optimising pm intervals · maintenance cost savings • extended the hydraulic and steering oil...

OPTIMISING PM INTERVALSPAUL KRANS: PHU BIA MINING.

Balikpapan 16th October 2018/Bangkok 18-19th October 2018

Preventative maintenance optimisation

Reviewing oil analysis data to fine tune

preventative maintenance intervals

Why optimise preventative maintenance?

More Less

Risk versus reward equation

Risk

Reward

It is all about finding the balance point

The oil analysis evolution

Monitor equipment

health

Look for unfavourable

conditions

Study wear metals that are

being generated

Look for trends

Optimise preventative maintenance

practices

Preventative maintenance intervals

Most equipment owners will adhere to the OEM recommendation

Caterpillar state the regular oil sampling should be used to optimise oil drain intervals for a given piece of equipment

Can we extend, or should we reduce preventative maintenance intervals?

What is ideal?

A cold, 3,500 metre altitude mine site

Tribology staff working with the LIMS

A condition report from our own laboratory

The Phu Kham 777D fleet

Iron, chrome and lead soot and TBN were studied for the engines

Iron, copper and lead and particle sizes (6µ and 14µ size) for:

• steering fluid

• Transmission

• Diff and final drives

• Front wheel bearings

We chose the following criteria to analyse

Iron ppm versus hours

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

0 100 200 300 400 500 600 700 800

Fe (

Iro

n)

PP

M

Hours on oil

TBN versus hours

4.00

5.00

6.00

7.00

8.00

9.00

10.00

11.00

0 100 200 300 400 500 600 700 800

TB

N (

alk

ylin

ity)

Hours on oil

ISO particle count versus hours

12

14

16

18

20

22

24

26

0 500 1000 1500 2000 2500

6 M

icro

n I

SO

co

un

t

Hours on oil

Maintenance cost savings

• Extended the hydraulic and steering oil drain

intervals to 4,800 hours

• Routine preventative maintenance costs reduced by

more than US$300,000 for the fleet

• 27.8 hours increased availability valued close to

US$800,000 annually

• The total cost saving of more than US$1 million was

realised

• Optimising preventative maintenance and other

initiatives saw the availability of the 777D fleet

increase from 91.65 to 95.45 per cent the following

year

Questions?