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Demand for vibration monitoring equipment increasing

29th August 2014

By: Mia Breytenbach

Creamer Media Deputy Editor: Features

  

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There is an increasing demand for remote diagnostics of mobile and fixed mining assets using portable vibration monitoring equipment, which is why process management solutions company Emerson Process Management aims to expand this type of technology, so that companies can detect developing operational issues and mechanical problems.

Emerson’s PeakVue technology enables the earliest available insight into the development of mechanical problems. This technology works by separating the high-frequency, short- duration stress waves from regular vibration data. These stress waves are generated from faults that cause impacting, friction and fatigue, particularly in gearboxes and rolling element bearings, thereby enabling mining companies to detect problems early.

“Mines are trying to move to zero unplanned downtime and being able to detect impending problems, prior to any impact on production and operations, gives them the ability to achieve this,” says Emerson Process Management mining marketing director Doug Morris.

He notes that, owing to the remoteness of many mine sites, there are not enough experienced analysts to meet the need for remote monitoring and diagnostics for condition monitoring.

Emerson Process Management is, therefore, performing these services remotely through its Middle East and Africa (MEA) and North American organisations, and currently has several MEA customers benefiting from remote vibration analysis services.

Morris believes that the need for increased reliability and availability is driving the adoption of this proven technology in the mining industry.

He highlights that demand has increased for Emerson’s vibration monitoring equipment, including its CSI 2140 Machinery Health Analyser, which has proven its capabilities in multiple applications.

Morris says the former model, the Emerson CSI 2130 Analyser, has led the industry in speed and power for route-based vibration analysis. The release of the faster, more powerful CSI 2140 Analyser, launched in June 2013, is a hand-held device that can detect impending mechanical defects in the gears and bearings of mining equipment, such as drive systems, transmissions, and bearings for electric rope shovels, stacker/reclaimers, conveyors, mills and slurry pumps.

The CSI 2140 portable analyser also has a battery life of more than ten hours, which is ample for a typical shift, he adds.

Sensors are fitted to the equipment, which provide the CSI 2140 with data. The analyser processes this data using Emerson’s PeakVue technology that enables the analyser to identify any possible issues in real time.

“Adoption of the CSI 2140 for portable vibration analysis in the market is rapid – more than Emerson had anticipated. It also has a wide use in every industry worldwide and several mines are using the technology,” Morris notes, highlighting the significant advantages of the device, such as speed, accuracy and analysis of reliable data.

While Morris believes the CSI 2140 Machinery Health Analyser is “gaining momentum in the field”, he adds that more than 60% of the CSI 2140 analysers have either displaced competitors or have been sold to new customer sites.

He attributes the increase in analyser sales to a leap-change in ease of use and user-friendliness, as Emerson has ensured that the analyser incorporates human-centred design principles.

Industry Trends
Morris notes that automation and the reliability of equipment are being acknowledged as vital requirements, owing to increased asset performance requirements, budget constraints and a declining availability of skilled workers.

He maintains that the mining industry is focusing more on using intelligent devices in the mining industry.

Further, the company notes that, as declining ore grades are being processed, there is a need to keep equipment on line. “Since more ore has to be processed to yield the same output from a plant, a premium is being placed on equipment availability, while companies are focusing on productivity instead of production volumes,” he says.

Therefore, companies are considering advanced process-control techniques to improve concentration plant recoveries.

In light of this, Emerson provides optimisation tools and capabilities to help plants improve operations. “With ore grades deteriorating, it has become more important to improve recovery rates,” Morris adds, noting that the company’s technologies can be used in these processes.

Nevertheless, the biggest potential for growth for new mining technologies still lies in online condition monitoring and advanced process control, as well as wireless measurement technologies and integrated reliability, he concludes.

Edited by Samantha Herbst
Creamer Media Deputy Editor

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