Mining Equipment Reliability, Maintainability, and Safety PDF
Preview Mining Equipment Reliability, Maintainability, and Safety
Springer Series in Reliability Engineering Series Editor ProfessorHoangPham DepartmentofIndustrialandSystemsEngineering Rutgers,TheStateUniversityofNewJersey 96FrelinghuysenRoad Piscataway,NJ08854-8018 USA Othertitles inthis series TheUniversalGeneratingFunctioninReliabilityAnalysisandOptimization GregoryLevitin WarrantyManagementandProductManufacture D.N.PMurthyandWallaceR.Blischke MaintenanceTheoryofReliability ToshioNakagawa SystemSoftwareReliability HoangPham ReliabilityandOptimalMaintenance HongzhouWangandHoangPham AppliedReliabilityandQuality B.S.Dhillon ShockandDamageModelsinReliabilityTheory ToshioNakagawa RiskManagement TerjeAvenandJanErikVinnem SatisfyingSafetyGoalsbyProbabilisticRiskAssessment HiromitsuKumamoto OffshoreRiskAssessment(2ndEdition) JanErikVinnem TheMaintenanceManagementFramework AdolfoCrespoMárquez HumanReliabilityandErrorinTransportationSystems B.S.Dhillon ComplexSystemMaintenanceHandbook D.N.P.MurthyandKhairyA.H.Kobbacy 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 Apartfromanyfairdealingforthepurposesofresearchorprivatestudy,orcriticismorreview,asper- mittedundertheCopyright, DesignsandPatents Act1988,thispublication mayonlybereproduced, storedortransmitted,inanyformorbyanymeans,withthepriorpermissioninwritingofthepublish- ers,orinthecaseofreprographicreproductioninaccordancewiththetermsoflicencesissuedbythe CopyrightLicensingAgency.Enquiriesconcerningreproductionoutsidethosetermsshouldbesentto thepublishers. Theuseofregisterednames,trademarks,etc.inthispublicationdoesnotimply,evenintheabsenceof aspecificstatement,thatsuchnamesareexemptfromtherelevantlawsandregulations andtherefore freeforgeneraluse. Thepublishermakesnorepresentation,expressorimplied,withregardtotheaccuracyoftheinformation containedinthisbookandcannotacceptanylegalresponsibilityorliabilityforanyerrorsoromissions thatmaybemade. Coverdesign:deblik,Berlin,Germany Printedonacid-freepaper 987654321 springer.com 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
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