Mining Forum 2010 Little Things Have A Big Impact

Contamination Control
Little things have a big impact
Simon Bishop
Product Support
Tucson - 2010
What I’ll cover today
• Contamination Control basics

• Contamination Control implementation
– Clean processes
– Clean parts
– Clean fluids
– Clean facilities
• Success stories
Caterpillar Confidential: Green CAT GLOBAL MINING 2

Caterpillar: Confidential Green
Extending component life
impacts uptime and operating costs
Customer value equation
Cost / Hour Cost / Ton Tons / Hour

(minimize) (optimize ) (maximize)
REBUILD COSTS COMPONENT LIVES PRODUCT AVAILABILITY
% A/F Repairs Design Application

• MTBS
Parts Reuse Application • Pit Depth
• Hand Distance • MTTR
Parts Price Maintenance
• Grades • Availability Index
Repair Quality • … • % Scheduled DT
Operation
Major components account for 60% of machine • Maintenance Ratio
• Operator Skill
mechanical costs
• Payload Mgmt
• Hydraulic components • Bunching
• Transmissions • Delays
• Final drives & differentials • Blasting
• Fuel injectors

Contamination Control:
The best way to maximize component life
Contamination is the No. 1 enemy of fluid systems
One of the greatest opportunities

for increasing component life and
lowering operating costs is to
effectively manage fluid
cleanliness.

Fluid contamination
You can’t see it. You can’t hear it.
The silent thief.

Contamination:
Anything in a fluid that doesn’t belong
CONTAMINANTS
Particulate Chemical
DIRT HEAT
THE
METALS SYSTEM WATER
FIBERS AIR

Contaminants are smaller than the eye can see
80
Diameter (µm)
HUMAN HAIR
BIG PARTICLE
15
AVERAGE CLEARANCE OF
10
HYDRAULIC COMPONENT
SMALL PARTICLE 5
1
FILM IN A BEARING &
FUEL SYSTEM

Contamination Control requires measurement
• Particle Count
– Measures CC efforts
– Quantifies particles by size &
amount
– Performed using a lab or Laboratory Pamas
portable counter or by patch
test
• The International Organization for
Standardization (ISO) has defined
a method for coding the level of
contamination by solid particles.
– Provides a common language
• Caterpillar cleanliness targets
based on ISO 4406.

Contamination Control: Implementing a program

A formal CC program is essential
Caterpillar Customer
A Contamination Control Contamination Control
program must be: Compliance Guide
• Established April 2010
• Implemented
• Sustained
Success requires:
• Support
• Discipline
• Diligence
Caterpillar provides training and materials to help customers.

Sites are scored on their level of compliance and achieve star
ratings for their performance.

All personnel must be trained
• Training should include all

components outlined by
Caterpillar.
• Classroom and on-the-job
training are required.

An equipment wash facility is essential
• All machines and components

should be washed before
entering the shop.
– High volume
– Hot / pressure / soap
• The path to the shop should be
concrete or gravel and kept
free of dirt and debris.
• Automatic, high-volume wash
equipment is most effective for
cleaning parts.

Hoses require special care
• All hose / tube ends should be appropriately

capped or plugged.
• All hoses and tubes that are removed during
the repair process must be cleaned prior to
reinstallation.
Hose cleaning
Have caps and plugs Hose gun with

Use of caps and plugs available projectiles

A preventive maintenance cart is recommended
All items bagged

Contents and protected
• Vacuum pump and tubing
• Clean exchange magnetic plugs / screens
• Sample bottles
• Filter cutting tool
• Digital camera
• Low-lint towels
• Latex gloves
• Resealable plastic bags

Clean oil spills immediately
• Use a vacuum or absorbent

pads and finish with powered
floor scrubber or mop with
degreaser.
• Avoid granular materials as

they create airborne debris.

Parts must be kept clean until installation
• Keep parts / components packaged

until ready to install.
• Protect work in-process parts /
components.
Not Recommended
Good Good

Provide protection when work is in process
• Protect open cavities.

• Protect components and parts.

Housekeeping makes a big difference
• Clean floors daily.

• Keep tools clean and organized.
• Protect and clean work benches.
• Store parts off the floor.
• Seal floors.
Not Recommended
Good Good

Contamination Control: Fluid management

Protecting bulk fluids: Storage
Bulk tank fluid sampling
Start with clean storage tanks

Protecting bulk fluids: Entry filtration

Protecting bulk fluids: High efficiency breather
Good Not Recommended
4 um breather with Vent

ability to remove water

Protecting bulk fluids: Tank maintenance program
• Tank cleaning
• Filtration
• Breathers
• Dispensed oil / fuel
cleanliness targets

Protecting bulk fluids: Dispensing filtered clean oil
• Filtered at point of use

• Dispensed at ISO -/16/13
• Kidney loop filtration as
needed

Oil sampling & particle counting ensure cleanliness
Ongoing SOS program including particle count Fleet consistency meets particle count
cleanliness PM & repair (shop & field)

Kidney loop filtration increases life & reduces costs
Cart circulates oil through the

machine tank or component and
filters out contaminants.

Example: Without kidney loop filtration
Without kidney looping
793C final drive wheel bearings at 13,000 SMU

1,200-hour oil change intervals

Example: With kidney loop filtration
With kidney looping
793C final drive wheel bearings at 18,000 SMU

4,000-hour oil change intervals

Contamination Control: Fuel management

Bulk fuel filtration removes dirt and water
SEPARATOR CARTRIDGE COALESCING FILTER ELEMENTS
SLUG CONTROL VALVE
4-MICRON PARTICULATE FILTER
AUTOMATIC DRAIN

Protect against contamination during fueling
Clean fueling ports and nozzles before fueling and cover them after fueling.
Fueling ports
Nozzles

Maintain machine fuel tanks
Drain tanks of sediment and water.

• At PM or per machine OMM
• Part of PM Checklist
Result: Clean and dry fuel

Contamination Control: Machine filtration

Machine filters provide final filtration
High efficiency secondary fuel filter

• Captures the most harmful (fine) particles
Water separator / primary filter (10 um)

• Prevents injector water damage
• 100% free water
• 90% emulsified water
• Extends secondary filter life

Use an appropriate machine tank breather
• Efficiency: Good or better than

downstream filter
• Location: Convenient to inspect and
change
• Change intervals: Every fluid change
or when they appear clogged
785C Engine Fuel System Filtered Fuel Cap Breather

Contamination Control: Success stories

U.S mine increases availability and component life
• 785B / 785C trucks in service – not new

• Mechanical Availability increased 15%
• Truck final drive and differential life
increased 33%
• Applying KL & PC to D10s and 5230
• Maintenance budget reduced 10% last
three years
• Maintenance manpower reduced from
79 to 64
– More PM work
– More proactive vs. reactive
• NORIA - Three articles published

Africa mine benefits from fluid cleanliness practices
• Quantify the benefits of world class fluid cleanliness practices

– Particle count and kidney loop components / systems
– Oil, fuel and machine filtration
• Component Life compared against WW 785Cs
– Engine +28.4%
– Transmission +54.9%
– Wheel Groups + 61.8% *
* Wheel Group rebuilds due to brake life
• Wheel bearings 18K hrs, 500 hr kidney loop,
6 um filtration – reused
– Planned component life extended to 20,000 hours
• One rear power train replacement gained in 785C life cycle
– $90,000 per truck
– Equates to $3 million saved for 785C fleet
• Only 16 injectors replaced in fleet of 24 machines with 20,000 hours
– One injector for every 35,562 operating hours

Latin America mine achieves 5 Star status
• Initiative began November 2003 793 MARC improvements (2005-2009)

– 5 Star obtained June 2005
– 5 Star last 5 years • Engine life increased 29%
• Component life increases saved • Transmission life increased 29%

$1.2 million • Differential life increased 27%
• Availability increased 3% (2003-2006) • Final drive life increased 13% (26%)
• Reliability increased 15% (2003-2006) • Availability increased 4.75%
• 35% reduction in unscheduled work
Unexpected benefits
• Fuel polishing unit delivered savings • Improved morale
on injectors and reduced low power
events • Improved employee retention
• Less rework
• Reduction in lost time injuries and
medical treatment injuries

Your Cat Dealer can provide assessments

Key takeaways
• Contamination is the No. 1 enemy of fluid systems.
• One of the greatest opportunities for increasing component

life and lowering operating costs is to effectively manage
fluid cleanliness in storage and machines.
• A formal contamination control program is essential to

ensure clean processes, parts, fluids and facilities—
maximizing component, fluid and filter life.


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Contamination Control

Little things have a big impact

• Contamination Control basics

Caterpillar Confidential: Green CAT GLOBAL MINING 2

Cost / Hour Cost / Ton Tons / Hour

REBUILD COSTS COMPONENT LIVES PRODUCT AVAILABILITY

% A/F Repairs Design Application

Caterpillar Confidential: Green CAT GLOBAL MINING 3

Contamination is the No. 1 enemy of fluid systems

One of the greatest opportunities

Caterpillar Confidential: Green CAT GLOBAL MINING 4

You can’t see it. You can’t hear it.

The silent thief.

Caterpillar Confidential: Green CAT GLOBAL MINING 5

Caterpillar Confidential: Green CAT GLOBAL MINING 6

Caterpillar Confidential: Green CAT GLOBAL MINING 7

Caterpillar Confidential: Green CAT GLOBAL MINING 8

Caterpillar Confidential: Green CAT GLOBAL MINING 9

Caterpillar provides training and materials to help customers.

Caterpillar Confidential: Green CAT GLOBAL MINING 10

• Training should include all

Caterpillar Confidential: Green CAT GLOBAL MINING 11

• All machines and components

Caterpillar Confidential: Green CAT GLOBAL MINING 12

• All hose / tube ends should be appropriately

Have caps and plugs Hose gun with

Caterpillar Confidential: Green CAT GLOBAL MINING 13

All items bagged

Caterpillar Confidential: Green CAT GLOBAL MINING 14

• Use a vacuum or absorbent

• Avoid granular materials as

Caterpillar Confidential: Green CAT GLOBAL MINING 15

• Keep parts / components packaged

Caterpillar Confidential: Green CAT GLOBAL MINING 16

• Protect open cavities.

Caterpillar Confidential: Green CAT GLOBAL MINING 17

• Clean floors daily.

Caterpillar Confidential: Green CAT GLOBAL MINING 18

Caterpillar Confidential: Green CAT GLOBAL MINING 19

Bulk tank fluid sampling

Start with clean storage tanks

Caterpillar Confidential: Green CAT GLOBAL MINING 20

Caterpillar Confidential: Green CAT GLOBAL MINING 21

Good Not Recommended

4 um breather with Vent

Caterpillar Confidential: Green CAT GLOBAL MINING 22

Caterpillar Confidential: Green CAT GLOBAL MINING 23

• Filtered at point of use

Caterpillar Confidential: Green CAT GLOBAL MINING 24

Caterpillar Confidential: Green CAT GLOBAL MINING 25

Cart circulates oil through the

Caterpillar Confidential: Green CAT GLOBAL MINING 26

Without kidney looping

793C final drive wheel bearings at 13,000 SMU

Caterpillar Confidential: Green CAT GLOBAL MINING 27

With kidney looping

793C final drive wheel bearings at 18,000 SMU

Caterpillar Confidential: Green CAT GLOBAL MINING 28

Caterpillar Confidential: Green CAT GLOBAL MINING 29

SEPARATOR CARTRIDGE COALESCING FILTER ELEMENTS

SLUG CONTROL VALVE

4-MICRON PARTICULATE FILTER