En­er­pac EVO sys­tem halves main­te­nance down­time while boost­ing safety

DEMM Engineering & Manufacturing - - MAINTENANCE PLANNING - DE­TAILS, NEVILLE STU­ART PH: 021 667 716 E- MAIL: NEVILLE@EN­ER­PAC.CO.NZ

Rou­tine main­te­nance is re­quired on a P&H 4100XPC Elec­tric Rope Shovel af­ter ev­ery 30,000 hours of op­er­a­tion.

These ma­chines re­quire main­te­nance in which the up­per sec­tion is lif ted off the car body to ma­chine bear­ing sur­faces and in­spect and re­pair struc­tural com­po­nents. Weigh­ing ap­prox­i­mately 1,000 US tons (ap­prox. 907,000kg), lif ting the up­per car body re­quires a sig­nif­i­cant amount of force and con­trol.

The main­te­nance team at Joy Global (now part of Ko­matsu) reached out to En­er­pac to de­liver a shovel lif t sys­tem to un­deck a P&H 4100XPC shovel in ap­prox­i­mately one hour and be trans­ported on the high­way with­out over­sized load per­mits. The EVO syn­chro­nous lif t tech­nol­ogy in­volved in this US lif t – tech­nol­ogy which is widely de­ployed by En­er­pac for heavy pre­ci­sion lif ts in Aus­tralia and New Zealand – pro­vided the speed and safety of the lif t that were crit­i­cal com­po­nents in re­duc­ing labour and equip­ment.

SO­LU­TION

The EVO sys­tem in­cluded four 500 US ton cylin­ders with 72 inches of stroke (ap­prox. 1829mm), an EVO syn­chro­nous con­trol unit and four cus­tom 8000 se­ries hy­draulic pumps. Each pump was built to op­er­ate in ex­tremely cold or hot en­vi­ron­ments. “En­er­pac had pre­vi­ously built a sim­i­lar shovel lif t sys­tem for Joy Global’s main­te­nance team in Chile. The sec­ond- gen­er­a­tion sys­tem built for Joy Global’s ser­vice team in Gil­lette, Wy­oming, pro­vided sig­nif­i­cantly more speed,” said War­ren Balti­neshter, Aus­tralasian Min­ing and Heavy Lift So­lu­tions Man­ager for the global En­er­pac or­gan­i­sa­tion, which has op­er­ated through­out Aus­trala­sia for more than 50 years. The EVO syn­chro­nous con­trol unit en­abled a sin­gle op­er­a­tor to con­trol the en­tire lif t and en­sure each lif ting point re­mained within 3/8 of an inch (9.525mm). The shovel was suc­cess­fully un­decked in ap­prox­i­mately one hour and the en­tire sys­tem was trans­ported on the high­way with­out over­sized load per­mits.

Prod­ucts in­volved were four cus­tom 500-ton cylin­ders with 72 inches of stroke, four cus­tom 8000 se­ries hy­draulic pumps and an EVO syn­chro­nous con­trol unit.

EVO LIFT SYS­TEM

En­er­pac EVO syn­chro­nous lif ting sys­tems re­place man­ual con­trol of hy­draulic heavy lif ting with PLC con­trol of mul­ti­ple cylin­der lif ts, of­fer­ing ac­cu­racy, safety and pro­duc­tiv­ity ben­e­fits for pre­ci­sion lif ting of heavy re­sources in­dus­try ma­chin­ery.

The EVO sys­tem is the evo­lu­tion­ary re­sult of En­er­pac’s 25 years of ex­pe­ri­ence in spe­cialised hy­draulic en­gi­neer­ing and lif ting tech­nol­ogy us­ing dig­i­tally con­trolled hy­draulics to ac­cu­rately and safely lif t some of the largest and most chal­leng­ing struc­tures on earth, in­clud­ing min­eral and oil and gas pro­cess­ing equip­ment.

Re­cent ex­am­ples range from 1500 ton grind­ing mills in Western Aus­tralia to the su­per­lift­ing and launch of a 43,000-ton float­ing oil pro­duc­tion sys­tem in Malaysia for the Gu­musut-Kakap off­shore field.

The lat­est EVO syn­chro­nous sys­tem of­fers eight stan­dard hy­draulic con­trol modes and can con­trol 4, 8 or 12 points with one hy­draulic power unit (HPU). A master con­trol unit is also avail­able that of­fers daisy chain con­trol of mul­ti­ple EVO sys­tems, giv­ing a max­i­mum of 192 lif ting points.

In­stead of whole teams of lif ting per­son­nel try­ing to man­u­ally co­or­di­nate with each other lif ts by hy­draulic cylin­ders dis­persed around a job, the EVO Se­ries Syn­chro­nous Lift­ing Sys­tem in­te­grates the high­pres­sure hy­draulic cylin­ders in­volved with a PLC sys­tem to mon­i­tor and con­trol pre­cise move­ment and po­si­tion­ing of heavy loads. Through an in­te­grated HMI (Hu­man Ma­chine In­ter­face), all move­ments are man­aged from a cen­tral con­trol po­si­tion that dis­plays live op­er­a­tion with real-time sta­tus up­dates for each lif ting po­si­tion.

The mul­ti­func­tional EVO-Se­ries can be used with mul­ti­ple stan­dard 700 bar (10,000 psi) sin­gle or dou­ble-act­ing cylin­ders and is of­fered with a 5 HP or 10 HP hy­draulic power unit with 250 litre (66 gal­lon) reser­voir.

Ac­cu­racy is one of the main ben­e­fits of us­ing the EVO sys­tem, which also of­fers in­creased pro­duc­tiv­ity, with less staffing re­quired than for man­u­ally con­trolled lif ting.

“With syn­chro­nous lif ting, one op­er­a­tor con­trols the en­tire pre­ci­sion lif ting process, dur­ing which the sta­tus of ev­ery lif ting point is con­stantly mon­i­tored and dis­played,” said Balti­neshter.

“Time sav­ing is an­other ad­van­tage of syn­chro­nous lif ting. The process does not have to be stopped af­ter any in­cre­men­tal value, checked, man­u­ally re­mea­sured and cor­rected. The EVO-Sys­tem car­ries out these ac­tions dur­ing the en­tire lif ting process, even with low lif ting or low­er­ing speeds. De­pend­ing on the ap­pli­ca­tion, time sav­ings up to 60 per­cent can be achieved.”

Safety ben­e­fits of the PLC- con­trolled sys­tem in­clude elim­i­na­tion of the po­ten­tial for er­ror with the multi- op­er­a­tor man­ual con­trol ap­proach. The dig­i­tally pre­cise EVO-sys­tem in­cor­po­rates warn­ings and stop func­tions. It of­fers full mon­i­tor­ing and con­trol, with pro­gram­mable fail­safe mon­i­tor­ing and safety alarms.

“Time sav­ing is an­other ad­van­tage of syn­chro­nous lift­ing. The process does not have to be stopped af­ter any in­cre­men­tal value, checked, man­u­ally re­mea­sured and cor­rected. The EVO-Sys­tem car­ries out these ac­tions dur­ing the en­tire lift­ing process, even with low lift­ing or low­er­ing speeds. De­pend­ing on the ap­pli­ca­tion, time sav­ings up to 60 per­cent can be achieved.”

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