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Improving BW Reclaimer Performance & Asset Integrity using SCADA Data
Bulk Materials Handling Conference, Perth
Mark BiggsAdam Mayers
Outline
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
• Introduction / context
• Operating within design envelope of machine – AS4324.1 Compliance
o Using SCADA data to compare actual operating loads to design loads.
o Operating loads (conveyor live load, digging loads, etc).
o Machine balance monitoring.
• Capital Planning – When will the machine reach the end of its life?
o Fatigue damage monitoring.
• Improving throughput performance by monitoring SCADA
o Fundamentals of Operation
o Reducing trips and unexpected downtime.
o Alternative control philosophies
o Identify opportunities for performance improvements.
Bucketwheel Reclaimers
• Bucketwheel reclaimers are extensively
used in materials handling facilities in
Australia. Predominately slewing,
luffing, long travel machine.
• Large, expensive items of equipment.
Many new machines have been
constructed in last 5 years.
• Typically high required availability and
utilisation.
• Machines typically fitted with SCADA
system (Supervisory Control and Data
Acquisition).
• Data available to optimise performance
within design envelope of machine.
Challenge is to turn this Data into
useful Information.
• Approach can be applied to different
equipment types.
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
AS4324.1 Design Envelope
• AS4324.1 – 1995 is the Australian
Standard relating to ‘Mobile
equipment for continuous handling of
bulk materials’
• Specifies how machine structures are
designed for structural strength and
fatigue life.
• New revision to be released in 2015
• Vast majority of new machines in
Australia have been designed to this
standard.
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
AS4324.1 Load Combination Table 3.7 – Related to Fatigue and
Strength Design Loads, and SCADA Data
Rare loads and
accidents – strength
design
e.g.
- Flooded Belt
- Collisions
- Grounding
- Cyclone
Operational
loads used for
strength design
- Dead weight
- Conveyor
- Digging
- Dynamics
Loads used to
calculate fatigue
life of machine
structure
- Conveyor
- Digging
Abnormal operation
strength design
- High digging loads
- Slew bearing
jacking
Many of the loads can
be related to drive
torque, or production
rate which are data
logged by the control
system (SCADA
system)Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Using SCADA Data to Compare Real Loads with AS4324.1
Luff cylinder forces:AS4324.1- Dead load
balance- Slew brg loads- Combined live
loads- Collisions
Belt weigher tonnes/hr:AS4324.1Conveyor live load (F)Flooded belt (FF)
BW drive powerAS4324.1Normal digging (U)Abnormal digging (UU)
Slew drive power and angle:AS4324.1- Lateral digging (S)- Lateral collision (FS)- No. Slew cuts for
fatigue
Bucketwheel boom
Counterweight
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Conveyor Live Loads
Live Load (F) is the normal operating load for strength design.
The load can be converted to tphusing the belt speed (green line)
Flooded Belt Load (FF) is the accidental load used for strength design
Measured conveyor throughput is below strength design envelopes.
Fatigue design to AS4324.1 is based on 0.8 x (F) = 15,113 tph
Conclusion: Conveyor live load is within strength and fatigue design envelopes during this SCADA data sample.
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
0 20 40 60 80 100 120 140 1600
x 105 BW motor current
BW motor current (A)
Bin
counts
(fr
equency)
0 20 40 60 80 100 120 140 1600
50
100
Cum
ula
tive s
um
(%
)
Cumulative sum
AS 4324.1 fatigue digging CU.U
Motor full load current 108 A
AS 4324.1 normal digging U 175 kN
AS 4324.1 abnormal digging UU 239 kN
Example – Digging Loads A histogram is useful for large data
sets as it gives an idea of the
amount of time at each load level.
Green line represents digging load used in fatigue calculations.
Blue line represents Normal Digging Load (U) used in strength design.
Conclusion: Digging load is higher than assumed in the fatigue design which may reduce the life of certain areas of the structure. The loads are generally within the strength design envelope
Magenta line represents the Abnormal Digging Load (UU) used in strength design.
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Luff Cylinder Loads
The combined effect of the live loads can be seen in the luff cylinder pressures/loads.
We can also infer information about the dead load balance e.g. counterweight trim compared to design.
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Luff Cylinder Loads
Machine is slightly discharge boom heavy compared to design balance (green line)
Peak tensile luff cylinder loads approach the AS4324.1 III/6 Flooded Belt and Blocked Chute Combination but are inside the strength envelope (red dotted line)
Loads exceed the fatigue design assumptions quite often (blue line) Conclusions:
- Strength OK.- May need CW trim- Fatigue life may be shorter than design
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Capital Planning – Remaining Fatigue Life
• Machines specifications typically require 20 years of operation or perhaps
100,000 operating hrs. Typically, primarily limitation on life of machine
structure is accumulated steel fatigue damage which results in cracking, at
which point, machine replacement is often required.
• Fatigue is caused by stress fluctuations at the welds. The magnitude of the
stress range and the number of cycles are important.
• For a Bucketwheel Reclaimer, the stress fluctuations and cycles are mainly
proportional to the number of slew cuts i.e. the digging and conveyor load
cycles, and magnitude of loads. The designer therefore converts the 20 year
life requirement to a number of slew cut cycles for the fatigue design
calculations. The conversion is based on the annual throughput rate,
stockpile shape and digging parameters.
• SCADA data can be analysed to count the number of slew cuts that actually
occur per million tonnes reclaimed and estimate the magnitude of loads, to
estimate remaining life based on historical throughput data.
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Remaining Fatigue Life
0 90 180 270 3600
500
1000
1500
2000
2500
3000
3500
4000
4500
5000Slew passes at slew angle
Slew angle (deg)
Sle
w p
asses p
er
million t
onnes r
ecla
imed p
er
quadra
nt
Statistic can be calculated for number of slew cuts per million tonnes reclaimed e.g. 4,300 slew cuts per Mt
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Remaining Fatigue Life
Historical production records converted to accumulated slew cuts e.g. 4,300 x annual production.
Variations in the production rate are captured.
Current point in time
Estimated point in time when the design fatigue life will have been consumed.
Suited to longer term capital planning i.e. approximate machine replacement
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – More Detailed Fatigue Assessment
SCADA analysis and FEA can be used
together to derive stress/cycle
distributions as inputs to fatigue life
calculations.
More accurate because it includes the
load variations and cycles.
Suited to life extension studies and
targeting resources for asset integrity
inspections.Finite Element Structural Model
Loads
Stress cycles
Fatigue life
calculation
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Improving Performance - Fundamentals of Operation
Re-positioning Losses at ends of cut
Trips result in production losses
Geometric & Control opportunities
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Modifying the Geometry of the Reclaim Process
SCADA data review and subsequent reclaim simulation indicated that a Stacker-Reclaimer was under-performing. One suggested change including moving from 4 bench to 3 bench reclaiming –estimated 10% improvement in average reclaim rate.
Change implemented in early 2015. SCADA review confirmed approx. 10% increase in average rate!
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Troubleshooting Trips to Minimise Production Delays
using 3D Graphics: Slew Clutch Alarms
Colour scale shows SCADA parameter as a function of 3D boom tip position e.g. BW current, throughput, slew torque
Black dots are logged alarms/trips which represent production delays (lost revenue) Concise way of finding patterns using very large data sets e.g. ~5 million data points in picture
below Easy to see that trips mainly occur at outer edges of lower benches using this technique Not easy to look at these patterns using normal “trend” software
1 month of 1Hz data
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Troubleshooting Trips to Minimise Production Delays
using 3D Graphics: Slew Clutch Alarms
Trips occur when slew speed is changing
quickly.
Zooming in on individual trips found that
the slew brakes were being applied
incorrectly.
Brake always applies before
trips
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Troubleshooting Trips to Minimise Production Delays
using 3D Graphics: Luff Cylinder Trips
Machine balance is boom heavy
Luff cylinders trip the machine due to
spikes in the digging load
Each black dot is a trip which stops the
machine until it is re-set. The average
delay is 3 mins
195 alarms in 90 days
195 alarms x 3 mins x 8,500 tph x $60/t =
$5M potential lost revenue per quarter
$20M annualised
195 trips
Trip frequency vs
duration
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Troubleshooting Trips to Minimise Production Delays
using 3D Graphics: Luff Cylinder Trips
Add 2 tonnes to counterweight
Trips reduce from 195 to 69
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Troubleshooting Trips to Minimise Production Delays
using 3D Graphics: Luff Cylinder Trips
Add 8 tonnes to counterweight
Trips eliminated
Need to do more struct/mech design checks, but
~5% mass increases are likely ok if machine is
originally compliant with AS4324.1
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Example – Identification of Repositioning Losses
12 second delay between weightometer and BW. Consider incl. some BW torque feedback or relocate weightometer.
Significant repositioning losses, particularly at far end of slew cut.
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Additional Opportunities
• Throughput measurements typically lag behind reclaim operation → slows control
system response. Alternative more direct feedback, such as bucketwheel current
or torque arm feedback control can be effective.
• Using SCADA data to benchmark performance against similar machines in fleet.
Recent example showed two identical machines were performing differently:
Reclaimer 1 average = 2815 TPH, Reclaimer 2 average = 3050 TPH → 8%
difference.
• Learn mode algorithms can be implemented to provide predictive feedback based
on SCADA data. Control of one slew reclaim cut is influenced by previous slew
reclaim cuts (e.g. pile edges, soft / hard sections of stockpile etc).
• Good stacking is very important!
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Summary – Benefits of SCADA based Engineering Analysis
Asset Management
• Understand whether operating machines are compliant with AS4324.1
• If not full compliant, risks can be explored
• Targeting structural integrity inspections to fatigue prone areas
• Understanding machine balance via the luff cylinders.
Capital Planning
• Estimate when machine may need to be replaced in the future based on
remaining fatigue life.
Production
• Reduce production losses due to overload trips
• Identify under-utilisation within the design envelope and opportunities to
increase production rates.
• Benchmark production performance against similar machines in the fleet
• Highly cost effective method of “sweating the assets” for maximum productivity.
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data
Thank you!
Improving BW Reclaimer Performance & Asset Integrity
using SCADA Data