Mining Equipment Reliability, Maintainability, and Safety

208 Pages·2008·4.003 MB·English

by  Balbir S. Dhillon (auth.)

Springer Series in Reliability Engineering
Series Editor
ProfessorHoangPham
DepartmentofIndustrialandSystemsEngineering
Rutgers,TheStateUniversityofNewJersey
96FrelinghuysenRoad
Piscataway,NJ08854-8018
USA
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SystemSoftwareReliability
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ReliabilityandOptimalMaintenance
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AppliedReliabilityandQuality
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ShockandDamageModelsinReliabilityTheory
ToshioNakagawa
RiskManagement
TerjeAvenandJanErikVinnem
SatisfyingSafetyGoalsbyProbabilisticRiskAssessment
HiromitsuKumamoto
OffshoreRiskAssessment(2ndEdition)
JanErikVinnem
TheMaintenanceManagementFramework
AdolfoCrespoMárquez
HumanReliabilityandErrorinTransportationSystems
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RecentAdvancesinReliabilityandQualityinDesign
HoangPham
ProductReliability
D.N.PrabhakarMurthy,MarvinRausandandTrondØsterås
B.S. Dhillon
Mining Equipment
Reliability, Maintainability,
and Safety
123
B.S.Dhillon,PhD
DepartmentofMechanicalEngineering
UniversityofOttawa
Ottawa
OntarioK1N6N5
Canada
ISBN 978-1-84800-287-6 e-ISBN 978-1-84800-288-3
DOI 10.1007/978-1-84800-288-3
SpringerSeriesinReliabilityEngineeringISSN1614-7839
BritishLibraryCataloguinginPublicationData
Dhillon,B.S.(BalbirS.),1947–
Miningequipmentreliability,maintainability,andsafety.
–(Springerseriesinreliabilityengineering)
1.Miningmachinery–Maintainability2.Miningmachinery–
Reliability3.Miningmachinery–Safetymeasures
I.Title
622’.028
ISBN-13:9781848002876
LibraryofCongressControlNumber:2008929518
(cid:2)c 2008Springer-VerlagLondonLimited
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Thisbookisaffectionatelydedicatedtomy
dearfriendDr. S.N. Rayapatiforhis
stimulatingconversations,support,and
friendshipover theyears.
Preface
Thehistory ofminingmaybe traced backto the ancientEgyptians,who operated
malachite mines. Today a large numberof people are employedin the mining in-
dustrythroughouttheworld.Forexample,intheUSAalonearound675,000people
work in the natural resources and mining sector. Today, the mining industry uses
varioustypesofcomplexandsophisticatedequipmentwhosereliability,maintain-
ability,andsafetyhavebecomeanimportantissue.
Althoughovertheyearsalargenumberofjournalandconferenceproceedingsar-
ticlesonminingequipmentreliability,maintainability,andsafetyhaveappeared,to
thebestofauthor’sknowledge,thereisnobookthatcoversallthreeofthesetopics
withinitsframework.Thiscausesagreatdealofdifficultyforinformationseekers
onthesubjectsbecausetheymustconsultmanydifferentanddiversesources.
Thus,themainobjectiveofthisbookistocombineallthreeofthesetopicsinto
asinglevolume,toeliminatetheneedtoconsultmanydifferentanddiversesources
in obtaining desired information. The sources of most of the material presented
are given in the reference section at the end of each chapter. This will be useful
to readers if they desire to delve deeper into a particular area. The book contains
achapteronmathematicalconceptsandanotherchapteronintroductorymaterialon
reliability,maintainability,andsafetyconsideredessentialtounderstandcontentsof
subsequentchapters.
Thetopicscoveredinthevolumearetreatedinsuchamannerthatthereaderwill
requirenopreviousknowledgetounderstandthecontents.Atappropriateplaces,the
bookcontainsexamplesalongwith their solutions,and at the end of each chapter
therearenumerousproblemstotestreadercomprehension.
Anextensivelistofreferencesonminingequipmentreliability,maintainability,
andsafetyisprovidedattheendofthebooktogivereadersaviewofdevelopments
intheareaovertheyears.
Thebookiscomposedof11chapters.Chapter1presentstheneedforimproving
miningequipmentreliability,maintainability,andsafety;mining-equipment-related
factsandfigures,importanttermsanddefinitions,andusefulinformationonmining
equipmentreliability,maintainability,and safety classified undersix distinct cate-
gories. Chapter 2 is devoted to mathematical concepts considered useful for per-
vii
viii Preface
formingminingequipmentreliability,maintainability,andsafetyanalysis.Itcovers
topics such as Boolean algebra laws, probability properties, useful mathematical
definitions,andprobabilitydistributions.
Chapter3presentsvariousintroductoryaspectsofreliability,maintainability,and
safetyincludingreliabilitynetworks,commonlyusedmethodsinreliabilityanaly-
sis, maintainabilityfunctions,maintainabilityanalysis tools, safety analysis meth-
ods, and safety indexes. Chapter 4 is devoted to mining equipmentreliability and
coverstopicssuchasreasonsforimprovingminingequipmentreliability,open-pit
system reliability analysis, programmableelectronic mining system failures, fault
treeanalysisofshovelmachine,anddump-trucktirereliabilityandfactorsaffecting
theirreliability.Variousaspectsofhumanfactorsanderrorinminingarecoveredin
Chap.5.Someofthetopicscoveredinthechapteraretheneedforhuman-factorap-
plicationinmining,humansensorycapacities,human-factorformulas,usefulgen-
eralhuman-factorguidelinesforapplicationinminingequipmentdesign,classifica-
tionsandcausesofhumanerrorsleadingtofatalaccidentsinmines,typicalmining
equipmentmaintenanceerrors,usefuldesignimprovementstoreduceminingequip-
mentmaintenanceerrors,andhumanerroranalysismethodsforapplicationin the
areaofmining.
Chapters 6 and 7 are devoted to mining equipmentmaintainabilityand mining
equipmentreliabilityandmaintainabilitytesting,respectively.Chapter6coverstop-
ics such as reliability test classifications, success testing, accelerated testing, con-
fidence interval estimates for mining equipment mean time between failures, test
methodstoobtainmaintainability-relatedtestdataforminingequipment,testmeth-
odsfordemonstratingdiversemaintainabilityparameters,andusefulguidelinesfor
avoidingpitfallsinmaintainabilitytestingofminingequipment.Someofthetopics
coveredin Chap.7 arethe meaningsofthe miningequipmentmaintainabilityand
design-induced maintainability problems of mining equipment, advantages of the
improved mining equipment maintainability design, mining equipment maintain-
ability designcharacteristics,maintainabilitymeasuresforminingequipment,and
commonmaintainabilitydesign errorsand usefulmaintainabilitydesign guideline
forminingequipment.
Chapter 8 presents various important aspects of mining equipment mainte-
nanceincludingmaintenance-relatedfactsandfigures,factorscontributingtoequip-
ment maintenance cost in mines, maintenance of explosion-protected switchgear
in mines, useful maintenance measures for mines, and mathematical models for
performing mining equipment maintenance. Various important aspects of mining
equipmentcostingarecoveredinChap.9.Someofthetopicscoveredincluderea-
sonsforminingequipmentcosting,methodsformakingminingequipmentinvest-
ment decisions, cost estimation models for mining equipment, life cycle costing
concept,andlifecyclecostestimationmodelsforminingequipment.
Chapter10isdevotedtotheintroductoryaspectsofminingequipmentsafetyand
coverstopics such as facts and figures, quarry accidents, causes of mining equip-
mentaccidentsandmajorsourcesofminingequipmentfires,methodsforperform-
ing mining equipment safety analysis, human-factor-related tips for safer mining
equipment,strategiestoreduceminingequipmentfiresandinjuries,andgeneralar-
Preface ix
easforsafetyimprovementsinmines.Finally,Chap.11presentsvariousimportant
aspectsofprogrammableelectronicminingsystemsafetyincludingprogrammable-
electronic-relatedmishaps,methodsforperforminghazardandriskanalysisofpro-
grammableelectronic mining systems, lessons learned in addressing the safety of
programmableelectronicminingsystems,andsourcesforobtainingprogrammable
electronicminingsystemsafety-relatedinformation.
Thisbookwillbeusefultomanyindividualsincludingengineeringprofessionals
workinginthe miningindustry,miningadministrators,miningengineeringunder-
graduateandgraduatestudents,miningengineeringresearchersandinstructors,re-
liability,maintainability,maintenance,humanfactors,andsafetyprofessionals,and
designengineersandassociatedprofessionalsconcernedwithminingequipment.
Theauthorisdeeplyindebtedtomanycolleaguesandstudentsfortheirinterest
throughout this project. The invisible contributions of my children, Jasmine and
Mark, are also appreciated. Last but not least, I thank my other half, friend, and
wife,Rosy,fortypingvariousportionsofthebookandotherrelatedmaterials,and
forhertimelyhelpinproofreadingandtolerance.
Ottawa,Ontario B.S.Dhillon
Contents
1 Introduction................................................... 1
1.1 Need for Improving Mining Equipment Reliability,
Maintainability,andSafety................................... 1
1.2 Mining-equipment-relatedFactsandFigures.................... 1
1.3 TermsandDefinitions....................................... 2
1.4 Useful Information on Mining Equipment Reliability,
Maintainability,andSafety................................... 4
1.4.1 JournalsandMagazines............................... 4
1.4.2 ConferenceProceedings .............................. 5
1.4.3 Books.............................................. 5
1.4.4 Organizations ....................................... 6
1.4.5 Standards........................................... 6
1.4.6 DataInformationSources ............................. 7
1.5 Problems ................................................. 7
References..................................................... 8
2 IntroductoryMathematicalConcepts for Mining Equipment
Reliability,Maintainability,andSafetyAnalysis ................... 11
2.1 Introduction ............................................... 11
2.2 Range,ArithmeticMean,MeanDeviation,andStandardDeviation. 11
2.2.1 Range.............................................. 12
2.2.2 ArithmeticMean..................................... 12
2.2.3 MeanDeviation ..................................... 13
2.2.4 StandardDeviation................................... 14
2.3 BooleanAlgebraLawsandProbabilityDefinitionandProperties... 14
2.4 UsefulMathematicalDefinitions.............................. 17
2.4.1 CumulativeDistributionFunction ...................... 17
2.4.2 ProbabilityDensityFunction .......................... 17
2.4.3 ReliabilityFunction .................................. 18
2.4.4 ExpectedValue...................................... 18
2.4.5 Variance............................................ 18
xi
xii Contents
2.4.6 LaplaceTransform................................... 19
2.4.7 LaplaceTransform:FinalValueTheorem................ 19
2.5 ProbabilityDistributions..................................... 20
2.5.1 BinomialDistribution ................................ 20
2.5.2 ExponentialDistribution .............................. 20
2.5.3 RayleighDistribution................................. 21
2.5.4 WeibullDistribution.................................. 21
2.5.5 NormalDistribution.................................. 22
2.5.6 LognormalDistribution............................... 22
2.6 SolvingDifferentialEquationsUsingLaplaceTransforms......... 23
2.7 Problems ................................................. 24
References..................................................... 25
3 IntroductiontoReliability,Maintainability,andSafety ............. 27
3.1 Introduction ............................................... 27
3.2 NeedforReliabilityandBathtubHazardRateCurve ............. 28
3.3 GeneralReliability,HazardRate,andMeanTime
toFailureFunctions ........................................ 29
3.3.1 GeneralReliabilityFunction........................... 29
3.3.2 HazardRateFunction ................................ 30
3.3.3 MeanTimetoFailure................................. 30
3.4 ReliabilityNetworks........................................ 31
3.4.1 SeriesConfiguration.................................. 31
3.4.2 ParallelConfiguration ................................ 33
3.4.3 k-out-of-mConfiguration.............................. 35
3.4.4 StandbySystem ..................................... 36
3.4.5 BridgeConfiguration ................................. 37
3.5 CommonlyUsedMethodsinReliabilityAnalysis ............... 39
3.5.1 FailureModesandEffectAnalysis(FMEA).............. 39
3.5.2 MarkovMethod ..................................... 39
3.5.3 FaultTreeAnalysis .................................. 42
3.6 NeedforMaintainabilityandMaintainabilityVersusReliability.... 47
3.7 MaintainabilityFunctions.................................... 47
3.7.1 MaintainabilityFunctionI:ExponentialDistribution....... 48
3.7.2 MaintainabilityFunctionII:WeibullDistribution.......... 48
3.8 MaintainabilityDesignFactorsandMaintainabilityAnalysisTools. 49
3.8.1 TotalQualityManagement ............................ 49
3.8.2 CauseandEffectDiagram............................. 50
3.9 Maintainability-Management-RelatedTasks
DuringtheEquipmentLifeCycle ............................. 51
3.10 NeedforSafetyandSafety-RelatedFactsandFigures ............ 51
3.11 EquipmentHazardClassificationsandCommonMechanical
Injuries ................................................... 52
3.12 SafetyAnalysisMethods .................................... 52
3.12.1 HazardandOperabilityAnalysis(HAZOP) .............. 52