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The Causes and Consequences of Hydraulic Machinery

The impact of downtime in the mining industry is particularly severe, as it often leads to a complete stop of production, causing a direct loss of revenue for mine operators [2]. This type of equipment failure not only leads to operational downtime but also affects the overall efficiency and productivity of the mine and its workers. A recent study highlights the importance of focusing on the parts of drilling machines that experience the highest amount of downtime, such as hydraulic hoses and feeders. The study found that these components' harsh conditions and unreliable nature play a major role in their frequent downtime. The study recommends employing a customized maintenance strategy tailored specifically to these parts to minimize this impact.[3]

A recent study in Poland utilizing cutting-edge technology to measure equipment downtime found that 20% of all machine-related downtime for a shearer loader in the mining industry was due to hydraulic issues. This accounted for a significant portion of the total 43.47% of machine downtime. In addition, the study revealed that mine operators could only utilize the machine 56.53% of the time.

Meanwhile, research conducted at the University of Wollongong in Australia estimates that approximately 37% of machine downtime in the mining industry results from hydraulic hose failure. This type of hydraulic component failure, referred to as "hydraulic downtime," can lead to decreased production efficiency, reduced work productivity, and even operational downtime or complete production halts. It is estimated that one in every two to three instances of machine downtime is related to a hydraulic component, causing a potential production halt and loss of income.

Unplanned hydraulic downtime can significantly impact businesses, resulting in losses in productivity and revenue. This type of downtime is caused by a variety of reasons, including equipment failure, poor maintenance practices, and environmental factors. The drilling, mining, earthmoving, civil, and logging industries are particularly vulnerable to hydraulic machinery downtime, and its causes can be classified into seven main categories.

1. Improper Maintenance: Neglecting regular maintenance, using incorrect fluid types, and failing to replace worn or damaged components can all lead to downtime.
2. System Contamination: Dirt, moisture, and other contaminants can cause damage to hydraulic components, leading to downtime.
3. Component Failure: Key components, such as pumps, valves, cylinders, and hoses, can wear out or break, halting machinery operation.
4. Hydraulic Fluid Problems: Poor selection, filtration, or overheating of the hydraulic fluid can cause downtime.
5. Electrical Issues: Power surges, short circuits, and broken wires are just a few examples of electrical problems that can cause machinery to stop working.
6. Operator Error: Incorrect usage or operation of hydraulic machinery can result in downtime.
7. Excessive Stress on Machinery: Overloading or using machinery beyond its design capabilities can result in downtime.

The most common causes of hydraulic machinery downtime are improper maintenance, system contamination, and component failure. It's important to stay vigilant and proactive in preventing downtime through regular maintenance and proper usage of hydraulic machinery.

Reducing Hydraulic Machinery Downtime: A Guide to Effective Maintenance

Component Failure:

Component failure in hydraulic systems is a significant cause of downtime, affecting productivity and profits. One of the most prevalent types of failure is hydraulic hose failure, which can be brought on by excessive pressure, abrasion, bending, and exposure to heat, chemicals, and UV rays.

A study of common drilling machines showed that high pressure in the front head of rock drills could cause damage to the cup seals, leading to a mix of water and oil that adheres to the valves in the hydraulic system. This issue was commonly reported by maintenance personnel in the mining industry.

To reduce the risks of component failure and minimize hydraulic downtime, it's crucial to invest in high-quality components and hoses that are specifically designed to withstand the demands and conditions of the operation. Regular inspections of hoses for signs of wear, the prompt replacement of damaged or worn hoses, and proper storage of the machine when not in use are also important steps to take.

System Contamination:

System contamination refers to the presence of foreign particles, such as dirt, metal shavings, and other liquids, that can interfere with the operation of a hydraulic system and cause significant damage to its components. In a recent study, the mixing of water and oil in high-pressure components of drilling machines was found to cause clogging of the system, leading to reduced flow and pressure.

Poor filtration, neglect of proper maintenance, and exposure to harsh environments are the most common causes of system contamination in hydraulic systems. Dirt can enter the system through air intake or open ports during maintenance, while water can enter due to condensation or exposure to moisture.

To mitigate the risks of system contamination and minimize hydraulic downtime, it's crucial to use proper filtration and high-quality hydraulic fluid designed for the specific operation. Regular maintenance procedures should also be implemented to ensure the longevity and reliability of the hydraulic system.

By investing in top-quality filtration and hydraulic components, as well as adhering to best maintenance practices, businesses can significantly reduce the risk of system contamination and hydraulic downtime, protecting their productivity and profits.

Preventive Maintenance: A Proactive Approach

Preventive maintenance is key in reducing hydraulic downtime and ensuring the efficiency of hydraulic machinery. In various industries, it has been observed that proactive maintenance is crucial in avoiding hydraulic issues.

To optimize maintenance efforts, a preventive maintenance program should be established, which can encompass regular checks and replacements of worn or damaged components, the use of high-quality hydraulic fluid, proper maintenance to prevent contamination, and proper training of workers.

Through proper training, workers can not only learn to perform the necessary maintenance tasks but also gain the knowledge to identify and address issues with hydraulic components. Implementing a preventive maintenance program can help minimize downtime, maintain efficiency, and ultimately lead to increased productivity and profits for your business.

Predictive Maintenance:

Predictive maintenance is a newer approach to hydraulic machinery maintenance, focused on predicting potential failures before they occur. This proactive maintenance strategy aims to improve efficiency, safety, product quality, reliability, and availability and reduce energy costs. It is based on the idea that 99% of machine failures are preceded by indicators, allowing for early intervention to prevent catastrophic failure. Predictive maintenance is different from traditional preventive maintenance, which is time-based, in that it uses data and machine learning algorithms to determine when maintenance is needed based on the actual condition of the machine. [4]

By using predictive maintenance, companies can avoid unexpected failures, resulting in safer working conditions and reduced expenses, both in terms of repairs and lost income. Predictive maintenance is an important aspect of modern reliability engineering, helping to ensure the long-term health and performance of hydraulic machinery.

In addition to technological advancements in predictive maintenance, it is important to recognize the value of human observation. The earliest form of predictive maintenance involves the use of an operator's senses to inspect the machine and detect any potential issues.

Despite the increased accuracy of modern technology, human factors, environmental factors, and the experience of the observer still play a significant role in determining when it is necessary to perform maintenance on a hydraulic machine. For example, an experienced operator may be able to identify unusual sounds or vibrations that indicate a problem, even before any technological monitoring system picks up on it. Therefore, it is essential to have well-trained operators who are knowledgeable in identifying signs of potential issues and able to perform routine inspections to ensure the hydraulic machine is operating efficiently and effectively.

A combination of technology and human observation is necessary for effective predictive maintenance and to prevent hydraulic downtime, reduce maintenance costs, and ultimately improve productivity and profits.

It is also essential to consider the impact of human factors and environmental factors on hydraulic machinery. In order to minimize unplanned downtime, it is important to provide proper training to operators and ensure they understand the design capabilities of the machinery, as well as follow proper maintenance practices. Regularly inspecting hoses, using high-quality components, and avoiding system contamination can help prevent downtime and reduce the impact of human error and excessive stress on the machinery. In conclusion, by addressing the top 3 causes of hydraulic machinery downtime, including improper maintenance, system contamination, and component failure, companies in the drilling, mining, earthmoving, civil, and logging industries can improve productivity, increase profits, and minimize unplanned downtime.

Sources:

[1] Brodny J, Tutak M. Applying Sensor-Based Information Systems to Identify Unplanned Downtime in Mining Machinery Operation. Sensors. 2022; 22(6):2127.

[2] Sottile, J., & Holloway, L. E. (1994). An overview of fault monitoring and diagnosis in mining equipment. IEEE Transactions on Industry Applications, 30(5), 1326–1332. doi:10.1109/28.315247

[3] Al-Chalabi, H. S., Lundberg, J., Wijaya, A., & Ghodrati, B. (2014). Downtime analysis of drilling machines and suggestions for improvements. Journal of Quality in Maintenance Engineering, 20(4), 306-332.

[4] Selcuk, S. (2016). Predictive maintenance, its implementation and latest trends. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 231(9), 1670–1679. doi:10.1177/0954405415601640