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Dragline Maintenance Engineering

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Dragline Maintenance Engineering University of Southern Queensland Faculty of Engineering and Surveying Dragline Maintenance Engineering A dissertation submitted by Bruce Thomas Jones in fulfilment of the requirements of Courses ENG4111 and 4112 Research Project towards the degree of Bachelor of Engineering (Mechanical) Submitted November, 2007 1 ABSTRACT This research project ‘Dragline Maintenance Engineering’ explores the maintenance strategies for large walking draglines over the past 30 years in the Australian coal industry. Many draglines built since the 1970’s are still original in configuration and utilize original component technology. ie electrical drives, gear configurations. However, there have been many innovative enhancements, configuration changes and upgrading of components The objective is to critically analyze the maintenance strategies, and to determine whether these strategies are still supportive of optimizing the availability and reliability of the draglines. The maintenance strategies associated with dragline maintenance vary, dependent on fleet size and mine conditions; they are aligned with the Risk Based Model. The effectiveness of the maintenance strategy implemented with dragline maintenance is highly dependent on the initial effort demonstrated at the commencement of planning for the mining operation. Mine size, productivity requirements, machinery configuration and economic factors drive the maintenance strategies associated with Dragline Maintenance Engineering. 2 University of Southern Queensland Faculty of Engineering and Surveying ENG4111 & ENG4112 Research Project Limitations of Use The Council of the University of Southern Queensland, its Faculty of Engineering and Surveying, and the staff of the University of Southern Queensland, do not accept any responsibility for the truth, accuracy or completeness of material contained within or associated with this dissertation. Persons using all or any part of the material do so at their own risk, and not at the risk of the Council of the University of Southern Queensland, its Faculty of Engineering and Surveying or the staff of the University of Southern Queensland. This dissertation reports an educational exercise and has no validity beyond this exercise. The sole purpose of the course pair entitled “Research Project” is to contribute to the overall education within the student’s chosen degree program. This document, the associated hardware, software, drawings, and other material set out in the associated appendices should not be used for any other purpose: if they are so used, it is entirely at the risk of the user. Prof F Bullen Dean Faculty of Engineering and Surveying 3 Certification I Certify that the ideas, designs and experimental work, results, analyses and conclusions set out in this dissertation are entirely my own effort, except where otherwise indicated and acknowledged. I further certify that the work is original and has not been previously submitted for assessment in any other course or institution, except where specifically stated. Bruce Thomas Jones Student Number: 0039340337 _______________________________ Signature _______________________________ Date 4 ACKNOWLEDGEMENTS Appreciation is given to the following groups for information and materials used in this project. BHP Billiton Mitsubishi Alliance (BMA) Maintenance Technical Institute (MTI) - Monash University Center for Mining Technology and Equipment (CMTE) – University of Queensland Bucyrus International, Inc 5 Table of Contents 1 Introduction................................................................................................................8 1.1 Study Outline.....................................................................................................8 1.2 Introduction........................................................................................................8 1.3 The Problem.......................................................................................................8 1.4 Research Objectives...........................................................................................9 1.5 Conclusions: Chapter 1. .....................................................................................9 2 Literature Review.....................................................................................................10 2.1 Introduction......................................................................................................10 2.2 Literature: Recent Decade................................................................................10 2.3 Literature: Previous Decades ...........................................................................13 2.4 Conclusions: Chapter 2 ....................................................................................15 3 Dragline Overview...................................................................................................16 3.1 Introduction......................................................................................................16 3.2 What Is A Dragline ..........................................................................................16 3.3 How Does It Operate........................................................................................17 3.4 Where It All Stared ..........................................................................................18 3.5 Geographic Location........................................................................................19 3.6 Conclusions: Chapter 3 ....................................................................................20 4 Major Maintenance Shutdowns................................................................................21 4.1 Introduction......................................................................................................21 4.2 Strategy ............................................................................................................21 4.3 Planning ...........................................................................................................23 4.4 Execution .........................................................................................................25 4.5 Close out..........................................................................................................26 4.6 Recommendations: Chapter 4 ..........................................................................27 4.7 Conclusions: Chapter 4 ....................................................................................27 5 Dragline Configuration............................................................................................29 5.1 Introduction......................................................................................................29 5.2 Manufacturers ..................................................................................................29 5.3 Boom Configurations.......................................................................................30 5.4 Walking Mechanisms.......................................................................................33 5.5 Universal Dig Dump (UDD)............................................................................34 5.6 Recommendations: Chapter 5 ..........................................................................36 5.7 Conclusions: Chapter 5 ....................................................................................37 6 Structural Integrity...................................................................................................38 6.1 Introduction......................................................................................................38 6.2 Tub ...................................................................................................................38 6.3 Revolving Frame..............................................................................................39 6.4 Recommendations: Chapter 6 ..........................................................................40 6.5 Conclusions: Chapter 6 ....................................................................................41 7 Electrical Systems ....................................................................................................42 7.1 Introduction......................................................................................................42 7.2 High Voltage Equipment (HV) ........................................................................42 7.3 Generators / Motion Motors.............................................................................44 6 7.4 Power Control Systems....................................................................................46 7.5 Recommendations: Chapter 7 ..........................................................................47 7.6 Conclusions: Chapter 7 ....................................................................................47 8 Mechanical Advancements ......................................................................................48 8.1 Introduction......................................................................................................48 8.2 Structural Components.....................................................................................48 8.3 Bearings ...........................................................................................................50 8.4 Gear Developments..........................................................................................52 8.5 Recommendations:
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