Professional Documents
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D2-8
D2-8 Anglo American Chile – Chagres Division
Location South America - Chile
Work environment:
• Corrosion by gases (S, SO2, SO3)
• Abrasion minerals handling
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
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
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
General Manager
Production Manager
Maintenance Spte.
Transverse Support
1 Mechanical Eng 1 Mechanical Eng 1 Mechanical Eng 1 Electrical Eng 1 Mechanical Eng
Contractors 45 Sup/Emp
(30% of total)
Termografía
Magnetic particle
& Penetrant Inspection Digital Ultrasonic Inspection
Magnaflux UE Systems Model UP9000
EQUIPOS EN ALERTA
EQUIPO OBSERVACIÓN MEDICIÓN ESTADO SEVERIDAD PROCESO
Bba. # 1 Enfriamiento Chaqueta Alta Vibrac. Tangencial lado Cola 8.5 mm/seg 27.08.2008 Inaceptable Fusión
Reductor Secador # 1 Alto Contenido Fierro, Cromo, Cobre, Silice 20.06.2008 Inaceptable Fusión
Vent. Filtro Mangas Tolva 50 Ton. Juego axial Motor 02.09.2008 Inaceptable Fusión
Compresor Demag # 2 Polvo R. Alto contenido Fierro, Cobre, Sodio, Si. 19.08.2008 Inaceptable 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
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
Bba. Diesel Agua Spray # 3 Juego Axial, entrada reductora 12.08.2008 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
Bba. Diesel Alta Presión # 1 Aumento Vibraciones lado Motor 19.08.2008 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
Gear inspection
of Gas Blower
Acid Plant
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
8 7
MULTIPLICADOR
MOTOR Measuring
6
5
point
2 1
4
3
N°4)
• 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
Penetrating inks
and magnetic particles
D2-8 28 Anglo American Chile – Chagres Division
Thermography was the solution
THE END