Crusher and Breaker Reliability

Preparing bitumen ore from the mine for separation in the primary extraction facility requires crushing and sizing the ore to an optimal size for mixing with hot process water to form a bitumen slurry, which is then pumped the primary extraction plant. This process is extremely hard on mechanical rotating equipment including crushers, breakers, and sizers. This equipment experiences extreme loading, impact forces, and other degradation, which effects the gearboxes and motors driving the equipment. Unplanned failures of the gear boxes and motors can result in huge production losses as well as safety concerns.

There are many challenges inherent to diagnosing the actual health and condition of crushers. Large slow speed rollers and gearboxes impact loading and the harsh operational nature of the crushers makes collecting accurate, valid data very difficult. Any upsets on the crushers can have major impacts on production. Utilizing AMS technologies allows for stress wave and modal analysis to address these challenges and can provide insight into the operational condition of the individual components of the crushers. The ability to determine the health of the motor, bearings, gearbox, and rollers as well as the root cause of any impending failures ensures optimum uptime.

Emerson's AMS Machinery Health Manager diagnoses and communicates the health of mechanical and rotating machinery using data from several predictive maintenance technologies. This includes integrating data from third-party, complimentary technology vendors such as mini labs and handheld oil analyzers from Spectro Scientific and popular infrared and thermography cameras from FLIR and Fluke.

The AMS 6500 Machinery Health Monitor is designed for process automation and protection system upgrade projects, and combines prediction and protection in a single chassis for rotating and reciprocating assets. The AMS 6500 is fully compliant with API 670 and integrates protection, prediction, real-time performance monitoring, and process automation by preventing missed trips. Emerson’s PlantWeb digital architecture provides enterprise-wide information needed for real-time decision making.

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