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Reliability-Centered Maintenance of Rapier Dragline for Optimizing Replacement Interval of Dragline Components
Mining, Metallurgy & Exploration ( IF 1.9 ) Pub Date : 2020-05-28 , DOI: 10.1007/s42461-020-00226-5
Sanjay Kumar Palei , Smarak Das , Snehamoy Chatterjee

Machine manufacturers’ recommendations on maintenance strategies of capital-intensive draglines are not always based on real data and therefore lead to losses from downtime. This paper proposes a preventive maintenance strategy for a dragline deployed in an opencast coal mine based on reliability-centered maintenance and failure-mode-effects analysis using real operational data. Reliability-centered maintenance replaced a cluster of critical failure components of the dragline while satisfying two specific conditions: (i) the components should be replaced at the earliest mean time to failure (MTTF) within the group and (ii) the time taken to replace all the parts should be equivalent to the maximum downtime within the group. Estimated threshold weightage factor identified twenty-six critical failure components for the preventive maintenance strategy, and clustering of components divided them into nine groups. In a group, the loss that is expected to occur by replacing some of the components before their failure, and the gain by reducing the overall maintenance downtime, has been explained through a cost-benefit analysis. The total net profit generated is calculated as US$200,178. This clustering activity also led to a reduction of annual downtime by 231 h, whose approximate market price as equivalent coal production costs $295,365.

中文翻译:

以可靠性为中心的剑杆拉铲维修优化拉铲部件更换间隔

机器制造商关于资本密集型拉铲维护策略的建议并不总是基于真实数据,因此会导致停机损失。本文基于以可靠性为中心的维护和使用真实操作数据的故障模式影响分析,提出了一种露天煤矿拉铲的预防性维护策略。以可靠性为中心的维护更换了拉铲的一组关键故障组件,同时满足两个特定条件:(i) 组件应在组内最早的平均故障时间 (MTTF) 和 (ii) 更换所需的时间所有部件应相当于组内的最大停机时间。估计阈值权重因子确定了预防性维护策略的 26 个关键故障组件,并将组件聚类将它们分为九组。在一个组中,通过在发生故障之前更换一些组件而预期会发生的损失,以及通过减少整体维护停机时间而获得的收益,已经通过成本效益分析进行了解释。产生的净利润总额计算为200,178美元。这种集群活动还导致年度停机时间减少了 231 小时,其市场价格与等价煤炭生产成本为 295,365 美元。已经通过成本效益分析进行了解释。产生的净利润总额计算为200,178美元。这种集群活动还导致年度停机时间减少了 231 小时,其市场价格与等价煤炭生产成本为 295,365 美元。已经通过成本效益分析进行了解释。产生的净利润总额计算为200,178美元。这种集群活动还导致年度停机时间减少了 231 小时,其市场价格与等价煤炭生产成本为 295,365 美元。
更新日期:2020-05-28
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