05Condition Monitoring Integration PT1– Click To Download PDF

CONDITION MONITORING INTEGRATION

(Process Strategy Beyond the 21st Century)
Albert K. Fletcher, CEO/PM Consultant, Dataman System Consultancy

Introduction

Maintenance ensures that equipment remains operational or is restored to optimal working conditions. In mining, maintenance constitutes a significant portion of total operating costs. The 21st century demands a holistic equipment management approach, focusing on the full lifecycle—from installation to decommissioning—to:

  • Preserve equipment functionality

  • Prevent consequential failures

  • Ensure productive capacity

The financial impact of unscheduled maintenance events is substantial, as these disruptions can drastically increase costs. According to Steven A. Tesdahl (1998), downtime-related production losses can multiply maintenance costs by up to 300%, making optimization crucial for profitability.

Paradigm Shift in Maintenance

There is a growing trend toward predictive maintenance technologies as a means of improving maintenance programs. Traditional manual data collection is increasingly costly, leading to production losses and reduced equipment availability.

However, integrating these technologies can be challenging due to:

  • Separate computer systems

  • Proprietary databases

Remote condition monitoring (RCM), combined with high-bandwidth communication systems, offers effective access to real-time data. Proper integration of RCM into daily maintenance workflows is essential to:

  • Manage vast volumes of data

  • Extract actionable insights

  • Enhance productivity

Recent technological advancements have provided tools to simplify integration and facilitate better decision-making.

Understanding the Equipment Failure Process

Mechanical components experience wear, corrosion, and fatigue over time, reducing reliability. Failures occur when performance deviates from user expectations. Key observations:

  • Traditional maintenance relied on fixed-interval inspections and servicing

  • Scheduled replacements often did not reflect actual equipment condition

  • Many failures are not age-related, making periodic maintenance outdated

  • Improper overhauls can even reintroduce “infant mortality” failures

Modern maintenance strategies should focus on condition-based and predictive approaches, rather than purely age- or usage-based schedules.

Maintenance-Related Costs: “Every $ Counts”

In North American open-pit mines:

  • Maintenance accounts for ~one-third of extraction costs

  • Direct mining costs include 30–50% maintenance costs, covering parts, labor, supplies, and contracts

Hidden costs—often unaccounted for in financial statements—include:

  • Production losses

  • Cost of temporary equipment

  • Loss of capital availability

  • Excess spare parts inventory

  • Increased crew requirements

Despite the significant cost impact, maintenance optimization receives comparatively little attention in mining operations.

End of Part 1 – to be continued

Leave a Reply