Ensuring Vibrating Screens’ Motion Location Emerald, QLD Services Project Overview Vibrating screens are crucial in coal handling preparation plants (CHPP). Their performance is dependent on the characteristics of the oscillating movement, which directly influence the speed of coal transport, material distribution on screen decks, and the quality of the final product. Monitoring the shape of the screen’s motion is critical to ensure consistent performance and longevity of the CHPP. The client is focused on keeping their vibrating screens in optimal condition for effective coal separation. The Challenges The main challenges of this project arose from working on the CHPP. However, these difficulties were nothing our team couldn’t handle! We were ready to collaborate with the client in two key areas: Firstly, we needed to coordinate with operators. This was a necessity given the requirement for multiple setups to fully capture the plant’s range of operations. Secondly, we had to overcome accessibility issues at certain locations due to ongoing plant activities. Despite these challenges, our team was fully prepared and capable of managing the situation. The Solution Our task was to inspect the operative parameters of the vibrating screens. We began with a thorough vibration assessment of the screens and their support structures. Our approach involved capturing acceleration measurements at all corners of the machine, collecting data across all axes. We placed sensors on the relevant axis of a vibrating screen to acquire acceleration data. Using durable computers and accelerometers, we gathered data from an accelerometer on a vibrating screen. This robust data was then carefully post-processed using our custom identification algorithms. These algorithms allowed us to determine key operational parameters such as the screen’s orbit shape, the amplitude of the vibration, and its operating speed. Our comprehensive analysis extended beyond the machine to evaluate the supporting structure, aiming to ensure the system operates at peak performance. The Impact Leveraging our data-driven approach and our specialized experience in vibration analysis, we offer early detection of machine malfunctions, preventing minor issues from escalating into major risks for both the plant and the machinery. We believe in proactive alert systems. This way, not only do we avoid potential damage, but we also offer operators a robust tool for efficient plant management.

CHPP Vibration Survey Location Emerald, QLD Services Project Overview Mincka was commissioned to run a vibration survey in the CHPP building in Emerald, Queensland. The customer was concerned about the excessive vibration on the centrifuges level in the CHPP building. A noticeable drifting motion from side to side horizontally, which was periodic in nature, was identified. In addition, some members appeared to be affected by the vibration generated by the excitation of the machinery on this floor. Previous Next The Challenges The main challenge of this project was the constraints related to the installation of sensor and data acquisition systems. In addition, the deployment of an entire team of modal testers in the CHPP building was too cost-prohibitive. Finally, the available time span to conduct the measurements was very short, so installing wired sensors was not feasible. The Solution Mincka performed a series of measurements using wireless accelerometers, which are portable, do not require a fixed power source, and are easy to deploy. We carried out a series of measurements using a Rover-reference technique; one accelerometer acts as a reference, while the others move (rove) around the designated area. This allows us to get several measurement points along the building, capturing a complete, dynamic response. With the recorded data we performed a experimental modal analysis. We identified the natural frequencies of the building, and were able to identify which ones were affected by the excitation generated by the machines. In addition, we used a finite element model to run a time-history analysis, in order to visualize all of the movement and the response of the structure. The Impact Mincka identified that the acceleration levels recorded in the building are harmful to the personnel working near the area. ISO standards were used as the criterion for the establishment of allowable acceleration levels, and the magnitude of the acceleration exceeded those thresholds. We recommended relocation of the personnel to a different area, to prevent incurring any health and safety risks. Mincka also provided recommendations for the maintenance and modification of the centrifuges’ insulators, to reduce the energy transfer between the machines and the structure.

R&D to Develop an Asset Management System Location Nelson Point, WA Services Project Overview The client wanted to reduce the time required by the maintenance coordinators to plan the remediation of structural defects for all Pilbara assets. This process was being done manually and included downloading different files to collate different layers of information, filter, sort, and cross-reference the data, in order to classify defects before the workflow proceeded to resourcing and scheduling of the remediations. This created siloing of the work process between departments, resulting in end-to-end process conflicts, inefficiencies, unnecessary revisions, as well as failed deadlines and incorrect remediation scopes. The objective of the project was to develop a planning tool in VBA programming language to automate the extraction and classification of information from the client database output. This tool would organise the remediation of defects within a given timeline, providing coordinators with a baseline for scheduling jobs. With this tool, the available information for resourcing the jobs would be enhanced, so it reduced the amount of time that maintenance coordinators required to plan remediations, which in turn would reduce conflicts. What it is also significant is that critical remediations can only be completed when the equipment is turned off. This can negatively impact production goals, because if an entire line is dependent on that asset, there is no iron production during that remediation. Lines are only halted 3 times during the year, so being able to implement strict and robust planning would serve to avoid costly, partially completed or postponed remediations. Previous Next The Challenges In order to have a proper understanding of how coordinators plan remediations, it was necessary to gather as much information from their knowledge and experience as possible, to accurately characterise the governing rules into a set of decision trees, as they pertain to a defect’s remediation work plan. This included rules related to asset replacement date, prioritization of a defect’s remediation, urgency of the remediation, remediation dates, shutdown dates, likelihood of failure of the structure, and the impact of that failure.  The Solution Mincka organised a set of workshops with client maintenance coordinators and our team of software developers to map out that knowledge and experience into abstract decision trees. The outcome of the workshops was to essentially “bullet proof” the decision a coordinator made, based on a given set of conditions for a particular defect. This approach was tested and proven with several coordinators, different equipment sets, and various lines of production. At the end of the process, the decision model achieved a 94.7% rate of accuracy. The next step was to provide a model to the development team, to build a user interface that presented the results. The tool uses raw data from the the client’s database, applies the model and then displays the results in a dashboard that easily allows making changes to planning activities. The tool was built in Microsoft Excel, allowing for high compatibility with existing corporate systems and making it easy to use. The tool was fully developed in record time (one month), including workshops, coding, implementation of functionalities and testing. The Impact The client’s coordinators went from spending days planning to literally just seconds. When using the tool for the first time, they were able to identify several defects that had been postponed many times and were long overdue. The availability of information was significantly increased, resulting in the ability to immediately prioritize the oldest defect remediations into the scope of work. Nowadays, they jump from their database directly into a timeline for the most important remediations that need to be implemented. The time that is saved is now leveraged to improve the process and manage the workload for the teams in charge of the repairs. The process runs smoothly and with more control, saving both time and operational costs. With effective planning, lines of production keep running and shutdown periods are leveraged to repair the maximum number of defects. This is only possible with proper scheduling and resourcing, made possible with the Mincka developed tool, and now provides significant value add to the organisation. We appreciate the trust BHP Billiton placed in us and look forward to working with them again.