FUELS AND OILS
as oil / gas wells and water lift stations, gave the company a first-hand understanding of how to develop a rugged package. Total Power has a heritage of research driven innovation with a very deliberate scientific approach to product development, so partnering with Schneider Electric’ s experienced design team was a natural fit.
“ The design team’ s proactive and inquisitive attitude led me to believe that this partnership was the right choice,” Dantus said.“ It allowed us to make the decision to go down the path of developing this product with Schneider Electric. It was a slam dunk for us.”
“ The designers took time to consider all of the client’ s needs and variables. Using a diligent, step-by-step approach, the Total Power and Schneider Electric teams looked at each fuelling system, each piece of equipment, and the environment. For example, the system needed to function in weather ranging from 20 to 120 degrees and despite ice, rain, dust, and snow in desert conditions.”
“ It couldn’ t be an off-the-shelf plastic box, because it had to withstand day-to-day operations,” Dantus said.“ We witnessed customers trying an off-the-shelf fuel management product, and it never worked.” Equipment in many fleets – from massive haul trucks to pickups and bulldozers – varies in size, shapes and brand. This posed a challenge, because each gas tank, windshield, and equipment ID was in a different position, so there was no cookiecutter way to embed identification sensors. Engineers developed a system using Schneider Electric’ s ClearSCADA™ remote monitoring software, Accutech™ wireless sensors, SCADAPac™ remote terminal units( RTUs) and programmable logic controllers( PLCs) in a protective housing rated for challenging remote environments.
Incorporating DNP3, an open standard, event driven protocol, provides the data integrity that backfills information in the event of a power outage. Equipment in fuelling lanes are identified using long range RFID, replacing traditional RFID readers on every nozzle and fuel tank. This automated system eliminates the potential for human error and keeps operators moving without delays. The collected data is used for asset allocation and asset management. Analysing fuel consumption and distance driven can result in asset implementation changes that optimise operations. In addition, the system provides close to a 9 % increase in data accuracy. For an operation with millions of dollars in fuel at a single location, data accuracy is important to control costs.
This system tracks fuel movements with high data granularity. The key is the data integrity and simplistic automation of a manual process, allowing the mine to track fuel use and invoice contractors more accurately for the fuel used. Prior to the project, the mine could not account for 10 % of the fuel they were billed. This mine consumes roughly one million gallons of fuel each month. The project therefore resulted in significant cost savings for the client.
Petro-Canada – and low viscosity oils
Paul Moore spoke with Brian Humphrey, OEM Technical Liaison, Petro-Canada Lubricants about the wider oils and lubricants market. He had this to say:“ The mining sector has many unique requirements compared to on-road and other offhighway industries. Equipment spends a significant proportion of its time idling or working at high power levels. The industry average idling time is 40 % according to manufacturer Komatsu – and the role and expectations on the engine oil are also higher, as the equipment is expected to perform optimally 24 hours a day, seven days a week.”
He adds:“ Required to work in the harshest of conditions and extreme climates, lubricant choices in the mining sector are made as longterm decisions. With the impact of downtime being so significant, this segment is careful to ensure that decisions do not impact the uptime and reliability of the operations. This has resulted in the growing interest and conversion regarding the new API CK-4 standard of heavy duty lubricants. API CK-4 oils are relevant for the mining industry as they offer improved resistance to oxidation and aeration, as well as increased shear stability plus all the performance of the previous API CJ-4 category. Off-highway engines can entrain higher levels of air than other vehicles, so improved aeration control is extremely important and crucial at the bearings, which require an oil film to protect them.”
He says the benefits of low viscosity oils are clear for mining operations located in colder regions. Oils such as API CK-4 SAE 10W-30 and 5W-40 can move more easily though the engine and flow faster at colder temperatures, preventing engine wear during start-up. Low viscosity oils also reduce the work rate of the engine saving fuel, which is an essential benefit for engines that regularly idle.
“ Uncovering any maintenance issues due to prolonged idling such as water or soot build up, a used oil analysis program can surface problems before they become serious and expensive to repair, making it a crucial tool in a maintenance team’ s arsenal. This is a significant benefit for operators in the industry as significant periods of unplanned downtime can make a real difference to the company’ s bottom line.”
Oil analysis is typically a three-step process: taking a representative sample from the equipment in question, sending the sample to a qualified used oil analysis lab, and interpreting / acting upon the recommendations of the results. This is most effective when performed at regular intervals, as it allows for a performance database to be generated, and for trends to be established and identified. These patterns, unique to each specific vehicle, can then help identify the potential to extend oil drain intervals – a process that should always be supported by recommendations from the OEM manual and advice from technical experts
TOTAL on extending oil drain intervals
Oil drain intervals( ODI) have generally been predetermined by the OEM and designed as such to provide protection to the compartments based on a wide variety of conditions. TOTAL told IM:“ Over recent years there has been a growing trend within the mining industry to extend ODI beyond the OEM recommended service intervals. Considering hydraulic systems, extending ODI are perceived to be one area where value can be easily delivered to the mining or power generation industries. This can be achieved if carried out correctly but it is important to understand the key risks involved with ODI extension as well as understanding what other tests are required to get a clear idea of the overall health of the oil especially in large volume hydraulic systems.”
The current practice particularly within the mining industry tends to be to hook up the hydraulic system to kidney loop filtration units during the scheduled maintenance plan for said equipment. Whilst good practice, the function of kidney looping is to essentially remove particulate particles and even moisture from the system. The removal of such contaminates helps to reduce wear of oil wetted components. In addition, laboratory test packages associated with routine oil analysis of hydraulic oil samples tend to cover only the following tests: spectrometric analysis( wear metals); viscosity; moisture and cleanliness.“ Some oil analysis laboratories will also carry out Fourier Transform Infra-red spectroscopy( FTIR) on samples but most would be reluctant to admit being able to accurately predict oxidation and overheating of
ANAC( ANAlysis Compared) is a service of TOTAL that provides a complete range of analytical monitoring systems for in-service mining oils
40 International Mining | JULY 2018