Emerson’s Condition Monitoring solutions help the world’s largest mining, metals and minerals operations improve reliability of their most critical assets.
Data from asset monitoring systems can be analyzed to create insights for predictive maintenance, and certain assets can be upgraded to dramatically lower total cost of ownership.
Mining companies are under increasing pressure to improve overall equipment effectiveness and make the best use of existing assets, requiring condition monitoring to enhance reliability. When implemented correctly, these types of solutions provide substantial benefits, with production rates increased by five to eight percent, recovery rates increased by two to five percent, and energy use reduced by five to eight percent.
Download Reliability Solutions for Mining, Metals & Minerals.
Monitor Your Most Complex Pit Asset – The Electric Rope Shovel
The mining pit is an inherently dangerous environment. The daily interaction between man and large, moving machinery creates an environment of ongoing risk. Add to that the unexpected shutdown of an electric rope shovel and the result is a real threat to both personnel safety and production goals. Everything on a shovel is subject to failure, and eventually you will experience a breakdown. The impact of that failure can be significantly reduced by monitoring key shovel components – the crowd, hoist, and swing drives. Emerson’s AMS 6500 has a proven history of monitoring for unique vibration characteristics found in rotating equipment – the same types found on many types of ore extracting assets, including the electric rope shovel.
AMS 6500 Balance of Plant Prediction Monitor
A versatile, scalable system that can be deployed in a variety of configurations to deliver online condition monitoring exactly as needed for your food and beverage application.
AMS 2140 Machinery Health Analyzer
The AMS 2140 Machinery Health Analyzer takes vibration data and analysis measurements to the next level. It features simultaneous four-channel plus phase data collection and unique peak detection capabilities for the earliest indication of bearing and gearbox degradation. In addition to delivering faster data collection for less time in the field or more machines monitored, the AMS 2140 is ergonomically designed for comfortable, single hand operation all day long.
AMS Machinery Manager
AMS Machinery Manager integrates multiple predictive maintenance techniques with comprehensive analysis tools to provide easy and accurate assessment of the machinery health across different types of mechanical assets in your facility. The modular technology applications incorporate diagnostic and reporting sources into a common database for analysis of machinery health across the entire plant. New releases are available at no charge to customers with Guardian Support.
Condition Monitoring for Challenging Mining Pit Conveyer Applications
As an arterial system in most mining operations, bulk conveyors must be properly monitored and maintained to avoid costly repairs, time-consuming and unsafe manual inspections, and unplanned downtime that could bring your entire process to a halt. Emerson can help minimize downtime with condition-based monitoring systems and wireless transmitters to continuously monitor critical components and provide safe and cost-effective data collection for continued conveyor operation.
Some components, such as the take-up pulley, are difficult to monitor because they travel as much as 100 feet. Wireless monitoring is ideal for this application, while online systems with tachometer inputs maybe be required for the variable speed operations on other parts of the conveyor.
AMS Asset Monitor
Manages pervasive sensing while providing prediction, protection and process monitoring capabilities. It is designed to mount at the asset, reducing cabling requirements and other installation costs. It accommodates up to 12 CHARMs including Vibration CHARMs as well as DeltaV CHARMs for process inputs.
AMS Wireless Vibration Monitor
Delivers full vibration data over a self-organizing wireless mesh network. It provides rich information about machinery health for both operations and maintenance personnel. Overall vibration, PeakVue measurements and temperature readings can be easily integrated into any control system or plant historian.
AMS 6500 Balance of Plant Prediction Monitor
A versatile, scalable system that can be deployed in a variety of configurations to deliver online condition monitoring exactly as needed for your food and beverage application.
Condition Monitoring to Ensure Reliability for Critical Grinding Equipment in Mining
Today’s mining operations must keep crucial milling assets online and running optimally, but variations in ore particle size, feed rate and moisture content, can lead to plugging, high vibration and machine bearing wear, and ultimately unscheduled stoppages and labor-intensive restarts. Emerson can help you achieve higher mill availability with advanced asset management and monitoring solutions to detect issues early and achieve a more consistent grind while reducing energy consumption.
AMS Asset Monitor
Manages pervasive sensing while providing prediction, protection and process monitoring capabilities. It is designed to mount at the asset, reducing cabling requirements and other installation costs. It accommodates up to 12 CHARMs including Vibration CHARMs as well as DeltaV CHARMs for process inputs.
AMS Wireless Vibration Monitor
Delivers full vibration data over a self-organizing wireless mesh network. It provides rich information about machinery health for both operations and maintenance personnel. Overall vibration, PeakVue measurements and temperature readings can be easily integrated into any control system or plant historian.
AMS 6500 Balance of Plant Prediction Monitor
A versatile, scalable system that can be deployed in a variety of configurations to deliver online condition monitoring exactly as needed for your food and beverage application.
AMS Machine Works
A comprehensive software solution that greatly simplifies the fault diagnosis and analysis process by combining predictive maintenance techniques with comprehensive analysis tools to provide easy and accurate assessment of machinery health in your facility.
AMS 2140 Machinery Health Analyzer
The AMS 2140 Machinery Health Analyzer takes vibration data and analysis measurements to the next level. It features simultaneous four-channel plus phase data collection and unique peak detection capabilities for the earliest indication of bearing and gearbox degradation. In addition to delivering faster data collection for less time in the field or more machines monitored, the AMS 2140 is ergonomically designed for comfortable, single hand operation all day long.
Efficient High Pressure Roll Grinding Monitoring
The consistency of product size can directly impact the profitability of your entire operation. Ensuring the accuracy of your grinding results means applying the right monitoring technology to the right point in the process. Emerson offers a variety of technologies that can be applied to the crushing, screening and grinding stages to avoid unexpected shutdown and confirm that your equipment is operating as it should to maximize production and accuracy.
AMS Asset Monitor
Manages pervasive sensing while providing prediction, protection and process monitoring capabilities. It is designed to mount at the asset, reducing cabling requirements and other installation costs. It accommodates up to 12 CHARMs including Vibration CHARMs as well as DeltaV CHARMs for process inputs.
AMS Wireless Vibration Monitor
Delivers full vibration data over a self-organizing wireless mesh network. It provides rich information about machinery health for both operations and maintenance personnel. Overall vibration, PeakVue measurements and temperature readings can be easily integrated into any control system or plant historian.
AMS 6500 Balance of Plant Prediction Monitor
A versatile, scalable system that can be deployed in a variety of configurations to deliver online condition monitoring exactly as needed for your food and beverage application.
AMS Machine Works
A comprehensive software solution that greatly simplifies the fault diagnosis and analysis process by combining predictive maintenance techniques with comprehensive analysis tools to provide easy and accurate assessment of machinery health in your facility.
AMS 2140 Machinery Health Analyzer
The AMS 2140 Machinery Health Analyzer takes vibration data and analysis measurements to the next level. It features simultaneous four-channel plus phase data collection and unique peak detection capabilities for the earliest indication of bearing and gearbox degradation. In addition to delivering faster data collection for less time in the field or more machines monitored, the AMS 2140 is ergonomically designed for comfortable, single hand operation all day long.
Prevent Roping, Plugging and Particle Misclassification with Effective Hydrocyclone Monitoring
Hydrocyclones are mineral processing equipment used in slurry pulps to separate coarse and fine particles according to their size and density. Under certain conditions roping and plugging can occur where the hydrocyclone ceases to classify the particles, the shapes of the discharge are visibly different than normal operating conditions.
To avoid these conditions and operate productively and reliably, Emerson mining controls experts developed hydrocyclone optimizer technology. This control and optimization application addresses the problems associated with roping, plugging, and undesired particle classification. It characterizes the different operating parameters of each cyclone and facilitates the execution of efficient control strategies.
AMS 6500 Balance of Plant Prediction Monitor
A versatile, scalable system that can be deployed in a variety of configurations to deliver online condition monitoring exactly as needed for your food and beverage application.
39% of plants plan to decrease unscheduled downtime by expanding their monitoring capabilities.
86% of plants outsource some of all their maintenance operations.
46% of plants plan to decrease unscheduled downtime by evolving to predictive maintenance strategies.
RELIABILITY CASE STUDY | MINING, MINERALS & METALS
Learn how a top North American mining company reimagined its vibration data collection with AMS Wireless Vibration Monitor in unsafe and difficult-to-access locations while slashing conveyer downtime.
Case Study
Newmont’s Minera Yanacocha complex in Peru is the largest gold mine in Latin America and the second largest in the world. Hear how this mining leader partnered with Emerson to improve reliability with wireless technology.
Case Study
A phosphate mine in the Mid-Atlantic (U.S.) sought a best-in-class vibration monitoring and predictive maintenance solution for its vital, heavy-duty draglines at the mine site. Learn how Emerson’s AMS 6500 machinery health monitoring solution allowed the mine’s reliability department to overcome multiple production pains while improving safety.
Case Study
“Our challenge was to run the mill as long as possible while minimizing the risk of a sudden failure in the gearbox bearings and internals. We needed to implement a continuous and intensive monitoring system that would monitor the gearbox condition and alert us to stop the equipment if we detected any further progression in the vibration levels,”
Request a consultation to discover how Emerson's team of mining industry condition monitoring experts can help you initiate, expand, or improve your current program or projects.
