Tag Archives: mine maintenance

Autonomous conveyor belt condition monitoring in times of a crisis

Bulk handling, Equipment maintenance, IoT, Mining consumables, Mining equipment, Mining maintenance, Mining safety, Mining services, Mining software, , , , , ,

As the digitalisation of processes in mines progresses, machines linked into the Industrial Internet of Things (IIoT) gain in importance, according to Bernd Küsel of CBG Conveyor Belt Gateway.

An important part of predictive maintenance and accident prevention is the continuous examination and diagnosis of steel cord conveyor belts, which are mainly used in the long-distance conveying of ores, coal and other raw materials. These conveyor belts are essential to many mining and loading facilities.

Many operators still rely on inspection personnel from service companies equipped with portable devices to inspect conveyors, but their appointment can be problematic. And, with today’s travel restrictions, this is close to impossible.

The problem comes as such inspections provide an insufficient picture of the condition of a conveyor belt that is reliant on interpretation by trained persons, with portable devices that only cover parts of a conveyor belt, according to Küsel. Moreover, inspections only offer a snapshot in time without the possibility to intervene in the case of threatening belt defects that could lead to a total failure of the conveyor system.

In times of crisis, such as the current COVID-19 pandemic, it is even more important to use a self-sufficient, automatic diagnostic system, according to Küsel.

“The virtually maintenance-free CBGuard scanner provides complete knowledge of the condition of the conveyor belt in real time,” he says. “It is operated from the user’s control centre or via the Internet.”

Damage can be repaired at the best possible time for the customer, reducing unnecessary downtime and the associated costs and loss of production that come with this.

The CBGuard scanner can be an indispensable part of a predictive maintenance program, Küsel says.

“With it, conveyor belts can be integrated into the IIoT, ie into seamless communication with other electronically monitored systems. CBGuard provides a complete, detailed knowledge of the condition of the conveyor belt – non-stop and online,” Küsel said. “Virtually every cubic millimetre of the conveyor belt is checked during operation. The CBGuard scanner compares the detected values with the target values in real time. Every critical change triggers a reaction. The operating personnel are immediately informed of serious errors via SMS. In addition, the exact thickness of the entire conveyor belt can be measured and outputted as a contour map.”

The CBGuard Life Extender, meanwhile, detects internal damage such as steel cord breakage, corrosion, misplacements and other defects of the tension member. The exact condition of each steel cord can be viewed on a monitor in real time. The same applies to certain belt breakers and conductor loops.

Damage such as holes, foreign bodies, protruding ropes, edge breakage, bubbles, rubber cover abrasion and even insufficient belt cleaning are detected. Each defect automatically generates a predetermined, individual reaction. Information about the findings is additionally available at any time as a photo, video or inspection report, which tells personnel exactly what kind of damage it is, how severe it is and the location of said damage.

The CBGuard scanner also prevents fatal consequences caused by splice defects, Küsel said. As the weakest links in a conveyor belt, splices pose a greater risk to the operation – with potentially devastating consequences.

The CBGuard Life Extender scans all splices. Every single splice is individually assigned in the database and compared with its target state. Any critical deviation generates an alarm or a stop of the system in case of threatening defects.

“No other method available on the market can provide such exact and comprehensive results,” Küsel said.

The way CBGuard works is similar to that of X-ray machines in the healthcare sector or in airports.
The device consists of an X-ray generator with a tube, a receiver module and a control unit. The generator produces artificial X-rays from electricity, with the ionising rays penetrating the moving conveyor belt and then hitting the receiver module – an amorphous silicon imaging field.

It is a process like that of photo diodes in a digital camera. Countless, seamless images are continuously generated and defined by CBGuard’s smart software – based on advanced face and palmprint recognition algorithms – checking the condition of the belt, while accounting for the individual structure, size, colour and position of deviations and reporting them as a specific event (eg damage).

“Using a CBGuard is safe,” Küsel said. “The device complies with all international regulations on radiation emission. It does not contain radioactive material!”

The compact design and low weight of the CBGuard makes for a quick and easy installation on almost any belt conveyor. The scanner is also almost wear-free, according to Küsel, as it has no moving parts or contact with the conveyor belt.

All functions of the CBGuard Life Extender can be remotely controlled via TCP/IP, with maintenance or programming work possible from anywhere in the world. The analysis software runs under Windows 7 and 10, and the program is intuitive and easy to use, he said.

CBGuard has proven its performance in over 300 applications, according to Küsel, noting that large copper mines in Peru and Chile rely on CBGuard. There are many other applications in Australia and Asia in the limestone and coal sectors, he added.

The CBGuard scanner ensures fully automatic, complete monitoring of steel cord conveyor belts making inspections by personnel or devices that only cover a part of the conveyor belt spectrum unnecessary, Küsel says.

The gain in safety, the independence from personnel availability and the reduction of capital expenditure and operating expenditure are convincing arguments for the use of a CBGuard, he explained.

On the operation expenditure side, for example, there is no longer a need to employ internal maintenance personnel or outsource external services to inspect the belt. Such inspections, typically carried out weekly, are conducted in belt ‘creep mode’ and involve a full shut down, according to Küsel.

“With the CBGuard, you do not have any production downtime because it is carrying out the inspections all the time at the normally operating conveyor, at its normal speed,” he said.

Belt repairs also only occur when necessary, with details of failures coming from the CBGuard. “You will see serious damage immediately, so you can repair them before they get worse and cost much more money to fix,” he said.

This also provides capital expenditure benefits, with the CBGuard telling operators when and which part of the belt is worn out. In many cases, only part lengths will have to be changed, not the entire belt length.

This comes with inventory benefits too, with companies no longer having to carry extensive stock belting as the CBGuard is able to predict in good time when the belt will need to be replaced.

Metso invests in Arizona repair facility after stellar 2019 results

Equipment maintenance, Mineral processing, Mining consumables, Mining equipment, Mining maintenance, Mining services, , , , , , ,

Metso has made further investments in its Mesa repair facility in Arizona, USA, in order to, it says, optimise safety and broaden service capabilities.

The facility offers repairs and field services while supporting Metso’s Life Cycle Services contracts. It has seen steady growth since the opening in 2015, with 2019 setting a record for safety performance, revenue and profitability, according to the company.

One of the many upgrades to the facility includes the installation of “a state-of-the-art stress relief oven”. This investment was made to offer a more complete service to customers on large rebuilds, Metso said. “This will improve quality control as well as accelerate the turnaround times for our clients,” the company explained.

In addition to the stress relief oven, Mesa has also invested in other equipment to support the repair of mining screens, Wet Low Intensity Magnetic Separator (LIMS) drums, and babbitted bearings for mills.

A screen test stand has been manufactured and will be operational by the end of March, the company said. This will allow each screen rebuilt at Mesa to be test-run before being sent back out into the field, which will reduce the potential for issues during installation and start-up, according to the company.

Equipment needed to repair LIMS drums was also put in place last year and has seen a steady inflow of repairs coming from mines in the Iron Range of Minnesota, the company said.

Metso said: “In the future, the facility aims to further grow its portfolio of value-added services, to improve productivity and reduce operational costs for its clients in both the mining and aggregates sectors.”

Enerpac and Cooper Fluid Systems aid dragline maintenance at coal mine

Coal technology, Equipment maintenance, Mining equipment, Mining maintenance, Mining safety, Mining services, , , , , , , ,

Enerpac and Copper Fluid Systems (CFS) have come to the rescue of a Queensland coal miner looking for a way to safely and efficiently carry out maintenance on its dragline.

The hydraulics leader, in tandem with Queensland distributor CFS, devised a solution that incorporated its RACH306 lightweight aluminium cylinders. This allowed operators to get out on the boom to provide essential maintenance.

Such a system requires special tools offering a combination of high power, light weight, compact size and reliability, Enerpac said. This is where the RACH306 cylinders provided a lightweight solution for tensioning the intermediate boom suspension on the dragline, ensuring it continued to operate without causing excess wear on the main frame.

With a total weight of around 11 kg each, the aluminium cylinders are roughly half the weight of their steel counterparts and provide the same power, with a capacity of 30 t, the company said.

CFS Queensland Regional Manager, Mark Lorber, said: “The lighter weight makes a significant difference to the safety and comfort of maintenance personnel, as the only way to get the tools up on the dragline is to individually transport them out on the boom and spend time precisely positioning them there.

“The Enerpac gear is used to tension the intermediate boom suspension ropes by sliding over threaded rods with 30 mm studs at each of the adjustment points. Hollow cylinders are used because they can slide over the top of the stud. The Enerpac RACH cylinders provide a 6 in (150 mm) stroke with smooth, reliable performance.”

Tensioning these suspension ropes on draglines is an essential maintenance task for mining operations, according to Lorber. A slack or loose rope can cause additional stress, or even cracking on the main frame – especially when digging, he said.

Lorber added: “With draglines typically costing in excess of A$100 million ($64 million), regular preventative maintenance is a vital part of minimising downtime and avoiding unexpected costs. The major advantages of using Enerpac tools in this application are the quality of a market-leading brand, coupled with service support on-site.”

CFS custom designs dragline tensioning system boxes, with each box containing four Enerpac P80 hand pumps, four Enerpac RACH306 aluminium hollow plunger cylinders and MDG41-compliant hydraulic pressure hoses. Four boxes are used in total for each dragline machine, where they are mounted on each boom.

The tensioning system boxes are designed to be weatherproof and protect the hydraulics against dust, which is highly prevalent on open-pit coal mining operations. Additionally, the boxes have a separate shelf for the pump so that it is further protected from dirt, grease and other contaminants, the company said.

Enerpac’s RACH-Series cylinders, with strokes from 50-250 mm, weigh from just 5.2-9 kg for the 20 t models through to a maximum of 48.9-77.2 kg for the range-topping 150 t models. The cylinders are comprised of composite bearings on all moving surfaces to prevent metal-to-metal contact, resist side loads and extend cylinder life.

Complementing the RACH-Series cylinders are Enerpac’s lightweight hand pumps, models P-392 or P-802, which are constructed of composite materials including aluminium to comprise the optimum lightweight pump and cylinder set, according to the company. The cylinders can also be powered by fast-acting Enerpac electric, air and petrol pumps.

Features of the full RAC range include:

  • Hollow plunger design allows for both pull and push forces;
  • Composite bearings increase cylinder life and sideload resistance;
  • Hard-Coat finish on all surfaces resists damage and extends cylinder life;
  • Floating centre tube increases seal and product life;
  • Handles standard on all models;
  • Steel base plate and saddle for protection against load-induced damage;
  • Integral stop ring prevents plunger over-travel and is capable of withstanding the full cylinder capacity;
  • High strength return spring for rapid cylinder retraction;
  • CR-400 coupler and dustcap included on all models; and
  • All cylinders meet ASME B-30.1 and ISO 10100 standards.

Kwatani upskills Northern Cape contractor to carry out maintenance work

Comminution of minerals, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, , , , , ,

Specialist vibrating equipment manufacturer, Kwatani, says it leveraging a recent multi-year service contract with a large mining customer in the Northern Cape of South Africa to further boost the area’s local economy.

Kim Schoepflin, CEO of Kwatani, said: “Our branch near the customer’s mining operation has for many years employed and developed local expertise. Our latest initiative takes this further, by upskilling a local sub-contractor to conduct certain maintenance work on our behalf.”

A lengthy selection process was conducted by Kwatani to find a suitable sub-contractor, followed by ongoing training to empower artisans and other workers with specialised skills. Schoepflin says it was also important to involve the mine itself, so that it remained confident in the strength of its supply chain.

“Promoting local employment, skills and sustainability cannot be a tick-box exercise,” Schoepflin says. “It has to be based on proper engagement, hands-on training and the sub-contractor’s own commitment.”

Mining legislation and regulatory pressure can tempt stakeholders to rush such a process, she warned. “This would be a mistake; rather, it should be treated as an opportunity to strengthen the capability of all stakeholders.”

Kwatani’s 35 years of experience in heavy duty minerals applications means the OEM now has around 800 vibrating screens and feeders in the Northern Cape. The maintenance contract is an ideal opportunity to involve and foster the technical capability of local players, Schoepflin says.

It was vital that the chosen sub-contractor already had considerable experience and capacity, equipment and relevant expertise, according to the company.

“As a South Africa OEM with our own technologies and intellectual property, we are able to certify the sub-contractor and their quality of work,” Schoepflin says. “Phase 1 of our initiative will see them conducting basic service and maintenance functions.”

Kwatani retains responsibility for all work conducted, and continues with services such as detailed technical inspections, engineering support, on-site testing and diagnosis. It also supplies OEM spare parts, ensuring quality control, increased lifecycle time and reduced downtime, the company said.

Schoepflin noted that communities countrywide are eager to see more benefits from economic activity, and the country’s Mining Charter provides clear guidance on how mining companies can contribute to this process. “Kwatani’s mining customer is therefore also eager and incentivised to promote local businesses, both directly and through the supply chains of its main local contractors,” Kwatani said.

Schoepflin highlights the importance of supporting local firms to build sustainability in the local economy. This also strengthens the skills base for this economy to diversify, making it less dependent on mining and more resilient to commodity cycles and eventual mine closure.

“Our own business is local from the ground up, sourcing 99% of direct purchases from inside South Africa,” she says. “So, we understand the positive role that local procurement and skills development can play.”

It also makes financial sense to root the company’s cost base in the local currency, making it less vulnerable to foreign exchange fluctuations and allowing more affordable and consistent pricing.

“Working collaboratively with our mining customers and businesses close to their operations, we can help spread local economic benefits,” she says. “In turn, we can continue to develop our focus on leading-edge technology and quality manufacture.”

Radicon’s Bloxwich on gearbox maintenance in mines

Equipment maintenance, Mining consumables, Mining equipment, Mining maintenance, Mining services, , , ,

As IM goes to press on its first monthly issue of 2020, which includes its annual feature on mine maintenance, Giles Bloxwich, Service Manager at Radicon, has warned miners that they need to prepare for gearbox failures with an effective maintenance program.

He issues this warning knowing full well that these components can take anywhere from 3-14 months to build and some operators have lost as much as £1 million/d ($1.32 million/d) as a result of gearbox failure and subsequent downtime.

As with other gearboxes, industrial gearboxes such as those used in mining, see bearings tire, oil seals break down and oil thin as they get older. All of these issues reduce the amount of protection for the gearbox, with wearing and damage accelerating at a startling pace when you get unprotected metal on metal, according to Radicon.

“Mining is one of the harshest of environments and, over time, gearboxes get a hell of a lot of battering,” Bloxwitch (pictured) said. “Underground conveyors, in particular, operate in the most extreme of conditions. An oil change every 12 months or more frequently is definitely needed.”

When Radicon was working with former coal miner, UK Coal, oil samples would be tested every three months, with the company looking at the viscosity of the oil and contamination levels. If the oil was too thin, or contamination was beginning to reach worrying levels, an oil change would be undertaken.

As well as analysing oil regularly, Radicon also recommends undertaking vibration analysis along with scheduled bearing and seal checks. New bearings and seals should, if they are good quality, last for around five years but this can be a lot less in a mine, according to the company.

“Bearing life is the limiting factor of gearbox life,” Bloxwitch said. “If a bearing collapses, gears will drop out of mesh causing shaft breakage and gear tooth damage. This is expensive to rectify and can lead to weeks of downtime.”

Bearings will also be affected by shock loads and jams, according to Bloxwitch, with Radicon recommending replacing bearings before they fail.

“You cannot see inside a bearing, so it’s impossible to know for sure that a bearing is damaged,” Bloxwitch said. “We always tell our customers to be cautious and, if they do have a jam or a shock load, to consider the bearings damaged and to monitor their gearbox closely.”

One method of monitoring is recording and analysing vibration, as this will identify issues with gear mesh or bearing wear. Radicon believes that vibration testing should be carried out every three months, if not more often.

As well as vibrations and the level of metal content in the oil, noise and heat are two other indicators that a service is needed, Radicon said. “If a gearbox becomes louder and hotter during operation, then it could well be time to undertake routine maintenance as the viscosity of the oil could have reduced to such a level that bearing wear is occurring,” the company explained.

Some bearings now feature a temperature probe and an accelerometer, which allows vibration and heat levels to be recorded. “It’s not commonplace but is worthwhile,” Bloxwitch said. “Adding this functionality to the gearbox means operators will be alerted as soon as something changes and that can save them thousands of pounds, if not tens or hundreds of thousands!”

As well as regular oil changes, vibration analysis and following a maintenance program that replaces consumables regularly, including bearings, breathers and seals, keeping the gearbox as clean as possible is another way of prolonging the unit’s life.

Boliden Kevitsa collaborating on process plant maintenance

Base metals, Comminution of minerals, Communications in mining, Equipment maintenance, IoT, Mine operation news, Mineral processing, Mining equipment, Mining maintenance, Mining services, Mining software, , , , , , , , , , , , ,

Boliden is a front-runner when it comes to applying technology and innovation to its Europe-based mines, and the company is now leading an industry move in condition monitoring and predictive maintenance in its process plants.

At its Kevitsa copper-nickel mine, 130 km north of the Arctic Circle in Finland, Boliden has been collaborating with the likes of IBM Maximo, OSISoft, SKF and Metso on condition monitoring and predictive maintenance solutions, according to Sami Pelkonen, Maintenance and Engineering Manager at Boliden Kevitsa.

Expansion in the plans

The mine is in the throes of an SEK800 million ($82 million) expansion that will see plant throughput go from 7.8 Mt/y to 9.5 Mt/y. This involves the addition of a new autogenous mill and peripheral equipment (including a new Metso MF series screen), and a new mill building. Commissioning of the new equipment is expected in 2020, with the mine reaching full 9.5 Mt/y capacity in 2021.

With this expansion going on, plant maintenance has moved up the agenda.

Some 80% of process plant maintenance is currently pre-scheduled, with the Kevitsa mine achieving, on average, 93% availability from its equipment, according to Pelkonen, but Boliden Kevitsa is looking to increase these numbers.

Pelkonen told IM late in October that the Kevitsa mine has been looking to acquire “good quality…and useful data to support our daily maintenance operations and procedures” at its plant. This is all part of the company’s plan to increase uptime and cut costs at the operation.

As part of this initiative, it installed the IBM Maximo asset management system in May of this year. At the same time, the operation has been working with the Boliden Mines Technology Department on a wider asset management program.

When it comes to plant reliability, Boliden Kevitsa has enlisted the help of SKF (for condition monitoring of bearings throughout the plant), OSISoft for process data acquisition, and Metso to ensure uptime of mineral processing equipment is maximised and unplanned downtime is reduced.

Partnering for performance

The partnership with Metso dates back to before the mine was acquired by Boliden in 2016, but in recent years the two have collaborated on crusher and mill uptime projects, with the OEM supplying mill liners and wear parts that can be switched out quickly and cost effectively. The two firms have also been in constant communication about accessing and analysing valuable process plant data during the last three years.

When the mine acquired a new MF screen from Metso in May (pictured), it decided now was the time to trial the new Metso Metrics predictive maintenance platform in this part of the flowsheet.

Pelkonen explained: “After the increase in production (to 9.5 Mt/y), the front end will be even more critical for us, so we have to be aware if any failures are developing in our front end; especially in our screen.”

The remote location of Kevitsa, situated some 40 km by road from Sodankylä, is also behind the need for this type of condition monitoring and predictive maintenance.

“If something happens like we have an equipment failure, it takes around one hour for our employees to get to the mine,” he said. “Condition monitoring helps us address the need to get resources to site in the correct time.”

The Metso Metrics test paid off almost instantly, when, soon after installation, the company noticed there was something wrong with the running speed of the screen.

“The indication we received from Metso Metrics helped us map out that there were two broken V belts. We were able to cut the downtime to a minimum thanks to the information coming from Metrics,” Pelkonen explained.

Sami Pelkonen was speaking to IM as part of an upcoming Insight Interview with experts from Boliden Kevitsa and Metso that will be published in early-2020

H-E Parts to work on mobile equipment fleets at Glencore coal mines

Equipment maintenance, Mining equipment, Mining maintenance, Mining services, , , , , , , ,

H-E Parts says it has been awarded a one-year supply agreement from Glencore that will see the company supply and overhaul new and service exchange radiators on mobile equipment fleets across 24 coal mines in Australia.

The contract with Glencore Coal Assets Australia has the provision for a further 12-month extension based on performance and includes all ancillary mining equipment, as well as prime production mining truck, excavator and drill rig fleets.

The contract will be managed by H-E Parts’ Mining Solutions Cooling Division branches and incorporates various styles of independent radiators and complete modular nose cones, including the radiator, fan and motor and charge air cooler as a complete assembly, according to the company.

H-E Parts says: “The complete range of COR Cooling™ products are designed to provide extended service intervals, improved performance and increased productivity, whilst reducing equipment downtime and associated life cycle costs.”

Ashley Hams, Mining Solutions Vice President, said: “Through historic and ongoing service delivery as well as continuous product engineering innovation, our COR Cooling product and service lines have advanced to be a market leader.”

Hams added: “The ability to supply application specific cooling systems to our mining and industrial customers working in some of the toughest conditions in the world has demonstrated the engineering and quality prowess that H-E Parts has become synonymous with.”

H-E Parts said it believes that the partnership of the proven COR Cooling product line, combined with in-house engineering and service support, will provide a flexible, cost-effective, long-term solution for Glencore.

Earlier this week, H-E Parts announced it had acquired Allgo Engineering (Allgo). Although occurring in late 2018, H-E Parts had deferred announcement to facilitate the completion of a new 100 t facility and the upgrading of equipment and machining capabilities that will allow Allgo to handle some of the largest mining, marine and oil & gas components required by the Western Australia market, it said.

Petro-Canada Lubricants bolsters fleet protection with new engine oils

Environmental, Equipment maintenance, Mining consumables, Mining services, Sustainable mining, , ,

Petro-Canada Lubricants has expanded its TRAXON™ and DURON engine oil product lines with the launches of DURON™ Advanced 5W-30 and TRAXON Synthetic 75W-85.

The company, a HollyFrontier business, said the introduction of these new oils demonstrates its continued product innovation to help fleets meet new and emerging market trends.

DURON Advanced 5W-30 is a fully synthetic formulation designed to meet and exceed the requirements of the American Petroleum Institute’s (API) FA-4 standard. It has also been approved by major diesel engine original equipment manufacturers (OEMs) Cummins and Detroit Diesel.

This product line offers durable low viscosity, high performing synthetic and synthetic blend heavy duty diesel engine oils that are designed for emerging and future fuel-efficient engines, the company said. “These oils provide enhanced fuel economy, durability, engine protection and shear stability for the latest heavy-duty engines.”

TRAXON Synthetic 75W-85, meanwhile, expands the existing TRAXON Synthetic range providing fleet owners and operators with enhanced efficiency and long-lasting wear protection that can lead to longer equipment life and reduced unplanned downtime and associated maintenance costs.

“Offering year-round performance in the harshest environments, TRAXON Synthetic 75W-85 provides easier start-ups and improved cold weather shifting for manual transmissions, hypoid gears and rear axles,” the company said.

This low viscosity hypoid gear oil is designed to meet API Gear Lubricant Service GL-5 and API MT-1 Gear Lubricant standards and MACK GO-J standards for heavy-duty manual transmissions. It is also approved against the SAE J2360 Global Standard, the company said. The oil is suitable for use where Volvo 1273, 12 (97312) and Meritor 0-76-J specifications are required.

Alex Buczek, Category Manager of Heavy-Duty Engine and Driveline Oils, Petro-Canada Lubricants, said the new oils were specifically formulated to exceed industry requirements and offer improved performance and protection for fleets.

He added: “Our entire high performance, heavy-duty product line is designed with one purpose – to protect your bottom line. Our products help to make fleet equipment longer-lasting and more reliable; therefore operations can be more productive and profitable.”

Weir Minerals takes a load off slurry pump maintenance

Comminution of minerals, Equipment maintenance, Mining equipment, Mining maintenance, Mining services, Water management, , , , , , ,

An often-overlooked component, lifting tools help keep workers safe, maximise equipment life and can reduce pump rebuild times, according to Weir Minerals.

These tools have become increasingly important for handling slurry pump parts during maintenance as processing equipment has become larger and larger.

David Russell, Trials Manager for Weir Minerals Australia, says: “We have a duty of care to our customers to ensure they remain safe when operating and maintaining our equipment. Adopting our uniquely engineered lifting tools for our slurry pumps mean that when the correct procedures are followed, it’s very safe.”

It was only in the 1990s when a Warman® AH® 20/18 pump, was one of the largest available on the market. Now, it is regarded as a medium-sized model, outdone by the likes of the Warman® MCR® 760 pump.

Weir said: “As equipment has rapidly increased in scale over the past couple of decades, Weir Minerals has developed specially engineered tools to safely disassemble and reassemble machinery, reducing the risks associated with lifting components.”

In the case of slurry pumps, Weir Minerals’ range of lifting tools are designed for use when performing wet-end overhauls. Specific lifting tools are used for impellers, throatbushes, suction covers, frame plate liner inserts, stuffing boxes, casings and volutes.

These tools have also been designed to lift multiple components together to make rebuilds easier and quicker. For example, a lifting beam has been developed that lifts a suction cover squarely with the throatbush still attached to it.
“Using purpose designed assembly equipment in accordance with OEM lifting procedures can reduce rebuild time, in some cases by up to 50%, leading to increased plant uptime and availability,” the company said.

Russell said: “When lifting pump parts weighing more than two tonnes in restricted areas, there is little room for error. Often, the components will be worn and it is crucial they can still be secured and lifted safely in accordance with the strict global standards that Weir Minerals adheres to.”

When designing lifting equipment, Weir Minerals says it also carefully considers the mechanical strength and the stresses placed on the components being lifted, since worn parts are likely to be weaker and more brittle than new parts.

When it comes to impeller lifting tools, some competitors may employ a simple hook design, increasing the risk of the impeller falling off. Weir Minerals has developed a tool with a fixed locking jaw so that the impeller eye is locked in position and the component is properly secured prior to being lifted, the company says. “This positive engagement across two points of contact ensures that components are lifted evenly and securely with minimal risk of injury,” it said.

Independently certified in each region, the tools are manufactured and sold to meet local health and safety requirements, according to the company.

Joel Goodwin, Weir Minerals’ Aftermarket Manager for Warman pumps, said: “Safety is central in everything we do at Weir Minerals.

“We are an OEM supplier who complies with global safety standards and we adopt a stage-gated development process incorporating risk assessments and product stewardship best practice for equipment design and lifting.”

ABB tightens bulk handling roller bearing offering with Dodge Safety Mount

Bulk handling, Equipment maintenance, Mining consumables, , , , ,

ABB says the built-in patented locking mechanism on its newly launched Dodge® Safety Mount spherical roller bearings reduces installation time by up to 75% compared with traditional products.

Best suited for bulk material and air handling applications, the new bearing mounts by tightening fasteners instead of using a hammer and other tools. The new system also allows for simple installation and removal from the same side of the bearing, which means only one person is needed for the task, according to ABB.

“The new mounting system replaces the blows of a hammer with the tightening of fasteners,” Jim Madsen, Dodge Mounted Roller Bearing Product Manager, ABB, said. “It also makes it faster to install large bearings, but more importantly, it makes is safer for the installer.”

Safety Mount bearings feature a triple-lip contact seal and corrosion-resistant flinger sealing system, which prevents contamination from entering the product during installation and operation, ABB says. A labyrinth seal option is available for high-speed and high-temperature applications.

Dodge Safety Mount spherical roller bearings come ready for installation of the ABB AbilityTM Smart Sensor for mounted bearings, a wireless sensor that monitors the health of bearings.

The company said: “Safety Mount spherical roller bearings combine the advantages of the Dodge Imperial family of bearings; factory sealed and greased, shaft ready out of the box, with no feeler gauges required.” They are offered in split cap and single piece housing options in standard SAF, metric SN, Type E, and Imperial housing dimensions in sizes 4-15/16” to 7” (115-170 mm).