Customer
TLT Service, a Belarusian industrial solutions provider, developed a robust hardware/software system for Condition Monitoring in mining equipment. This visionary initiative, catering to a global potash fertilizer giant, was seamlessly realized with Applied Systems’ expertise. The endeavor focused on implementing control software for the hoisting shaft monitoring system.
Challenge
The challenge lay in orchestrating smooth hoisting shaft operations, ensuring target skip speeds, and promptly identifying potential issues. The solution was designed to encompass:
• Real-time data processing and analysis from accelerometers, gyroscopes, position transducers, and various sensors, facilitating Condition Monitoring during operational and maintenance phases.
• Statistical analysis of 24-hour historical data to pinpoint critical areas within the mine shaft.
• Root cause identification of irregular shaft equipment behavior.
• Streamlining organizational workflows and optimizing mining equipment maintenance schedules.
Solution
The cornerstone of the solution, the Propheto platform, seamlessly handles data acquisition, storage, processing, and visualization. Augmenting the platform with domain-specific add-ons and integrating a new module enriched the system's capabilities. Applied Systems adopted a two-step approach to ensure incremental improvements:
First Stage: Implementation of an analytics module for daily measurement analysis. Our adept developers devised a statistical analysis system and intuitive visualization tools. These tools empower personnel to tactically plan and execute daily maintenance tasks.
Second Stage: Structured data warehousing and analytical tools for long-term trend analysis. The system accommodates an extensive channel count of 80-120 for persistent data storage, preserving measured results for up to 5 years. Leveraging the fusion of diagnostic equipment data, winding machine insights, and service logs, Predictive Maintenance techniques optimize workflows and elevate equipment efficiency.
Results
The project seamlessly adhered to the planned timeline. The comprehensive solution empowers machine operators and maintenance personnel to strategically plan checks, enhance machinery efficacy, and minimize downtime.
The analytical toolset showcased the following accomplishments:
• Enhanced usability, fostering swift and intuitive navigation through process data.
• Amplified visibility into hoisting shaft equipment performance.
• Streamlined training procedures.
• Elevated key operational workflows, specifically maintenance tasks.
