Coal Age

DEC 2012

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prairie state continued 11% to 14% moisture levels, 25% ash, relatively low sulfur and no chlorine," said Krivokuca. "The fuel component is the real key to the success of this project. We know we are a model for the future. Our intention is that we don't just want to be Illinois Basin class, but world class. We're putting the components and the workforce in place to ensure that. This is not just another mine, but a project that really shows the vitality and long term opportunities for us to be an energy independent nation that uses the resources we already have domestically," said Krivokuca. A Mission of Reliability Because of the nature of their relationship with the power plant, as sole source supplier, the mine is "challenged to build a reliability centered maintenance and performance program. We cannot simply always be in the process of reacting, but must be proactive so we're able to improve our circumstances, and ensure that bad things don't become issues," said Aaron Jackson, underground operations manager, PSEC. December 2012 To ensure that a small series of odd vibrations on a unit do not lead to a worse situation, PSEC is participating in a comprehensive data monitoring and collecting initiative with JoyGlobal. To help facilitate the project, PSEC hired Tom Grogan, a reliability expert who worked in mines in Pennsylvania and then worked for FedEx, to be the mine's maintenance manager. There are two components to the data study. One is a Life Cycle Management program. For this, PSEC has partnered with JoyGlobal to track the life of the mine's machinery from initial purchase, through the rebuild process and into the replacement process. PSEC is also participating in a second program called Smart Services. A service that JoyGlobal instituted in South Africa, "JoyGlobal is now continuously collecting data from our continuous mining machines, yielding a real time time-study, gathering motor currents, sumping speeds, cutting rates, the times it takes to change from place to place, and other data that the machine can tell you in real time," said Grogan. JoyGlobal has a group in Mt. Vernon, Ill., that basically sits in a control room and "watches our machines run. They are looking for trends, but also errors, warnings, and anything that a machine might be signaling that could lead to adverse operations down the road. They call back to us and inform us before there is a problem. They are looking at oil levels, hydraulics and monitoring to see if there is enough pressure—that indicates wear. They are trending this data too. They can determine if they are starting to see unusual changes in currents, or something on a motor that might indicate an imminent engine breakdown. Long term, these trend determinations help us to understand how a particular machine is running, what's normal for it, what isn't and what we need to look at. Short term, we always know how well the machine is currently functioning and if our crews are running them properly," said Grogan. "We partnered with JoyGlobal because we're a stand alone mine. This relationship gives us a partner to broaden out how we are doing and how we can evaluate that performance against others in the industry. That helps us with relia- 41

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