Unlocking Uptime: 5 Key Benefits of Condition Monitoring for Mining Operations

The pressure on mining operators to improve asset reliability, reduce unplanned downtime, and maintain rigorous safety standards is constant. The efficiency and productivity of sites also depend on the reliability of assets. These include fixed assets like crushers as well as mobile assets like haul trucks, which are crucial for the transport of materials but can be challenging and expensive to maintain. 

Despite these challenges, many organizations still rely on manual processes and traditional approaches to monitoring and maintaining asset health. Asset condition data is collected manually, exposing personnel to potentially unsafe conditions. Data collection is also typically time-based, which is ineffective for monitoring assets like haul trucks with intermittent operation.

Advancements in condition monitoring provide a practical solution to these challenges. Combining hardware, software, and services, the latest condition monitoring solutions enable online and state-based data collection and offer real-time insights into asset health and performance. They also deliver tangible benefits for mining operators seeking to increase efficiency and production while carefully managing costs and risk. 

5 key benefits of condition monitoring for mining

1. Reduced downtime

With today’s condition monitoring solutions, strategically placed sensors allow online data collection from fixed and mobile assets at the right time and under predefined conditions. So, consistent data on vibration and other critical parameters can be gathered on a more continuous basis.

At Baker Hughes, we work with customers to integrate data and telemetry sources on a single software platform that supports advanced diagnostics and analytics using first principles models, enhanced artificial intelligence, and machine learning. This enables operators to detect changes in asset condition and take proactive steps to prevent failures and unplanned downtime.

2. Lower maintenance costs

Without effective condition monitoring, organizations may rely on time-based maintenance, where assets are maintained or replaced at fixed intervals regardless of age or condition. Or maintenance could be more reactive with a reliance on spares and urgent repairs.

Shifting to condition-based maintenance reduces the risk of under- or over-maintaining assets, which can lead to failure or excess costs. It also allows for scheduled maintenance, minimizing the need for unplanned shutdowns or emergency parts and labour.  As an added benefit, condition-based maintenance can extend asset life and defer replacement costs.

3. Improved safety

Condition monitoring has traditionally involved manual inspections, sometimes requiring personnel to access hazardous areas or to take readings while equipment was operational. While manual or portable data collection still has value in certain circumstances, modern condition monitoring solutions can be easily deployed in harsh and rugged environments. This limits the need for manual inspections in hazardous areas and enables more continuous monitoring and predictive interventions.

4. Increased equipment lifespan

With real-time insights on asset condition, operators can maintain optimal operating conditions, optimize maintenance, and reduce risks such as potential failure from overload or overuse. In this way, condition monitoring can help to extend the lifespan of equipment and defer the need for costly capital investments.

5.  Data-driven decision making

In addition to helping predict and prevent failure, condition monitoring can support better fleet planning and performance tracking. For example, by collecting data and applying tools like anomaly detection and failure mode identification, operators can enhance predictive capabilities and improve maintenance and resource planning. They can also make more informed, strategic decisions to better manage costs and efficiency.

Real-world impact: Validating the value of condition monitoring

Condition monitoring can deliver rapid and tangible value through reduced unplanned downtime and maintenance spend. One customer implemented Baker Hughes condition monitoring solutions to detect failures in key mechanical components of a haul truck, including the generator, water pump, oil pumps and the wheels – specifically, the internal bearing. By accessing real-time vibration waveform data and analyzing fault frequencies from the bearing installed in the wheel, an anomaly was detected using an accelerometer placed on the internal bearing of the wheel motor. Through the early detection of this anomaly and the subsequent replacement of the bearing, the customer estimated a savings of approximately $300,000.

This is just one example of how condition monitoring and other digital tools can help improve reliability and uptime while also reducing costs. For those operators seeking increased efficiency, safety, and cost savings, condition monitoring is a strategic investment that should not be overlooked.

Contact us to learn more about condition monitoring and how we can help your mining operations run more efficiently.