Introduction to infrared condition monitoring with Viking Mining Services

Introduction to Thermography & Condition Monitoring

THI004 – Introduction to Thermography & Condition Monitoring. Created 02.02.14. Reviewed 19.05.14 Page 1

Thermography Division

The past 18 months has seen Viking Mining Services save our clients millions of dollars by identifying warrantable repairs and diagnosing failures on many types of mining and industrial equipment.

Viking has developed and introduced a non-‐destructive, non-‐invasive and in most cases, non-‐interruptive inspection system to companies such as Glencore/Xstrata, Anglo Coal and CSL, Australia’s largest shipping company.

Our success is due to a combination of 20 years of mechanical experience, expert training, continuous product development and the utilisation of state of the art, military grade inspection equipment and analytics software.

In the following document, we will outline how our service will assist you in increasing production and reducing downtime through this safe, non-‐contact, non-‐disruptive method of inspection.



INDEX

1. Introduction……………………………………………………………...3

2. How we save you money……………………………………………...4

2.1 Safety

2.2 Decreasing Unplanned Maintenance

2.3 Increasing Warranty Claims

2.4 Limited Inspection Downtime

2.5 Real Time Solutions

3. Compare Our Service………………………………………………….5

4. Reporting ……………………………………………………………….6

5. Points of Difference…………………………………………………….8



1. Introduction.

Thermography, or the use of thermal imaging is certainly not a new concept. It is widely used on electrical equipment and switchboards, however, the advantages it offers in mechanical condition monitoring on heavy mobile equipment and fixed plant has been severely understated and under-‐utilised.

The past 18 months has seen Viking Mining Services develop and introduce diagnostic and condition monitoring methodologies for the following equipment:

! Draglines ! Electric face shovels ! Hydraulic excavators and face shovels ! Bull dozers ! Coal handling and preparation facilities ! Haul trucks – mechanical and diesel electric ! Self-‐unloading ships

Our system works by using our simple approach to all machinery:

1. Consult site to obtain critical plant and equipment list 2. Identify baseline operating temperatures at full load 3. Customised inspection, trending and reporting tools to suit all machinery

types and site specific requirements 4. Monitor and identify trend components over time using temperature

markers as KPIs 5. Alert site staff on severity of anomalies found 6. Consult site staff and follow up on identified anomalies



2. How our service saves YOU money.

THROUGH OUR REGULAR EXPERT ANALYSIS YOU WILL SAVE TIME AND MONEY THROUGH:

! Increasing safety " Without having to touch the equipment and with the ability to

investigate machinery from outside the high risk zone, this is the safest and most efficient way of diagnosing and monitoring equipment faults.

! Decreasing un-‐planned maintenance " Increases in temperature are pre-‐cursors to failure, trending

the component temperature over time assists in accurately planning component repairs or replacement.

! Increasing warranty claims " Many of the anomalies Viking identifies are components that

are still under warranty. " By identifying anomalies early and are able to track them over

time, offering you time and date stamped proof that there is a problem. These factual records ensure the equipment owner has a full history, and are therefore able to qualify the claim with evidence.

! Limiting inspection downtime " With our powerful telephoto lens, most inspections are able to

be carried out from outside high risk mining zones. " It is a requirement to have machinery operating in normal

conditions to record accurate data, therefore minimal interruption to operations is required.

! Offering real time solutions " Our trained technicians and advanced trending systems allow

Viking to provide clients with real time data as reports are delivered whilst our technicians are on site. This also allows for the client to request a further more acute inspection on the spot if required.



3. Compare Viking’s service ! The existing use of thermography.

" Many sites have introduced some use of infrared technology, however, very few have the high grade equipment, time or resources to develop, implement and carry out regular, thorough surveys on their machinery.

" The issues of training, continuity and quality of inspections, as well as purchase and care of the equipment continuously plague their inspection process.

" Viking’s qualified, trained personnel specialise in getting your business the best results.

! Vibration Analysis. " Vibration analysis is an excellent tool for diagnosing faults that

already exist in the bearing and predicting life expectancy of parts.

" Whilst effective, there are many areas that vibration analysis cannot be utilised. This includes on undercarriage, slew bearings, excavator and shovel pins to name a few. Guarded areas also propose challenges for vibration analysis.

! Lubrication Analysis. " Lubrication analysis is also an excellent condition monitoring

tool, however, it also has limitations and it is not real time. " Viking is able to image components such as excavator pins and

bushes, sealed components such as conveyor rollers, track pins. The list is endless.

Adding Viking’s Thermography service to our client’s condition monitoring regime has delivered savings previously not thought possible.

Let us help you achieve the same type of benefits that we are already delivering to others.

We are specialists in every facet of Thermography and that is why with Viking, you will get results, every time.



4. Reporting

Two types of reporting tools are available within our system.

! Simple, yet effective temperature trending tools that offer the following information:

" A snapshot of how the component is performing on the date of the survey in comparison with other same, or similar components.

" A graph for each component that shows the temperature trend of the component over time.

" A colour coded summary from each inspection that refers to the findings of the survey.

! Urgent action reports that identify critical components requiring immediate attention. This is delivered in an easy to read PDF format with thermal images of the components and recommendations actions moving forward to prevent unnecessary cost or downtime.



Examples of our customised trending and reporting service.

Temperature Record Chart

Our temperature chart is formatted to change colours automatically to alert you of any abnormal temperature differentials between components.

Component Temperature Graphs

Each component has its own temperature graph, allowing you to easily determine its trend and therefore, its condition.



Site Survey Summary

This summary tool offers you a quick reference point to the machinery we have inspected during any given visit. We are able to customise any of these reporting tools to suit your requirements.

5. Viking Mining Services points of difference: ! We are a team of trained and certified thermographers ! Our equipment is calibrated regularly to meet NATA standards ! Viking is an active affiliated member with the Australian Professional

Thermography Association (AUSPTA) www.auspta.asn.au ! We strive to continuously improve our services through constant

training and memberships



Thank you for taking the time to review our thermography service in detail.

If you have any further questions, please don’t hesitate to call me on 0400 696 505 or email. Alternatively, I would be more than happy to travel to your office, to discuss our thermography services and how Viking can help you save money and avoid downtime.

I look forward to hearing from you.

Kind regards

Jeff Erichsen Managing Director Viking Mining Services 17 Ginger Street Paget, Qld 4740. P: 07 4952 6510 M: 0400 696 505 E: [email protected] W: www.vikingservices.com.au

Technology

Introduction to infrared condition monitoring with Viking Mining Services