MINING CASE STUDY
Longer Service Intervals for Mining Fleets
See how an open-pit copper mining operation used Tan Delta oil condition monitoring to extend fleet service intervals and reduce maintenance costs and oil consumption.
500 HOURS
Previous service interval
678 HOURS
Revised service interval
26% REDUCTION
Maintenance costs and oil consumption
THE OPERATION
An Open-Pit Copper Mining Fleet
The case study covers a large open-pit copper mining operation in the United States, mining more than 20,000 tonnes per day.
Its fleet comprised 60 trucks, 10 shovels and 15 auxiliary units. The operator needed to minimise maintenance costs while maintaining equipment reliability and availability.
THE CHALLENGE
Fixed Intervals, Costly Fleet Downtime
The fleet followed fixed 500-hour service intervals, regardless of actual oil condition. This created routine maintenance downtime and oil changes that could occur before they were needed.
Between services, the maintenance team also needed earlier warning of developing problems. With dump truck downtime costing up to US$1,000 per hour, the challenge was to reduce unnecessary servicing while maintaining equipment reliability.
THE SOLUTION
Condition-Based Fleet Servicing
SENSE-3 monitoring kits were retrofitted across the fleet to provide real-time oil condition data. Readings were transmitted via WiFi or 4G, helping the maintenance team plan servicing around actual oil condition.
Connected Fleet Monitoring
Oil quality sensors monitor individual engine, gearbox and hydraulic oil systems. The SENSE-3 gateway transmits condition data for remote access by the maintenance team.
Condition-Based Servicing
Water, fuel, coolant and other process fluids can enter the lubrication system through seals, condensation, leaks or operating conditions, affecting the oil’s ability to lubricate and protect components.
THE OUTCOME
From 500 to 678 Hours Between Services
Using oil condition data to guide servicing, the operator increased the service interval from 500 to 678 hours. Tan Delta reports a 26% reduction in maintenance costs and oil consumption for this application.
Continuous monitoring also gave the maintenance team earlier visibility of abnormal oil condition changes, supporting investigation and preventative maintenance before developing issues caused further damage.
Source: Tan Delta Systems’ published mining case study. Results relate to this application and will vary with equipment, operating conditions and maintenance practices.
LOCAL TAN DELTA SUPPORT
Discuss Your Mining Equipment Monitoring Requirements
Speak with Oreflow about monitoring your fleet or fixed plant. We can help assess your equipment, installation and data-access requirements to identify suitable Tan Delta monitoring options.