Coal Age

AUG 2016

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August 2016 www.coalage.com 37 dragline maintenance continued connecting lacings welded to the chords at cluster joints. Stresses are concentrated at the cluster joint weldments and over time, fatigue cracking becomes endem- ic. This methodology prevents the need to cut and replace windows in lacings by removing the problematic design detail and improving load paths. Furthermore, DuraCluster can dramatically extend the fatigue life of dragline booms by reducing the stress concentrations. A boom replacement can cost as much as $20 million and require a three- month machine outage. With BMT's modification and repair, the cluster de- sign can be upgraded in around one week per cluster, depending on the extent of chord repair required, while multiple clusters can be modified simultaneously. With equivalent repair costs reduced to approximately $2 million, this is an ex- tremely attractive incentive for mining companies. While DuraCluster provides a step change in life to cracking for tu- bular boom construction, it is equally applicable to tubular masts. The innovative design allows lacings to be cut away from the chord, providing easy access to remove damaged or pre- viously repaired material. The exposed chord can then be inspected and fully weld repaired before installing the plate. Full patent rights for the DuraCluster de- sign have been granted in Australia, South Africa, India and North America, and dis- cussions are taking place with potential clients in all these territories. Another area of significant techno- logical advances made over the past 15 to 20 years is the dragline slew bearing, also known as the roller circle. The roller circle and the supporting structures immediate- ly above and below are vital mechanical and structural component of the dragline. Installation and maintenance activities in these areas carried out to a poor standard can lead to large amounts of cracking in the tub and the revolving frame and very poor bearing life. BMT WBM has devel- oped supporting and repair techniques ensuring that the welding and machining of the upper and lower rail pads are done to a very high standard resulting in good bearing load distribution and long roller circle service life. Although there is welcome optimism for the future of the mining industry as whole, mining companies are focusing heavily on cost efficiencies and produc- tivity gains in the short to medium term. Pushing innovation and embracing the technologies that are available can play an integral role in realizing these efficien- cies, but this is only one part of the jigsaw. Effective maintenance strategies, which consider tools and techniques such as RCM and simultaneously aligned with the need to be production focused, will cre- ate a step change in maintenance man- agement, helping to improve productiv- ity and availability of critical assets and in many cases, reduce the overall cost of maintenance in the long term. Ryan Sharp is the vice president of BMT WBM's Denver office and Charles Constan- con is the director of Canadian Services. Sharp can be reached at (303) 792-9814 or ryan.sharp@bmtwbm.com. quakerchem.com/minexpo info@quakerchem.com | 1.800.523.7010 DUSTGRIP® KEEPS YOU WORKING HARD BY KEEPING DUST IN ITS PLACE. © 2016 Quaker Chemical Corporation. All Rights Reserved. When you work in harsh conditions, the last thing you need is dust getting in your way. Quaker's dust suppressant product line, DUSTGRIP,® helps support a safer work environment, improve worker health, and optimize operational efficiency by significantly reducing airborne dust. And with over 30 years of industry experience, you won't find a better partner, especially when new regulations come down the line. So team up with Quaker, and when work conditions get rough, we'll make sure the dust settles. Trust a partner who knows the mining Industry from the Inside. Visit us at booth 25313 (South Hall)

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