CONDITION monitoring plays a pivotal role in the mining industry, offering significant advantages in terms of operational efficiency, cost effectiveness, and safety. It involves the continuous assessment of equipment and machinery to detect potential faults, identify early warning signs, and prevent catastrophic failures.
WearCheck, a specialist condition monitoring company, has been boosting efficiency and productivity for businesses operating in the mining sector – and other industrial operations – for more than 45 years.
The company’s managing director, Neil Robinson, shares some key reasons why condition monitoring is crucial in the mining industry.
‘Firstly, condition monitoring helps to optimise equipment performance and prevent unplanned downtime. Mining operations rely heavily on complex machinery and equipment, such as crushers, conveyors, and excavators, which are subjected to harsh operating conditions. By monitoring their condition regularly, operators can identify issues like wear and tear, component fatigue, or lubrication problems. This enables timely maintenance and repairs, avoiding unexpected breakdowns and maximising production uptime.
‘Secondly, condition monitoring contributes to cost reduction. Unplanned equipment failures can result in costly repairs, lost productivity, and delayed project timelines. By implementing a proactive approach through condition monitoring, mining companies can reduce maintenance costs by replacing components or performing repairs during scheduled downtime. This helps to extend the lifespan of equipment, optimise spare parts inventory, and minimise overall maintenance expenses.
‘Moreover, condition monitoring enhances safety in mining operations. Equipment failures can pose severe risks to personnel working in close proximity to these machines. By continuously monitoring equipment condition, potential hazards can be identified early on, allowing for prompt corrective actions. This helps to prevent accidents, injuries, and even fatalities, safeguarding the well-being of workers and improving overall safety performance.
‘Additionally, condition monitoring enables data-driven decision-making and predictive maintenance strategies. By collecting and analysing equipment data, mining companies can gain valuable insights into equipment performance, degradation patterns, and optimal maintenance intervals. This facilitates the implementation of predictive maintenance programmes, where maintenance activities are scheduled based on actual equipment condition rather than fixed time intervals. As a result, maintenance efforts become more efficient, minimising unnecessary maintenance tasks and reducing costs.
‘Condition monitoring is of paramount importance in the mining industry as it optimises equipment performance, reduces downtime and maintenance costs, enhances safety, and promotes data-driven decision-making. By leveraging condition monitoring technologies and practices, mining companies can ensure a more productive, efficient, and sustainable operation,’ says Robinson.
WearCheck’s core business is the scientific analysis of used oil, fuel and other fluids, whereby samples are analysed in the laboratory for trace particles which indicate which component is suffering unusual wear patterns. This information is assessed by a team of specialised diagnosticians, who make recommendations on the required remedial action for the component in question.
Additional predictive maintenance techniques offered by WearCheck – which are employed depending on the type of machinery being monitored – include asset reliability care (ARC) services, water analysis, transformer chemistry services and advanced field services (AFS) such as non-destructive testing, technical compliance and rope condition assessment. The company also offers lubrication enabled reliability (LER), providing clients with bespoke solutions to ensure that their lubrication systems are well managed, efficient and cost effective.
For more information visit: www.wearcheck.co.za, Email marketingt@wearcheck.co.za, or Tel: +27 (31) 700-5460.
