dipper, coupled with an accurate bi-axial servo based accelerometer measurements of the dipper motion, has allowed BMT WBM to offer an “accurate, dynamically compensated payload measurement system.”

Configured to communicate with any third party truck dispatch system, the Pulse TerraMetrix RS system can be applied to different models of electric rope shovels including the P&H 4100 and Caterpillar 7495. Recent developments of the system have included a comprehensive machine health monitoring capability using strain sensing transducers placed on the A-frame and boom structures. These transducers allow the system to track boom jacking and adverse swing events, identify alarm events and quantify the mechanical damage per swing cycle. Productivity indicators provide meaningful online feedback to the operator including average bucket/truck payload, overall shift production, swing cycle time, as well as operating and delay times.

Teck has also deployed the Pulse TerraMetrix RS system. This system will manage the machine health, production and payload measurement of Shovel 30, another P&H 4100, at Teck’s Greenhills coal operation near Elkford, in southeast British Columbia.

Oils/lubes and hydraulics

Shell Lubricants’ new Russian facilityShell Lubricants’ new Russian facility

Emerson Process Management and Spectro have announced an exclusive alliance to combine technical innovation and expertise to deliver expanded best-in-class oil analysis solutions. By integrating Emerson’s industryleading oil analysis applications for the industrial process industry with Spectro’s extensive oil analysis product line and expertise, the companies told IM that users will gain more meaningful and accurate information on the health of their machinery, helping to prevent costly machine repairs.

Under the new agreement, Spectro gains rights to a suite of Emerson-developed and patent protected intellectual property in the field of oil analysis for predictive machine maintenance. Included in this portfolio are Emerson’s AMS Suite oil analysis software module as well as the CSI 5200 Machinery Health Oil Analyser, the multi-functional analyser that is uniquely capable of detecting most lubricant-related problems in gears, pumps, compressors, turbines, engines, hydraulics, and process machinery. With effect from October 2012, Spectro has become the exclusive, world-wide supplier of the CSI 5200 Machinery Health Oil Analyser product and services offering.

“Emerson and Spectro will work closely as we continue to develop leading technology solutions for the process industry,” said Ron Martin, Vice President/General Manager of Emerson’s Asset Optimisation and Lifecycle Care business. “By aligning with Spectro Inc to deliver advanced oil analysis solutions, we can better provide our customers with predictive diagnostics to make more informed decisions about their assets.”

“The relationship with Emerson opens the door for customers to expand their predictive maintenance programmes by accessing the expertise available with Spectro’s extensive oil analysis product line, industry knowledge and global distribution network,” said Brian Mitchell, President and CEO of Spectro. “This means that Emerson customers can now take advantage of the same long-term technology solutions and growth path currently available to Spectro customers worldwide.”

Lubrication Engineers has introduced Almamoly HD Grease, a high-performance grease containing a special blend of solid lubricants and calcium sulphonate thickener.  Formulated to withstand elevated temperatures, heavy loads and exposure to water, Almamoly HD Grease is intended for long-lasting use in heavy-duty mobile equipment such as that used in open pit mining. It contains Almasol, LE’s proprietary solid additive, as well as 5 % molybdenum disulphide. Compared to other solid lubricant-containing greases that rely on moly or graphite alone, Almamoly HD Grease’s synergistic combination of moly and Almasol helps ensure reliable wear-resistant lubrication, “staying in place even when the lubricant is squeezed out of the contact zone due to extreme pressure or heavy shock loading.” The calcium sulphonate thickener – an increasingly popular choice in the marketplace – provides additional performance features that Lubrication Engineers state make the grease desirable for extreme conditions. In contrast to other thickeners, calcium sulphonate inherently prevents rust and corrosion. It has a very high dropping point and exhibits excellent mechanical stability and extreme pressure properties.

Bel-Ray’s Clear Gear Lubricant can eliminate metal to metal contactBel-Ray’s Clear Gear Lubricant can eliminate metal to metal contact

“Purchasing a high-quality heavy-duty grease is much less expensive than repairing or replacing parts and equipment and losing valuable production time,” said Darren Booth, LE’s vice president of operations. “By using a calcium sulphonate thickener with the synergistic combination of molydisulphide and Almasol solids, we have come up with a robust grease formulation that will protect heavy equipment from extreme wear and tough operating conditions.”

Almamoly HD Grease can be used for equipment that requires or specifies greases containing solid lubricants, including heavy-duty mobile equipment requiring 5% moly grease. It also meets the requirements of major OEMs. Typical applications include articulated trucks, backhoes, bulldozers, conveyors, crushers, excavators, loaders and shovels. It is stated as being especially useful for swivelling and pivoting parts including articulated joints, bucket pins, sleeve bearings, pivot bearings, hinge pins, latches, locks, spindles, threaded parts, cams and slides. An NLGI 1 grease, Almamoly HD Grease (1488) comes in 14 oz grease tubes, 35 lb pails and drum-sized bulk containers. It can be used in automatic lubricators and centralised lubrication systems.

Oil and hydraulic fluid contamination control in mines is a key problem and is an area addressed by specialist group Des-Case. A coal mining operation in Montana needed a solution to extend equipment life and lower overall maintenance costs on their mobile equipment fleet, and looked to AMS Filtration, a Des-Case company, to improve diesel engine reliability.  The mine conducted oil analysis to determine the service life of their engines was being cut short by particles the OEM full flow filtration was not designed to remove. Their machines included draglines, bulldozers, haul trucks and loaders. The first vehicles analysed were Caterpillar 992G wheel loaders equipped with 3508B engines that hold 27 gal of an SAE 15W40 engine lubricating oil. Oil analysis on one 992G in the mine’s fleet indicated a particle count by pore blockage method of 22/21/18 with copper and iron levels at 118 ppm and 53 ppm, respectively. Oil analysis on the other loaders indicated similar conditions.

Des-Case manufactures customisable filtration solutions including dedicated filtration kits specifically tailored for mobile equipment.  One such system, the ENG-2, was installed to filter the engine oil. The Des-Case ENG-2 mobile equipment engine kit provides filtration with depth media for a constant contamination control solution at very low ISO cleanliness levels. The system works by taking small amounts of the oil flow after the OEM full flow filter and directing it through the ENG-2 system.  Oil flows through the canisters at a set rate and is returned directly to the engine sump. The system is designed to prevent the canisters from being emptied when the equipment is shut down, while the small amount of oil directed through the ENG-2 system at any given time ensures the engine is never starved of oil. A pressure relief valve is also installed to prevent accidental over pressuring of the canisters during cold cranking. The ENG-2 is a depth type secondary (slip-steam) filtration system. The system is designed to meter engine oil flow through the filters at 0.5 gal/min. This slow flow rate, combined with the depth filtration, allows the system to have significant impact on soot and particles less than 1 micron in size. After 931 hours, oil analysis was conducted to determine ISO cleanliness levels went from ISO 22/21/18 (c) to ISO 17/16/13 (c), soot levels were maintained at or below 0.1% volume, copper levels dropped from 118 ppm to 2 ppm, and iron levels dropped from 53 ppm to 7 ppm. Based on life extension projections, cleanliness levels of ISO 17/16/13 (c) in an engine should result in a four-fold increase in engine life.

Timken has expanded its line of sealed spherical lower swing bearings, offering mine operators improved machine availability on many of the most common dragline and shovel models. The sealed lower swing bearings feature industry-leading technologies to enhance sealing capabilities, simplify installation and reduce both direct and indirect maintenance costs. The newest design replaces cumbersome bolts and retainer plates requiring multiple torque adjustments with a pre-sealed, pre-greased bearing that utilises a locknut arrangement, cutting the number of installation steps in half. With integrated seals to keep lubrication in and debris out, this package bearing is designed to require no additional lubrication after installation. Timken sealed spherical lower swing bearing designs also feature modification-free interchanges. Working closely with OEMs and mine operators, these bearings have been developed to help maximise machine availability and performance.

FLK, a new medium pressure filtration technology in hydraulic filtration for OEMs has been launched by Donaldson Company.  Manufactured using Donaldson’s industryleading Synteq XP media, the FLK system satisfies a variety of performance requirements and is an ideal solution for a variety of applications, including heavy-duty vehicle and mining operations. Donaldson’s new FLK assemblies provide higher pressure fatigue ratings than traditional filters. With its re-usable filter housing and replacement cartridge design, it offers several advantages for disposal of used filters. The FLK’s industrial, raised hand-grips make it easy to remove the housing from the head without the need for special service tools.  The versatile filter head accommodates multiple filter lengths, while the housing locks the filter cartridge in place, providing a clean filter service process and simplifying positioning during assembly. Synteq XP media technology provides lower operating pressure drop, higher efficiency, superior cold-start filtration, extended filter life and versatile and smaller filter packaging configurations. Donaldson RadialSeal creates a clean, leak-tight seal – with no metal-to-metal contact – that protects the system from harmful ingressed contaminants, preventing cross contamination of oil. “As hydraulic fluid cleanliness requirements have tightened and more compact filtration systems are launched, we’ve seen increased demand for better hydraulic filter solutions that meet requirements for lower pressure drop, higher efficiency and longer service life,” said Richard Lewis, General Manager of the Liquid Filtration Product Business Unit, at Donaldson.

Donaldson also recently showcased three new air filtration offerings. The StrataCap and TopSpin HD air pre cleaners expand Donaldson’s line-up of innovative pre-cleaners and give both OEMs and aftermarket customers the ability to extend air cleaner life and performance by separating dirt, dust and other debris before it reaches an air cleaner. With these two new additions, Donaldson’s pre-cleaner portfolio now offers options for super-high efficiency and super durability. Both new designs allow for contaminants to be automatically purged. “Precleaners are an essential component of many of today’s most advanced engine air intake systems,” says Andrew Dahlgren, General Manager of Donaldson Engine Air Filtration. “In a world where OEMs are challenged to fit increasing amounts of high-tech equipment into decreasing under hood space, Strata Cap precleaner allows them to filter and expel up to 96% of dust and debris before it ever reaches the air cleaner.” Strata Cap is the highest efficiency self-contained pre-cleaner offered by Donaldson. Manufactured from lightweight, corrosion-resistant materials, Strata Cap is a 2- in-1 injection moulded, space-saving (above the hood) pre-cleaner and rain cap unit. Two sizes are offered to accommodate a range of airflow requirements, from 350 to 1,300 cfm. Strata Cap has no moving parts, making installation and service a breeze, and its low profile improves operator visibility. As a scavenged system, a connection to the vehicle’s exhaust system is required.

Donaldson’s new TopSpin HD pre-cleaner is manufactured with an all-metal construction, high-efficiency design and low restriction to eject the most stubborn contaminants even in challenging environments. TopSpin HD precleaner separates and ejects up to 80% of incoming contamination before it can reach the engine’s air cleaner. According to Donaldson it delivers longer filter life, less frequent replacement, lower operating costs and less maintenance downtime. TopSpin HD is also offered in eight sizes, so the customer can choose one that provides optimal restriction at any airflow level.

The company has also introduced the Donaldson PowerCore PSD14 Air Cleaner, which expands the successful PSD family of air cleaners into a larger size and airflow range – now up to 1,450 cfm. The PowerCore PSD family – which also includes the PSD08, PSD09, PSD10, PSD12 – offers the features and benefits of twostage filtration (with a built-in pre-cleaner) in a single, compact unit.

Schroeder Industries, another global leader in filtration and fluid conditioning products, has introduced its Asset Management Filtration Station (AMFS), which provides “ultra-efficient, cost-effective filtration” with complete fluid quality monitoring, tracking and reporting capability via Schroeder’s enhanced Asset Management software program, in one unit. The AMFS is equipped with an on-board PC and controller that logs all of the data, while flushing, filtering and monitoring to ISO cleanliness all at the same time. The data is summarised into a simple Microsoft Excel report tracked by the equipment ID number for easy import into most maintenance programs.  Schroeder’s AMFS is completely automatic, and can be programmed to run until the desired cleanliness codes are achieved. The touch screen display provides real-time graphics for easy monitoring of the filtering progress.

Michael Lamers, Vice President of Sales & Marketing at Schroeder told IM: “AMFS offers fleet maintenance of equipment to maintain contamination control on a unit by unit basis with minimum additional tracking other than identifying the truck or unit number. Minimum training is required to operate the AMFS as all the requirements and manuals are in the computer on board the unit. This unit can be units for the hydraulic, brake fluid, transmission fluid, the only requirement being that the element be changed from fluid to fluid.”

Chevron Lubricants introduced three new premium hydraulic oils at MINExpo 2012. Clarity Synthetic Hydraulic Oil AW, Rando HDZ and Rando HD Premium Oil MV offer multi-viscosity or high-viscosity index (VI) formulations that deliver fuel cost savings and increases in productivity when compared to conventional monogrades, according to Chevron. The new premium hydraulic oils also feature improved oxidation and shear stability which deliver robust protection to hydraulic pumps.

For optimum protection in severe duty and extreme climates, the fully synthetic Mobil SHC Gear OH Series “delivers superb wear protection for mining electric wheel motor drives” according to the group. Featuring the latest in advanced Mobil SHC technology, Mobil SHC Gear OH Series helps to enhance productivity through exceptional low-temperature fluidity, outstanding load-carrying capabilities and robust oxidation and thermal degradation resistance. The Mobil SHC Gear OH Series’ very high viscosity index – allowing it to maintain high film thickness at elevated temperatures – combined with a unique additive system, helps enable it to provide higher performance and maximum component life under severe high and low-temperature operating conditions.

The Mobile Flushing Unit (MFU) from CC Jensen aims to avoid unexpected mining truck and excavator breakdowns and saves frequent oil changes. According to the company, field tests in Canada have proven that the CJC MFU exceeds expectations when it comes to quick and effective filtration of thick gear oils – even at very low temperatures. Over a period of months, the CJC MFU was tested on wheel motors and differentials of Komatsu, Caterpillar and Bucyrus machines. Within the time frames of the planned service checks, the oil has been cleaned to a level below specified cleanliness. In certain gearboxes, with hundreds of litres of oil, the task has been solved in very few hours.

The principle of operation of the CJC MFU is to drain and flush the oil in the gearbox through a hose. The oil can temporarily be stored in a 280 litre tank in the MFU itself, and be pumped from the tank to the gearbox through special CJC Filter Inserts, as many times as necessary. An oil preheater ensures that the oil can circulate with a max. speed, and a particle monitor gives the possibility to stop the process when the wanted cleanliness level has been obtained.  Furthermore, the monitor measures and logs the cleanliness degree throughout the whole filtration process.  The CJC MFU is also built on wheels and is thus easy to move. It is also easy to operate and requires minimal training.

Bel-Ray’s Clear Gear Lubricant is used in grinding mills, kilns, pelletisers and other mining process equipment. In a recent grinding mill application, the use of Bel-Ray Clear Gear eliminated a vibration that occurred when a different lubricant product had been in use. In a separate mill application, the use of Bel-Ray Clear Gear immediately stopped a progressive macropitting condition. After more than 4,000 hours of use, no further progression of pitting occurred and a gear temperature of 12% was obtained. Bel-Ray states that the Clear Gear Lubricant “is a fully synthetic, high performance open gear lubricant, using the most advanced technology in the industry. The addition of micropitting protection eliminates most premature gear failures. Bel-Ray Clear Gear Lubricant also offers a high viscosity index to ensure maximum film thickness at gear operating temperatures, excellent drain-ability to ensure the removal of used lubricant to a waste collection container and complete clarity that enables the operator to inspect gear tooth condition without the typical pre-cleaning necessary with a black open gear lubricant.”

Bel-Ray Clear Gear Lubricant is a full fluid film or hydrodynamic open gear lubricant. Due to the thick film obtained from its high viscosity index, it can eliminate metal-to-metal contact. In more than 10,000 hours of field testing conducted at one of the world’s largest copper mines, the use of Bel-Ray Clear Gear Lubricant reduced gear and pinion temperatures by up to 20% on several of the company’s grinding mills. Available in four viscosity grades, Bel-Ray Clear Gear Lubricant can be applied to open gears by drip, spray or immersion.

Lubricants also play an integral part of Shell’s mining offering. The company told IM: “Today, lubricants can do more than just protect mining machinery and other capital equipment. We have a portfolio of products with proven fuel economy impact – such as Shell Tellus S4 ME, a hydraulic fluid for fix plant applications. With the latest ‘synthetic’ technology, lubricants can deliver enhanced protection and greater equipment availability, helping to lower overall operating and maintenance costs. It is here that understanding our customers’ needs and applying that during R&D plays a crucial role.  Reported savings, both from operators internationally and rigorous field trials, suggest new synthetic lubricants make a difference to mining operators.” A mining operator in Australia switched to an advanced synthetic lubricant (Shell Tellus S68) for their fleet of excavators operating in an open cast mine. In doing so, they managed to reduce their operational costs. At the same time, new supply arrangements also meant they now have a supply of the oil fed directly into on-site storage tanks in order to reduce product ordering through the use of bulk loads. From these efficiencies, the estimated savings came up to approximately $30,520 per year.

Shell Lubricants also worked with Barrick Gold which sought to improve performance and reduce energy consumption at a gold mine in Western Australia. Shell suggested that the company may benefit from changing its hydraulic motor lubricant to Shell Tellus S4 ME.  This resulted in a six month trial in two Hagglunds MA 200 hydraulic motors installed on conveyors at the mine.

The results of the trial showed that using Shell Tellus S4 ME in their two hydraulic motors reduced their energy consumption by the equivalent of 5.27% per annum, which equates to $10,520. There were also extended oil-drain intervals and reduced labour costs and downtime.

Shell has just opened a major new lubricants blending plant in Russia, the first built by an international oil company in the country. The new plant in Torzhok, in the Tver region northwest of Moscow, is ideally located to supply a range of finished consumer, transport and industrial lubricants to customers in Russia. It can blend up to 200 million litres of lubricants a year, making it one of the largest in Shell’s current global plant network. Shell’s industrial lubricants mining customers in Russia will now be able to receive bulk delivery of finished lubricants, speeding up delivery times and reducing storage costs. The plant was constructed to incorporate world-class lubricant blending technology. All processes in the plant are automated and commanded by a control room developed to the latest international standards. The plant is also equipped with a stringent quality control system that conducts tests at all stages of production.

Australian company Dingo’s foundation is its internet based software called Trakka; a tool to analyse and store all the information required for an effective Condition Based Maintenance system using oil sample data. Trakka is designed to allow “seamless, electronic data flow from any oil analysis lab into the database for rapid turnaround time.” Tailored, site specific alarm settings can then be implemented, enabling the use of equipment group analysis to spot trends and lubrication issues fleet-wide.  Trakka also stores the mine’s unique set of procedures that are used to guide the detailed corrective actions that need to be taken to correct any issues that are identified.

Since the acquisition of Lincoln, SKF has introduced five new lubrication products. The LFC Smart Truck System helps to track costs and improve service truck efficiency by recording where fluid is being used. A user interface in the lube truck controls solenoids and pulse meters at each fuel and lubrication reel, and the system uses an equipment database to dispense the correct fluid into each piece of equipment. The LFC Smart Truck System records lubricant and fuel service consumption by truck number, job number and/or asset number.

An upgrade to the existing FlowMaster line, the FlowMaster II was developed to increase pump life and simplify installation, operation and service. The new models feature enhancements to the crankcase, follower, reservoir and upper ball check design, as well as a two-year warranty. In addition, the FlowMaster II is less susceptible to grease contamination, and its pump and reservoir combination models are ready to accept grease level sensor and shut-off systems.

The FlowMaster Reservoir Level Sensor and Overflow Prevention System automatically shuts off grease fill supply to the reservoir, preventing dangerous and costly overfills. The system senses the position of the follower in the reservoir and sends a signal to a high-pressure shut-off valve before overfilling occurs. Grease level can be determined at all times, and the level indicator signal also can be integrated into on-board systems. It can be retrofitted to all FlowMaster pump and bucket combinations with a follower.

Other new products include the Hydraulic PowerMaster Motor and Centro-Matic Fill Filter, which was developed for the mining, offhighway and industrial markets. This highpressure, high-flow unit features a clogged-filter indicator with quick reset. A red indicator pin is triggered when the filter element is almost clogged. If it becomes completely clogged, the grease will vent safely to the atmosphere, preventing contaminated grease from entering the reservoir.

Service warranties

The new David Brown 3X extended warranty package is now available to mining customersThe new David Brown 3X extended warranty package is now available to mining customers

David Brown has announced the introduction of 3X, a new and market leading three-year extended warranty package for customers. The 3X is available for any gearbox brand and model – even those of competitors – and provides access to David Brown’s gearing expertise and global network of service and repair centres for “speedy, local service and efficient upkeep.” The 3X also covers new gearboxes designed and manufactured by David Brown. Gearboxes will be installed, commissioned and maintained at regular intervals, as necessary, by a specialist David Brown service engineer under the warranty which includes the option to install CMaS, a remote conditioning monitoring system to gather critical information while the gearbox is in operation and help ward off unexpected failure. The introduction of 3X is described as a “natural evolution of the service and repair support David Brown already provides globally” and is aimed at helping customers to ensure maximum availability and minimal downtime – reducing the total cost of gearbox ownership and giving at least three “hassle-free” years.

“We’ve introduced the 3X in response to our customers’ needs – going beyond the industry norm of 1-2 year warranties – to give our customers at least three full years of extra assurance, reduced downtime and easy access to service expertise. Some independent gearbox repairers offer as little as 3-6 months. The results of recurring downtime can lead to costs at least 20 times higher than working with an experienced team to ensure your gearbox problems are solved with reliable, long lasting and guaranteed repairs. From Flender, Falk, Radicon, Hansen, SEW, Allen Gears and Santasalo right through to heritage gear brands such as GEC – there is no gearbox that David Brown cannot service, repair and upgrade” said Steve Watson, David Brown Global Service and Repair Director. He adds: “At David Brown we’re passionate about delivering the maximum possible uptime to customers. The 3X works by proactively managing their gearbox – scheduled inspections and maintenance ensure potential issues are identified and resolved quickly, before failure occurs. The condition of gear teeth, oil and bearings are key problem areas whose risk can be significantly reduced, often completely removed, by regular review in this way. We’ve already received strong customer interest.”

Service centres and teams

Metso is also ramping up its already extensive local services offering for mining customers in northern Sweden by expanding the services hub in Gällivare. The new hub will also include a distribution centre for spare and wear parts. In addition to Gällivare, Metso has a significant existing customer service organisation in Kiruna and Lulea, and is about to open a service centre in Pajala to support its new services contract with Northland Resources.

Elsewhere worldwide, Metso is opening three new service hubs and training new personnel to meet the growing demand for expertise in the Chilean, Peruvian and Mexican mining industries. The new service hubs will widen the geographical reach of Metso’s existing service hub network which consists of more than 70 locations on six continents and some 2,000 field-service technicians worldwide. In 2012 and early 2013, Metso will open new service hubs in Antofagasta in Chile, in Arequipa in Peru and in Cananea in Mexico. And as a result of the Life Cycle Service contract signed with Russian Copper Co last year, Metso is also increasing its number of service personnel and facilities in Russia. In 2011, services business accounted for 50% of Metso’s Mining and Construction segment’s net sales.

Boart Longyear, the world’s leading integrated drilling products and services provider, opened a new parts and service centre in Salt Lake City, Utah, in October 2012. The centre provides aftermarket equipment support for Boart Longyear’s third party customers in the mining industry through technical support, repair and rebuild services, preventive maintenance, and training programmes. Drilling contractors use these services to increase productivity and to reduce downtime of their drilling equipment. “We strive to help our customers properly maintain their equipment – and to offer timely solutions when repair or refurbishments are needed,” said Michael Norris, Senior Manager of Aftermarket Products for Boart Longyear. “By opening the Salt Lake City location, we are better able to service the mining industry in the Great Basin region of the USA.” The Salt Lake City location was chosen for a parts and service centre due to a high density of Boart Longyear customers in the area. The facility is 20,000 ft2 which includes a 15,000 ft2 shop and 5,000 ft2 of office space.

Boart Longyear says it has recognised the need to have the right spare parts and services available in more convenient regional locations.  Expansion of their parts and service centres globally along with an enhanced global distribution network, allows regional centres to service Boart Longyear rigs with parts and technicians more efficiently, thereby minimising downtime.

The Salt Lake City location adds to existing parts and service centres in Adelaide, Australia and Nottingham, UK. The global expansion of the Boart Longyear parts and service centres also includes the further development of the North Bay, Ontario, and the Lima, Peru locations, which will be upgraded to fullcapacity parts and service centres. Boart Longyear will also be opening new parts and service centers in Santiago, Chile; Belo Horizonte, Brazil; Johannesburg, South Africa; and Khabarovsk, Russia, by the first quarter of 2013.

Global wear parts major, ESCO, has been expanding the reach of its own trained specialist technicians globally. “It just made sense for us to take our expertise and bring it directly to our customers,” said Jon Owens, President of ESCO’s Engineered Products Group. “This way they get our great products coupled with expert service that keeps them productive and safe.”

Example ESCO service teams include those in Australia’s Bowen Basin, where a group based out of Mackay travels three to five hours one way to call on mine operators; Carajas, Brazil, where ESCO has more than 60 employees providing maintenance and service work under a contract with Vale’s Sossego copper mine; and in Phoenix, Arizona, where ESCO technicians service mines and a recycling plant in the area.

The mobile ESCO service teams offer a full travelling repair facility. Each region modifies a 5t truck, outfitting it with welding equipment, tools, products and any other requirements, with each location customises its truck and services to fit the needs of customers in very different mining regions. According to ESCO, success in Australia, Brazil and North America has seen customers in other markets asking for the dedicated services to be expanded into their regions. In Brazil, five trucks service the Sossego and Onca Puma mines to tackle bucket, truck body, stick and boom repairs, as well as new truck body assembly.

Greg Williamson oversees ESCO’s mobile operation in the Bowen and Queensland Coal Basins in Australia. Eight trucks work out of Mackay and Kingaroy, which are the closest towns to key mines in the region. The trucks are outfitted with welding machines and lockers that hold everything technicians need for a job, allowing them to stay on-site for several days at a time. The impact of ESCO’s mobile service is illustrated by one customer in the Bowen Basin, which is a five hour drive from the nearest ESCO facility. In the past, maintenance or repair work often meant shipping equipment to ESCO’s Mackay or Kingaroy facilities. The mobile service teams eliminate that transport and significantly reduce the amount of money a company can lose on an idle machine. The repair and maintenance work handled by ESCO on-site also frees up mine employees to tackle other projects. Williamson said ESCO is also enhancing the impact of its mobile operation by embedding employees with mine companies, a common practice in the area. By having its own employee on- site, ESCO says it is able to better anticipate a customer’s needs and further reduce the lost time mine operators experience due to equipment problems.

Marty Hockett, ESCO’s Field Service Project Manager for North America, said the mobile programs in the region are particularly focused on creating services that best fit with specific customers and markets. In Phoenix and Farmington, New Mexico, the team has created an exchange program with bulldozer moldboards. Hockett said they bought three used moldboards and are installing those on customer machines while the customer’s own moldboards are brought back to the local ESCO branch for repair, eliminating downtime. Mines in Gillette, Wyoming and Kilgore, Texas are also interested in creating a similar program in their areas. The Phoenix office also found a way to complement sales of protective components in the Universal Wear Systems line by developing a method for applying those components in the field. The field installation of carbide overlay is particularly useful to ESCO’s dragline customers.

David Brown Bharat Forge, an Indian joint venture between leading global gearing expert David Brown and Bharat Forge, a global leader in the manufacture of automotive and nonautomotive components, has celebrated the opening of its first industrial gearbox service and assembly facility in Hosur, Tamil Nadu, India. The facility which is fully equipped with an industrial crane and has the capability to service, repair, upgrade and provide strategic gearbox maintenance as well as supply new gearboxes for customers in industries such as mining, power generation, metals, cement and renewables. The 56,000 ft2 Hosur service, repair and assembly centre’s range of equipment includes a 100 t hydraulic vertical press, lathe, milling machine, a spray booth and other service-specific tools and equipment.

Weir Minerals has announced a significant investment in Turkey, opening a new dedicated sales and service centre to support its growing Turkish customer base. The business, which has opened new offices in a strategic location from which it can support customer operations across the whole of Turkey, has been working in the Turkish mining and aggregates sector for more than 20 years. Based in Istanbul, the new 600 m2, sales and customer support centre will house a permanent team of Weir Minerals engineers. The location of the new facilities will provide faster delivery of services and repairs and enable tailored regular service programmes, ensuring minimum operational downtime for Weir customers. Stock will also be kept at the site allowing commonly ordered smaller items to be delivered rapidly to customer locations.

Weir Minerals supports some of the largest players in the Turkish mining industry. Earlier this year it announced that it was working with Turkey-based contractor Tekfen, on a €12.5m, 200 km-long pipeline project in Morocco. Tony Locke, Managing Director of Weir Minerals Europe said: “Turkey is an important market for the future growth of Weir Minerals Europe.  We’ve made a significant commitment to extend the level of support we can offer our Turkish-based customers through the new service centre, particularly in the case of operationallycritical repair and maintenance which we can now deliver more rapidly and efficiently.”

At MINExpo 2012, Sandvik Mining introduced a comprehensive suite of service products, tailored to the needs of a specific customer site.  These services can be selected from a ‘menu’ that will be consistent across all Sandvik support centres, allowing customers to tailor the support they need and enabling them to receive the same services, regardless of the location of their operation. The service portfolio is based on traditional life-cycle, enhanced technical and business services, all of which are aligned to improve the overall safety situation, secure competence and knowledge for mine operations and increase customer productivity, throughout all stages of the mining equipment life cycle. Sandvik’s service structure includes services that are independent of equipment and which are based on customers’ business requirements.

“We believe that it is of great value to our customers to be able to know the exact range of services that are available to them from each Sandvik location around the world. As we continue to develop more services that take full advantage of the available technology, not only on the equipment itself, but also within the mining environment, we are moving closer to providing real-time information to our customers. Enabling them to take decisions not only on the condition of their equipment, but also on the performance of their operations”, said Dan Allan, President Customer Services, Sandvik Mining.

By standardising the individual elements within the service portfolio, the customer has access to a consistent delivery of services, regardless of their location. It also enables Sandvik to ensure that the appropriate skills are available for each job.

Sandvik launched four completely new and unique packages in what is called Service IQ.  The four packages in Service IQ are Safety, Competence, Reliability and Productivity. “By combining Sandvik’s expert knowledge of mining application with detailed machine data and an in-depth understanding of our customers’ operations through continuous collaboration, we are able to deliver ‘decision level’ reports that will, in combination with our advisory services, improve our customers’ bottom line. We do this in a collaborative approach to ensure knowledge transfer, sustainability and ownership, whilst focusing on the activities that will reduce or eliminate our customers’ operational bottlenecks”, said Allan.

Tyre maintenance and TPMS

As has been documented in numerous IM articles, of critical importance to keeping machines operating is monitoring the performance of the tyres those machines run on.  Tyres present a challenge to mining fleets of all types worldwide. Fleet maintenance staff understand the challenge of working with mining tyres as well as the damage that can be caused when tyres are low on pressure, high on pressure or heat and the resulting damage from those conditions. The high cost of damaged tyres, replacing tyres, vehicle downtime, maintenance time and costs and more can impact any mine’s bottom line and safety can become jeopardised for the vehicle, driver and maintenance crews.

At MINExpo 2012, Tyre Pressure Monitoring Systems (TPMS) provider, PressurePro, exhibited its offering for the mining sector.  Phillip Zaroor, President and CEO comments:  “Providing real-time tyre pressure and temperature information and alerts, PressurePro has taken TPMS technology to new heights by being the first TPMS provider to offer remote monitoring options to mining fleets and adding data logging capabilities as a standard option to their product line. New additions such as Local Area Network (LAN) and cellular based telematics options allow mining fleets to add communication between the vehicle and an office based management system, cell phone or more, allowing fleets to revolutionise their tyre maintenance programs. PressurePro’s advanced technology also allows mine operators to communicate other readings and updates from the vehicle, such as axle weight and engine diagnostics alongside their TPMS information – giving fleets a deeper look into the performance and health of their equipment.”

Service vehicles and solutions

The new Konecranes speed control options allow mining users to achieve high average hoist speeds without increasing motor sizeThe new Konecranes speed control options allow mining users to achieve high average hoist speeds without increasing motor size

Konecranes has introduced two speed control options – the Extended Speed Range and Adaptive Speed Range – for overhead lifting equipment motors in the mining industry, described as as “cost-effective options to achieve high average hoist speeds without increasing motor size.” Konecranes’ says its mining expertise has been developed with hands-on experience, continuous R&D, and a global team with shared knowledge, to ensure that its products are ideal for the specific needs of the mining industry. The new Extended Speed Range from Konecranes has been developed for high duty applications where near capacity loads are routinely lifted. It also uses inverter technology to allow increased hoist speed for light loads. The faster hoist speed allows operators to return empty hooks to position or move smaller loads with more speed and efficiency, reducing average hoist cycle time and increasing productivity.

The Adaptive Speed Range from Konecranes automatically varies the speed of the hoist according to the load. For full capacity loads, Adaptive Speed Range forces a slower, more deliberate speed to enhance safe lifting.  Moderate loads can be moved with additional speed, while light loads are afforded even more speed.  Designed for applications where high capacity lifts are performed less frequently, the Adaptive Speed Range from Konecranes uses a compact motor, maximising productivity and safety, while reducing unnecessary motor power and maintenance costs.

Mazzella Lifting Technologies, a manufacturer and distributor of lifting and rigging gear has opened a new branch in Virginia, Minnesota. The Virginia facility is in a central location for serving the local taconite iron ore mines for whom Mazzella is providing lifting and rigging products and inspection services. “We see the Mazzella Companies’ expansion into the Mesabi Range of Minnesota as a natural progression of our long-term relationship with US Steel. We value this relationship and the opportunity to supply the Minntac and Keetac taconite plants from our Virginia, Minnesota location.” said Craig Hayward, President, Mazzella Companies. Mazzella will maintain an inventory of wire rope, chain and synthetic slings; wire rope; rigging hardware; hoists; hoist parts; pullers and other related rigging products.

Manitou’s Aerial Work Platform (AWP) range is used to lift personnel to work on large machines on the surface, or in underground workshops. They also provide lifting to assist with the provision and maintenance of underground infrastructure – such as piping, ventilation and roof support. Manitou Rotating Telehandlers (MRT) are essentially three machines in one – a forklift, a crane and an AWP.

They offer up to 36 m in working height or a 1,000 kg capacity platform. Highly specialist machines include the CH 10 cylinder handler. This greatly assists and improves boom, stick and bucket cylinder maintenance on large shovels, for example. With up to a 10 t capacity, it can handle 85 to 630 mm cylinder diameters.  The CH 10 offers smooth and accurate workflow, safety, faster operation, is easy to use and saves downtime, according to Manitou. It is monitored by a radio remote control.

The cylinder handler can clamp cylinders at a specific height from the ground and load placing to fine tolerances is manageable. By comparison, using a mobile crane provides poor access to the cylinder. It means a suspended and swinging load with poor accuracy.  Hazardous human eye estimation of the centre of gravity may lead to an approximate and unsafe placing of the load. Similarly, the CH 4 strut handler accommodates struts and accumulators (185 to 600 mm) up to 4 t. It is specially designed for confined spaces providing safe maintenance of front struts, hoist cylinders, rear suspension struts and accumulators on haul trucks.

A Getman fuel/lube palletA Getman fuel/lube pallet

Getman Corporation offers two solutions to mining customers for fuel and lubrication delivery vehicles. For mines requiring a full time mobile fuel and lubrication delivery system the company offers the dedicated A64 Fuel/Lube truck, or for part-time use offers a fuel/lube cassette for use on the A64 Pallet Handler.

The utilisation of dedicated lube/fuel trucks is getting more and more popular with the increase in fuel prices, as moving a single truck to make the daily service of the fleet instead of moving the all fleet can save a lot of money according to the underground configuration. In selling a package of utility vehicles to a new mine, there are nearly always lube/fuel trucks included.

Mathieu Collette, Getman Business Development Manager – Europe, Africa & CIS told IM: “From our perspective a dedicated vehicle is most applicable in situations where tramming distances are long or where large fleets require servicing. A cassette system may be more appropriate for newer operations with smaller fleets and shorter tramming distances, thus allowing the customer to utilise the unit part-time as a lubrication vehicle. As always, our target is to maximise the utilisation of our equipment and thus the investment of our customers.”

The Getman standard configuration for a dedicated unit includes four services totalling 2,550 litres of fluid capacity, however, the product can also be adapted to the specific needs of our customer – in the past the company has made everything from fuel trucks with a single tank to fuel/lube trucks containing as many as 8 fluid services. In all configurations tanks are linked to the service station located at the rear of the trucks, and each tank is fitted with a hose and nozzle that is mounted on highquality spring return reels. Further to the tanks, the service truck is equipped in standard with air service and a pressurised grease drum.

The alternative cassette system, the A64 Pallet Handler, is similar in function and features to the dedicated system except with a slightly reduced capacity of approximately 1,600 litres.  The primary advantage of this solution is versatility – when the pallet handler is not needed as a lubrication truck it can be applied to other purposes including personnel transport, general utility, and water spraying. This versatility allows the mine to maximise the utilisation of the truck to achieve the maximum return on their investment.

Additionally, the cassette approach allows customers the option of creating a mobile pit stop underground that can be relocated as needed by the mine. In this case the lubrication pallet can be deposited in a temporary location and can be powered by mine air, creating an autonomous lubrication station that can easily be refilled as needed.

While fuel and lubrication trucks are dedicated to performing daily maintenance on an underground fleet, Getman has also developed a range of vehicles able to support the repair of equipment that has experienced failure or breakdown underground. Machines that have experienced failures in a gallery or on a haul road can quickly lead to lost productivity and potentially dangerous situations. Getman can customise a maintenance vehicle to the specific needs of the mine, such as the mounting of a crane, welding system, toolbox, air compressor, or hydraulic hose making equipment.

Scania has an agreement with Rio Tinto covering the supply of trucks, buses, parts and aftersalesScania has an agreement with Rio Tinto covering the supply of trucks, buses, parts and aftersales

The company reports that it recently worked on an underground pit stop concept, where the customer wanted to create mobile workshops.  Their plan was to create six mobile workshops able to follow the progress of the production.  Each of them was composed of one autonomous fuel/lube pallet electrically powered and one workshop truck with a crane, a welding machine, toolboxes and a hose-making kit. The six fuel/lube pallets are planned to be handled by two pallet handler trucks.

Apart from its well known range of mining tippers and haul trucks for ore, coal or overburden, Scania also delivers a wide range of surface mining support trucks. In Australia, Scania has a preferred supplier agreement with Rio Tinto covering the supply of trucks, buses, parts and after sales. The typical units sold to Rio Tinto in Australia are water carts, diesel tankers, fuel and fuel/lube trucks, and crane and platform trucks.

In Indonesia, Scania offers a 6 x 6 Crewcab unit for the use in servicing semi-stationary equipment in the mine as well as transporting staff into surface mines. Scania also supplies mining adapted buses to transport people to and from the mine as well as within the mining area.

The new Scania containerised service workshop is a highly flexible solutionThe new Scania containerised service workshop is a highly flexible solution

Finally, Scania has developed field workshops as a flexible alternative to permanent structures.  These container solutions are an ideal option for mining customers who don’t have easy access to regular service workshops. The field workshop solution is mobile, can be quickly installed and is cheaper than a permanent workshop. It is also flexible and easy to adapt to local business and operational needs.

“It is an ideal start-up solution in new mining markets but is equally handy in mature markets, for example during refurbishments.  It’s essentially a plug-and-play solution,” says Markku Markkanen, Project Manager, Scania Real Estate Services. “The workshop, tools, compressor and other features are all fixed to the container, but customers have to arrange access to water, electricity and sewage.”  Customers also need to ensure that local building regulations are met, along with site preparation, insurance and other external factors. The container workshop is a two-bay solution where four trucks can be serviced at one time. There are eight modules – workshop, parts, office, lubrication, ablution, accommodation, kitchen and environmental (for sorting waste). These can be combined to meet the specific needs of individual customers. Field workshops have already been put to the test in a number of locations, including Thailand, India, Estonia and Iraq, and are targeted for new projects in Australia, Brazil, Russia and elsewhere.

“Demand for this type of solution is especially high in the mining and forestry segments,” says Markkanen. “Customers can concentrate on their core business, while we take care of servicing and providing them with more uptime.” IM