Page 61 - Hub-4 Magazine Issue 70

Quarrying
Condition monitoring systems, like those offered by Haver & Boecker Niagara, include permanently affixed sensors for 24/7 monitoring and data collection for trends analysis. Some systems include automated alerts if problems are detected, allowing for a quick shutdown
accumulating data can be used to improve efficiency by illustrating trends, making predictions as to how long before an issue may arise, and more. Some around-the-clock monitoring systems allow OEM certified technicians to monitor results remotely, analyze the data and send expert recommendations to ensure equipment longevity.
While many vibration analysis and condition monitoring tools are available, only a small number are manufactured by a vibrating screen OEM. An OEM offers the benefit of having engineered the equipment, fully understanding its operational parameters, and providing in-depth analysis and recommendations.
In one recent example of an operation benefiting from these tools and services, a British Columbia producer worked with an OEM to conduct a vibration analysis on a vibrating screen that appeared to be healthy. The resulting data indicated a problem, however, and caused the operation to discover a broken spring which had led to damage to the vibrating screen’s foundation. Catching the problem early saved the producer money in downtime and repair costs.
Many producers conduct biannual vibration analysis tests on their vibrating screens. Another western Canadian producer has saved significant time and money through the service by detecting problems early on that he and his team weren’t able to immediately otherwise identify, including a twisted frame on one of the vibrating screens. In this case, they knew something was wrong, but it took a vibration analysis to determine exactly what.
Plant Simulation Software
Plant simulation tools offer a high-level view of an entire operation’s efficiency. This helps optimize processes and look at opportunities for improvement in both existing sites and new mines or quarries for all mineral processing operations. The software also helps operations spot and fix bottlenecks.
Plant simulation programs take into account the equipment used throughout the plant, from material washers and conveyers to crushers and vibrating screens. The operation’s existing setup, or a proposed setup, is entered into the program to understand and predict overall performance and
plant flow. The systems use scientific calculations to monitor input, output and waste piles, as well as calculating mass and volumetric flow rates based on machine placement and machine-specific operating parameters. The tool is also useful for insights into product specification or production rate changes — such as dry and wet crushing, screening and sorting — as the software can be used for pre-calculations.
A quick search will turn up a handful of brands of plant simulation software, but few are created by processing equipment OEMs. While solid functionality and user interface are clearly important, extensive experience and understanding of the equipment and processes the software is meant to optimize may be more so. Partnering with an OEM can allow for the most accurate simulations and enhanced features based on engineering expertise and application knowledge gained from actual site visits and understanding an operation’s challenges firsthand. An OEM can interpret the data to provide recommendations for improvements within the operation
Partnering with an OEM can include the benefits of site visits by certified technicians who not only know how to use the vibration analysis, condition monitoring, and plant simulation tools, but are able to conduct thorough vibrating screen and screen media inspections to complement the
analysis.
regarding production and profits. In addition, OEMs may offer virtual or on-site training of their software, teaching both how to use the software correctly and how to implement it in a way that benefits plant flow and design.
Comprehensive Service Approach
Any service tool is most effective when paired with a comprehensive, hands-on service approach. Partnering with an OEM can include the benefits of site visits by certified technicians who not only know how to use the vibration analysis, condition monitoring, and plant simulation tools, but are able to conduct thorough vibrating screen and screen media inspections to complement the analysis. Some OEM technicians follow the inspections with diagnostic reports to point out areas that could be improved.
OEM warranty programs can be another benefit of partnering with a manufacturer on a service program. Some are offered for up to three years and include biannual site visits, inspections, vibration analysis, screen media evaluations and overall recommendations.
A Member of your Team
Choosing to partner with a technical OEM for equipment monitoring through diagnostic tools — in addition to regular service — results in a comprehensive service program designed to optimize plant flow, boost production and increase profits, keeping the heart of an operation in optimum health.
Plant simulation tools — like Haver & Boecker Niagara’s NIAflow, pictured here — offer a high-level view of an entire operation’s efficiency. This helps optimize processes and look at opportunities for improvement in both existing sites and new mines or quarries for all mineral processing operations. The software also helps operations spot and fix bottlenecks.
www.hub-4.com Sept-Oct 21 - Issue 70
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