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Kumba Iron Ore Sishen
Kumba Iron Ore Sishen
Kumba Iron Ore Sishen
Hennie Matthee
ITC Certification Thermographer Lev III
Planning and Developing
Diagnostic Engineering, Thermography
The Anglo American Conference on Condition Monitoring and Non-destructive Testing
18 & 19 November 2008
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DISCUSSION
• Location of Sishen Mine
• Case studies
– Quaternary crushers oil tanks
– Conveyor idlers
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Location of Sishen in South Africa
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VIEW OF PIT (SOUTH)
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SISHEN PLANT
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INPIT STACKER, PRIMARY- AND TERTIARY
CRUSHING PLANT
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CASE STUDY
QUATERNARY CRUSHERS OIL TANKS
Routine inspection. LCD Display of crusher
Objective – to (Identification Nr.F752 G3200)
determine the
accuracy of the PT100 PT 100 not in position.
by comparing counter Trip Temperature (60°C)
shaft and oil
Temperatures with
LCD display.
52.3°C 46.6°C
45
50
AR01
40
AR01 45
35
40
30
35
25
33.6°C 24.8°C
Thermogram of PT 100 at Oil Tank return line. Thermagram of Crusher Counter shaft
AR 01 : Max Temperature 51.9 °C AR 01: Max Temperature 46.4 °C
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Oil reservoirs indicate Temperature differences at
the bottom of some oil reservoirs.
42.8°C
LI01
40
35
Oil level SP01 SP02
30
25
20
16.1°C
40 45
35 40
30
LI01 35
25
30
21.2°C 28.7°C
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Clarify the abnormalities
• Oil samples where taken from the bottom of
the reservoirs on all the reservoirs which
indicated Temperature differences in the
Infra Red images.
• The pipe was immerse into the oil. When
the PVC pipe is at the base of the reservoir
the plunger of the valve opens the valve
and the oil flows to the inside of the pipe
due to the oil level gravity. The pipe is
removed from the reservoir and the oil is
drained in to the sampling bottle. One way valve 20mm PVC Pipe
• The oil analysis reports indicated that the Plunge
oil is very contaminated and that the Lab
instruments filters blocked in the analyzing
process.
• What the IR image actually revealed is the
residue and build up at the bottom of the
tank.
• These findings were discussed with
maintenance personnel to resolve the
problem at hand and to establish the best
solution for this problem.
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Oil samples and results
Identification F755 G3200
Unit Fe Cr H2O Si Pb PQ
756-3200 10459.0 1635. 798.5 2095.0 5424.0 5749.0 Identification F756 G3200
0 0
Oil level
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Recommended solutions
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New Oil Reservoir Design.
• Maintenance personnel
decided to redesign the oil
reservoir and to install the
new oil filter system on all
the reservoirs.
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Results eight months after modification.
• The IR image revealed no build up at
the bottom of the tank.
• Oil reports indicated that the oil is very Identification F755 G3200 39.9°C
clean.
35
Unit Fe Cr H2O Si Pb PQ 25
3200 19.4°C
34. 4°C
756- 13.0 132.0 2.0 190.0 188.0 25.0
3100
30
752- 5.0 0.0 1.0 0.0 35.0 24.0
3200
25
19. 0°C
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Identification F756 G3200
Summary
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CASE STUDY
CONVEYER IDLERS
Sishen Mine (Kumba Iron Ore) was asked to do an Infrared
inspection at SAPO (South African Port Operations)
Saldanha since the problems experienced there have a
direct impact on the mine.
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Infrared images of the some of the problems.
33.9°C 45.2°C
30 40
AR02
AR01 30
AR01
20
20
SP01
10 10
5.8°C 5.0°C
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Idler Premature Failures
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Infrared images of different suppliers.
SP06 SP02
133.9°C 48.1°C
AR02
120
SP03
40
100 SP01
AR01
80 SP04
30
SP05
60
40
20
20
5.5°C 11.6°C
Supplier A. Supplier A
AR01 : max 166.3°C SP01: 63.0°C, SP02: 48.1°C
AR02 : max 67.2°C2. Supplier B
SP05: 19.8°C, SP06: 24.1°C .
Supplier C
SP03: 16.8°C, SP04: 18.5°C
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Idler Failure
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Inside view of idlers
Supplier A Supplier B
30 mm Shaft 30mm Shaft
No inner seal Good inner seal
Bearing end cap < 2mm Bearing end cap 4mm
6203 “No name” bearing brand 6203 SKF bearing
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Inside view of idlers
Supplier C
25 mm Shaft
4 contact inner seal
Bearing end cap 19mm
11 ball bearing specially
manufacture for supplier
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Reason for failure
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SUMMARY
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Thank You.
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