Document

Report
Gregory Crinum Mine – Rotary
Breakers
Gregory Rotary Breaker Old Lubrication System
Gregory Crinum Mine
1
19th of February 2004
Crinum Rotary Breaker New Lubrication System
Rotary Breaker – Lubrication
System Improvements
PROBLEMS
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Lubricant being splashed on the Rotary Breaker
chain and surrounding structures
Lubricant spillage causing an imminent workplace
and safety issues
Unnecessary waste of lubricant
Environmental impact (Penetration into the soil,
costly and unsafe disposal)
Gregory Crinum Mine
2
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
Lubricant spillage
• Chain splashing
lubricant over
surrounding
structures
• Pools of lubricant
laying underneath
Rotary Breaker
•Lubricant
deteriorating floor
plate and dripping
into the ground
Gregory Crinum Mine
3
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
OBJECTIVES
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Improvements to current Automated Lubrication
System
Addition of air operated pump to agitate lubricant
prior to pumping
Addition of brushes for lubricant application
Ensure that lubricant reaches critical points on the
chain
Gregory Crinum Mine
4
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
COMPARISON
Previous System
Automated
Lubrication
System:
Lubricant
application for 10 seconds every 40 minutes
Consumption: 205 Litre Drum of Mobil 630 or BP GR
– XP 220 per month. (Not including down time
due to shutdowns or other maintenance factors)
Cost:205 Litre Drum - $351.35
Gregory Crinum Mine
5
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
Improved System
Automated Lubrication System: 300mL of Lanotec
Heavy Duty Lanolin (HD) applied during 10
seconds every 8 hours (3 applications daily).
Consumption: 205 Litre Drum of Lanotec Heavy
Duty Lanolin (HD) will allow for 683 applications,
which is equivalent in time to 7.5 months. (Not
including down time due to shutdowns or other
maintenance factors).
Cost:205 Litre Drum – Price on application
Gregory Crinum Mine
6
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
New System
Installation
• New Lanotec
Lanolin drum
• Air pump
installed
• Lubrication lines
installed
• Brushes
installed
Gregory Crinum Mine
7
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
3-MONTH TRIAL (Started November 2003)
Results
Improved Automated Lubrication System
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Controlled and efficient application of lubricant
Lubricant application in critical areas
Excessive presence of lubricant in chain and
surrounding structures eliminated
Lubricant waste factor eliminated
Gregory Crinum Mine
8
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
Equipment Life
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Chain life was approx. 4-5mths
Chain life currently 3 years and still going!
Sprockets wear reduced
Deterioration of surrounding structures reduced
Gregory Crinum Mine
9
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
Performance & Costs
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Improved equipment efficiency
Reduced maintenance costs
Increased maintenance intervals
Increased equipment life
Reduction of lubricant drums in stock
Down time and loss of production reduced
Workplace health and safety impact reduced
Disposal costs eliminated
Gregory Crinum Mine
10
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
Environmental
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Lubricant is bio-degradable
Non toxic
Non carcinogenic
Ozone friendly
Safer to dispose
Gregory Crinum Mine
11
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
Results
• No lubricant
spillage
• System performing
efficiently
• Chain properly
lubricated
• Cleaner work area
Gregory Crinum Mine
12
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
COST EFFECTIVE RESULTS
12 Months Expectations
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Savings of $604.19 in lubricant purchase per year
Maintenance costs reduced (equipment, parts and
labour)
Lubricant usage reduced from 2460 Litres (12
drums) to 328 Litres (1.6 drums) per year
Delivery and storage costs reduced
Handling and disposal costs reduced
Gregory Crinum Mine
13
19th of February 2004
BMA Savings (over 2 yrs) using
the Lanotec Lubrication System
Old System
Lube System
N/A
Lubricant Cost
$9,200
Chain replacement(5)
$30,000
Labour on above
$3,000
Lost Production (30hrs) $3,000,000
TOTAL
=
$3,042,000
SAVINGS (2yrs) =
Gregory Crinum Mine
14
19th of February 2004
Lanotec System
$3,000
$7,500
NIL
NIL
NIL
$10,500
$3,031,500
Rotary Breaker – Lubrication
System Improvements
INITIAL INVESTMENT
•
•
Chain Lube Pump/Spray unit
Installation
TOTAL COST: Price on application
Gregory Crinum Mine
15
19th of February 2004
Rotary Breaker – Lubrication
System Improvements
CONTACT INFORMATION
MARK PEATEY
CHPP MAINTENANCE PLANNER
GREGORY CRINUM MINE
BHP Billiton Mitsubishi Alliance
PO Box 1526
Emerald, QLD 4720
Phone (+61) 07 4982 8237
Fax
(+61) 07 4982 8274
Email
[email protected]
Gregory Crinum Mine
16
19th of February 2004
STEVE GREEN
WESTERN AUSTRALIAN
BUSINESS DEVELOPMENT MANAGER
LANOTEC AUSTRALIA PTY LTD
Phone
Mobile
Email
(+61) 07 3373 3700
(+61)417 638 004
[email protected]

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