Condition Monitoring Planning
Moving from preventive to predictive maintenance

Problem

Increasing reliability and lowering maintenance costs are key differentiators in today’s highly competitive mining environment. Understanding mine equipment criticality and failure shows where maintenance effort should be focused to mitigate risk. One of the areas of focus based on criticality is conveying systems. These conveyors are typically single points of failure and, therefore, have high criticalities. The conveying system’s multiple rotating components, length and remoteness increase the complexity of maintaining these systems. When conveyor operations are closely monitored, it’s possible to predict mechanical failures before they occur. In fact, recent studies indicate up to 90% of machinery malfunctions are predictable. In many cases, maintenance can be performed online without any interruption in service. The largest mining company in india is looking for online condition monitoring solution for their critical assets of coal washery.

Solution

As a part of solution implementation, smart vibration sensors were commissioned on conveyor belt systems across the coal washery. When we say smart sensors, it means that these sensors are equipment with edge computing features. These sensors understand the vibration patterns and machine kinematics and intelligently push processed data to cloud servers. Next stage of intelligent computing happens on cloud where the machine learning algorithms work on the data and identify hidden patterns in data. These intelligent algorithms continuously learn from machine behavior and predict next breakdown event. With the current machine and deep learning algorithms. From being reactive, the customer migrated themselves to a platform where they no longer need to worry about next maintenance activity and machine health analytics. It’s all intelligent now!!!

ONLINE

CONDITION

MONITORING

OF 12

CRITICAL

ASSETS

4% OVERALL

SAVINGS IN

MAINTAINANCE

COSTS

ABILITY TO

DETECT

TRANSIENT

AND

SPURIOUS EVENTS

The solution enabled the stakeholders to diagnose the problem early with the predictive health algorithms doing their job. Now there is no need of unplanned diagnostic plant shutdowns in the middle of the day. With the operational data already been available on Adani cloud data center, it has become much easier to correlate machine health with operational parameters.

WE DID THIS FOR THEM.

WE CAN DO IT FOR YOU

Find out more about how you can use IOT for manufacturing and target for zero losses and waste.

Reach out to us at

sales@carbynetech.com