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Copper Ore Processing Facility
In June 2002, this large copper processing facility began
using Dingo's new MaintenanceGuy Oil Analysis program, which
for a single sample price includes:
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best practice sample kits
-
testing at the laboratory of your choice
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world class MaintenanceGuy software
This customer was dissatisfied with a traditional oil
analysis program provided by their oil company, for a number
of reasons including:
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poor analysis tools (the lab provided a web based tool
which allowed the customer to view their sample reports
online)
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inaccurate billing
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inaccurate posting of the results, and inconsistent
sample point naming
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poor quality lab analysis
The customer's lubricant sales representative made them
aware of the MaintenanceGuy Oil Analysis program, and after
a brief discussion, the customer decided to give it a
try. A day later, the customer had new sample
kits. After brief training, the customer entered
equipment data directly into MaintenanceGuy and printed
sample labels for #1 Ball Mill, a $23 Million crushing
machine critical to their operations. The samples were
sent to a lab they selected from the list of supported labs
in the MaintenanceGuy Program.
Several days later, the Maintenance superintendent
received an e-mail alert notifying him that he had received
new sample results in his MaintenanceGuy account.
Clicking the link in the e-mail took him direct to his
account, and a red flag beside #1 Ball mill told him
immediately that there was a problem. A wise
decision, to purchase "Blue" kits, which include
both particle count and analytical ferrography paid
off. Ball mill #1 pinion bearing had ISO codes of
27/22 and noticeable concentration of large (>25um) brass
particles.
  As luck would have it, the machine was scheduled for a
shut down, due to a moving of major mining equipment which
starves the mills of ore supply.
A quick inspection
revealed significant spalling on rolling elements. The
bearing (a 12 internal diameter monster) was replaced in
time during the shutdown, in time for the machine to come
back into production as scheduled.
Vibration analysis detected the problem 2 weeks after it
was detected in oil analysis, too late for the necessary
planning to be done in time. Oil analysis was credited
with the saving. Here are the calculations developed by the customer:
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SAVINGS:
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Bearing degradation
found before failure occurred.
| Downtime
cost/ hr = $5,000.00 24
hours if unscheduled |
$120,000.00 |
| Bearing
cost/bearing $14,000.00* |
$14,000.00 |
| Shaft
cost (if not detected) = $95,000.00 |
$95,000.00 |
| Labor
cost at $30/hr 4 men |
$2,880.00 |
| TOTAL
SAVINGS |
$231,880.00 |
| *Need
to replace 2 (may be able to reuse undamaged bearing
after inspection). |
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The customer who reported this saving within
weeks of starting the new program, has since expanded their
use of MaintenanceGuy Oil Analysis program throughout other
areas of the facility.
Would you like to get started with a program like the one
that saved this customer $231,880? Why not order
some kits for as little as $105 for your first ten pack,
and get started towards saving money TODAY.
You can also see an on line demo of the software. Click
here to do it now!
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