Application of Predictive Techniques

in Smelters for wear monitoring and

early detection of failures

Rubén Barrientos Figueroa

Maintenance Superintendent
Anglo American Chile
Chagres Division

The Anglo American Conference on Condition Monitoring and Non-destructive Testing

18 & 19 November 2008

D2-8
D2-8 Anglo American Chile – Chagres Division
 Location South America - Chile

D2-8 3 Anglo American Chile – Chagres Division

 Current Process (flow sheet)

D2-8 4 Anglo American Chile – Chagres Division

 Extreme conditions in the process

P T°C Flux Speed

Concentrates handling - 200°C - -
Steam handling 6,500 kPa 276°C 24 ton/hr -
Metallurgical Gases (blowers) - 400°C 150,000 Nm3/hr 4,500 rpm
Liquids copper slag and matte - 1300°C - -
Oxygen Production (compressors) - - - 4,000 rpm

Work environment:
• Corrosion by gases (S, SO2, SO3)
• Abrasion minerals handling

D2-8 5 Anglo American Chile – Chagres Division

 Maintenance Approach based AM
Maintenance Approach Strategy 2

Criticality B Criticality A
Goals: Goals:
Develop application specific tasks per Develop application specific tasks per equipment and component through full RCM-
equipment through a RCM-based process. based process with support from OEM’s.
Tactics: Tactics:
Production unit and equipment criticality Equipment and component criticality + failure analysis
EMP per equipment EMP sheet per equipment and component
Bi-annual review of tasks Annual review of tasks APL’s contain:
Review as triggered by RCA (level 2+) Review as triggered by RCA (level 2+) Mandatory, optional spares
Performance tracking per production unit Performance tracking per equipment Pre-inspected identified spares
Special tools and resources
Criticality C APL’s contain: Inventory Management Policy:
Mandatory, optional spares Criticality A
Goals: Inventory Management Policy: Expected Approach Profile:
Adopt OEM generic task Criticality B
Consequences

recommendations per equipment

and review/improve through
triggered RCA. Expected Approach Profile:

Tactics:
Production unit and equipment criticality
OEM generic specifications and equipment type
tasks KPI’s: KPI’s:
Performance tracking per production unit Availability per production unit OEE per production unit, drill
Performance rate per down to equipment level
production unit MTBF per equipment
APL’s contain: MTBF per production unit MTTR per equipment
Mandatory spares MTTR per production unit Programmed v Un-programmed
Inventory Management Policy: tasks
Criticality C

Expected Approach Profile: KPI’s:

Availability per production unit
MTBF per production unit

Condition based Maintenance

Probability of Failure
D2-8 6 Anglo American Chile – Chagres Division
 Maintenance Chagres: Global Approach

50%

40%
Utilization

30%

20%

10%

0%
Run to Failure Usage Based Condition Based Design Imp

Chagres World Class

D2-8 7 Anglo American Chile – Chagres Division

 How many
resources do we
have for
Predictive
Maintenance?

D2-8 8 Anglo American Chile – Chagres Division

 Chagres Maintenance Team

General Manager

Production Manager

Maintenance Spte.

Fusion Conversion & Refining Acid Plant & Supply Electricity

Maintenance & Predictive
Instrumentation &
Engineerig
Control

Transverse Support
1 Mechanical Eng 1 Mechanical Eng 1 Mechanical Eng 1 Electrical Eng 1 Mechanical Eng

09 Mechanics 08 Mechanics 11 Mechanic 10 Electricians Mechanical Service

10 Instrumentalist 09 Mech
(shits included) 02 Mech Services

Own 6 Supervisors 03 Predictive Tech

65 Employees
(26% of total)
03 Planners

Contractors 45 Sup/Emp
(30% of total)

D2-8 9 Anglo American Chile – Chagres Division

 Predictive Techniques and Equipment

Termografía

Infrared Thermal Images Vibration Analysis

FLIR Model P60 Predict DLI – Mod. DCX-XRT

Ultrasonic thickness measurer

Panametrics Model 26XTDL

D2-8 10 Anglo American Chile – Chagres Division

 Predictive Techniques and Equipment

Magnetic particle
& Penetrant Inspection Digital Ultrasonic Inspection
Magnaflux UE Systems Model UP9000

Digital Ultrasonic Tester

Krautkramer Model USM25S

D2-8 11 Anglo American Chile – Chagres Division

 Some examples
on condition
monitoring

D2-8 12 Anglo American Chile – Chagres Division

 Infrared
Thermography

D2-8 13 Anglo American Chile – Chagres Division

 Infrared Thermography Report

• Includes thermal and normal image

• Extremes temperature identification
• Analysis and diagnosis
• Recommendations

D2-8 14 Anglo American Chile – Chagres Division

 Infrared Thermal Image

Gas Pipelines Boiler cooling circuit Slag Cleaning Furnaces

Obstruction & Wear Obstruction & Wear Wear

D2-8 15 Anglo American Chile – Chagres Division

 Vibration
Analysis

D2-8 16 Anglo American Chile – Chagres Division

 Vibration Analysis Individual Report

Page 1 Page 2 Page 3

General Information Measuring points and values Analysis
Standard applied Diagnosis
General state Recommendations

D2-8 17 Anglo American Chile – Chagres Division

 Vibration Analysis Monthly Report

INFORME MENSUAL MANTENCIÓN PREDICTIVA - AGOSTO 2008

EQUIPOS EN ALERTA
EQUIPO OBSERVACIÓN MEDICIÓN ESTADO SEVERIDAD PROCESO

Ventilador # 2 Sala Acustica Fuera de Servicio Inaceptable Fusión

Bba. # 1 Enfriamiento Chaqueta Alta Vibrac. Tangencial lado Cola 8.5 mm/seg 27.08.2008 Inaceptable Fusión

Colector de polvo Wheelebrator Desbalanceo Impulsor 03.04.2008 Inaceptable Fusión

Reductor Secador # 1 Alto Contenido Fierro, Cromo, Cobre, Silice 20.06.2008 Inaceptable Fusión

Ventilador # 1 Sala Acustica Desbalanceo Impulsor 14 mm/seg 21.08.2008 Alerta Fusión

Vent. Filtro Mangas Tolva 50 Ton. Juego axial Motor 02.09.2008 Inaceptable Fusión

Compresor Demag # 1 Polvo R. Altas Temperatura y Vibraciones 29.08.2008 Inaceptable Suministro

Compresor Demag # 2 Polvo R. Alto contenido Fierro, Cobre, Sodio, Si. 19.08.2008 Inaceptable Suministro

GHH # 2 Aumento Vibrac.Multiplicador 6R 13mm/seg 18.08.2008 Inceptable Suministro

Soplador Aire Proc.y Comb.# 2 Desbalanceo, Soltura Punto 4 18.08.2009 Inaceptable Suministro

Bba. # P60 Pta. Oxigeno Aumento Vibrac. Lado Bba. 13mm/seg 11.07.2009 Inaceptable Suministro

Vent.# 2 Prezurización Corona Desalineamiento, Vibrac. Motor 09.07.2008 Inceptable Refinación

Soplador Aire Comb.H. Refino 1 Aumento Vibrac. Lado motor 12mm/seg 19.08.2008 Inaceptable Suministro

Soplador Aire Comb.H. Refino 2 Aumento Vibrac. Lado motor 13mm/seg 19.08.2008 Inaceptable Suministro

D2-8 18 Anglo American Chile – Chagres Division

 Vibration Analysis Monthly Report
EQUIPOS EN ALERTA
EQUIPO OBSERVACIÓN MEDICIÓN ESTADO SEVERIDAD PROCESO

Bba. Diesel Agua Spray # 3 Juego Axial, entrada reductora 12.08.2008 Alerta Fusión

Turbina Alimentación Caldera Incipiente soltura Punto N° 4 08.08.2008 Alerta Fusión

VTI Lurgi # 1 Desbalanceo de Impulsor 5mm/seg 02.09.2008 Alerta Fusión

Extractor de Vahos # 2 Comprobar desgaste y tensión de correas 08.08.2008 Alerta Fusión

Soplador Aire Proc.y Comb.# 1 Vigilar Acoplamiento, soltura descanso rodete 18.08.2008 Alerta Suministro

Soplador Aire Proc.y Comb.# 3 Incipiente soltura Rodamiento motor L.Libre 18.08.2008 Alerta Suministro

Compresor Elliott # 2 Aumento Vibraciones Multiplicador 6A 8mm/seg 18.08.2008 Alerta Suministro

Bba. Diesel Alta Presión # 1 Aumento Vibraciones lado Motor 19.08.2008 Alerta Suministro

Compresor Transp.Neumatico # 1 Carga12mm/seg

Seca Lado Compresor 18.08.2008 Alerta Suministro

Compresor Transp.Neumatico # 2 Carga12.7mm/seg

Seca Lado Compresor 24.07.2008 Alerta Suministro

Soplador KKK # 2 Desbalanceo Incipiente 5 mm/seg Punto 8 25.08.2008 Alerta Pta. Ácido

Bba. P103.2 Torre Enfriamiento Aumento Vibrac.lado Bomba 5mm/seg 26.08.2008 Alerta Pta. Ácido

Bba. # 2 Caldera Fenco Aumento vibrac. lado cola motor 6mm/seg 17.07.2008 Bueno Pta. Ácido

Bba. 279 C Abs. Intermedia Vibrac.niveles Satisfactorio 7mm/seg 22.08.2008 Bueno Pta. Ácido

Bba. P102.2 Torre Venturi Moderado Desiquilibrio de Bomba, Cavitación 25.08.2008 Alerta Pta. Ácido

Compresor Demag Pta.Oxigeno Aumento Vibrac. Lado Rotor 7mm/seg 20.08.2008 Alerta Suministro

Bba. # 2 Refriger. Campana Soltura Lado Impulsor 5mm/seg 18.08.2008 Alerta Refinación

D2-8 19 Anglo American Chile – Chagres Division

 Successful Example N°1

Gear inspection
of Gas Blower
Acid Plant

D2-8 20 Anglo American Chile – Chagres Division

 Prior Infomation

Blower Gear
Manufacturer : Kunhkle, Kopp & Kaush Eickhoff
Model : SFL 12 a CAN - 360
Flow : 110,000 Nm3/hr
Power : 3,150 KW / 4.16 KV
Gear ratio : 1,490 / 4527
79 teeth / 26 teeth

• In December 2006 the vibration analysis showed a slight difference.

• Monitoring Online and oil analysis were normal
• New vibration analysis, now with increased frequency visual range to 300,000 CPM,
detected high values to the primary frequency and 2nd harmonic
• Preliminary diagnosis: Potential wear on the teeth of the multiplier.

D2-8 21 Anglo American Chile – Chagres Division

 Monitoring Online (rms values)

Vibration level: normal

D2-8 22 Anglo American Chile – Chagres Division

 Vibration Analysis
SOPLADOR

8 7
MULTIPLICADOR
MOTOR Measuring
6
5
point

2 1

4
3

Frequency Spectrum (point 2nd Harmonic

N°4)

D2-8 23 Anglo American Chile – Chagres Division

 Planned Shutdown (March 2007)

• Damage was detected in the teeth of gear

• Visually similar to metal delamination Malfunction

• There is no change of roughness to the touch of
lubrication system
• The damage is flank attack of the teeth and is
VIDEO
present all around the sprocket

D2-8 24 Anglo American Chile – Chagres Division

 Planned Shutdown (March 2007)

D2-8 25 Anglo American Chile – Chagres Division

 Successful Example N°2

Preheater Gas SO2

Acid Plant

D2-8 26 Anglo American Chile – Chagres Division

 Prior Infomation

 Diesel fuel 33,513 Nm3/hr - 1.27 Kg/NM3.

 T° in: 871°C / T° out: 329°C.

 Gas SO2 flow 44,174 Nm3/hr - 1.29 Kg/Nm3.

 T° in: 10°C / T° out: 482°C

 457 pipes (steel 304)

• The preheater completed its life cycle (new equipment arrives in April 2009).
• From January to May 2008 the equipment showed 7 failures because of broken
pipes, with high impact to environment and production.
• From April 2009, we applied different predictive techniques in order to detect as
soon as possible, broken pipes.
• The traditional techniques to detect areas with low thickness, in order to anticipate
failure, are not alternatives, because they require the preheater stopped for a long
time.
THEN…….WHAT DO YOU DO?
D2-8 27 Anglo American Chile – Chagres Division
 Techniques applied

Pressure Test Ultrasonic

Inspection

Penetrating inks
and magnetic particles
D2-8 28 Anglo American Chile – Chagres Division
 Thermography was the solution

D2-8 29 Anglo American Chile – Chagres Division

 Conclusions

Due to the process conditions (high temperature,

pressure and speed), the thermography, vibration
analysis and thickness measurements are the
most succesful.

Chagres has had an important progress in

strengthening the monitoring of conditions and is
making the necessary investments to achieve the
required standard by the Asset Management.

D2-8 30 Anglo American Chile – Chagres Division

 Conclusions

THE END

D2-8 31 Anglo American Chile – Chagres Division