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Reliability analysis of mining equipment: A case study of a crushing plant at Jajarm Bauxite Mine in Iran

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  • Barabady, Javad
  • Kumar, Uday

Abstract

The performance of mining machines depends on the reliability of the equipment used, the operating environment, the maintenance efficiency, the operation process, the technical expertise of the miners, etc. As the size and complexity of mining equipments continue to increase, the implications of equipment failure become ever more critical. Therefore, reliability analysis is required to identify the bottlenecks in the system and to find the components or subsystems with low reliability for a given designed performance. It is important to select a suitable method for data collection as well as for reliability analysis. This paper presents a case study describing reliability and availability analysis of the crushing plant number 3 at Jajarm Bauxite Mine in Iran. In this study, the crushing plant number 3 is divided into six subsystems. The parameters of some probability distributions, such as Weibull, Exponential, and Lognormal distributions have been estimated by using ReliaSoft's Weibull++6 software. The results of the analysis show that the conveyer subsystem and secondary screen subsystem are critical from a reliability point of view, and the secondary crusher subsystem and conveyer subsystem are critical from an availability point of view. The study also shows that the reliability analysis is very useful for deciding maintenance intervals.

Suggested Citation

  • Barabady, Javad & Kumar, Uday, 2008. "Reliability analysis of mining equipment: A case study of a crushing plant at Jajarm Bauxite Mine in Iran," Reliability Engineering and System Safety, Elsevier, vol. 93(4), pages 647-653.
    • Handle: RePEc:eee:reensy:v:93:y:2008:i:4:p:647-653
    DOI: 10.1016/j.ress.2007.10.006
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    Cited by:

    1. Rajkumar Bhimgonda Patil & Basavraj S Kothavale & Laxman Yadu Waghmode, 2019. "Selection of time-to-failure model for computerized numerical control turning center based on the assessment of trends in maintenance data," Journal of Risk and Reliability, , vol. 233(2), pages 105-117, April.
    2. Sheo Shankar Rai & Vemavarapu M. S. R. Murthy & Nalamasa Sukesh & Akkiraju Sairam Teja & Simit Raval, 2021. "Operational efficiency of equipment system drives environmental and economic performance of surface coal mining—A sustainable development approach," Sustainable Development, John Wiley & Sons, Ltd., vol. 29(1), pages 25-44, January.
    3. Ali Nouri Gharahasanlou & Mohammad Ataei & Reza Khalokakaie & Abbas Barabadi & Vahid Einian, 2017. "Risk based maintenance strategy: a quantitative approach based on time-to-failure model," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(3), pages 602-611, September.
    4. Macchi, Marco & Kristjanpoller, Fredy & Garetti, Marco & Arata, Adolfo & Fumagalli, Luca, 2012. "Introducing buffer inventories in the RBD analysis of process production systems," Reliability Engineering and System Safety, Elsevier, vol. 104(C), pages 84-95.
    5. Yuriy Zhukovskiy & Aleksandra Buldysko & Ilia Revin, 2023. "Induction Motor Bearing Fault Diagnosis Based on Singular Value Decomposition of the Stator Current," Energies, MDPI, vol. 16(8), pages 1-23, April.
    6. BULUT, Merve & ÖZCAN, Evrencan, 2021. "A new approach to determine maintenance periods of the most critical hydroelectric power plant equipment," Reliability Engineering and System Safety, Elsevier, vol. 205(C).
    7. P Viveros & E Zio & F Kristjanpoller & A Arata, 2012. "Integrated system reliability and productive capacity analysis of a production line. A case study for a Chilean mining process," Journal of Risk and Reliability, , vol. 226(3), pages 305-317, June.
    8. Prerita Odeyar & Derek B. Apel & Robert Hall & Brett Zon & Krzysztof Skrzypkowski, 2022. "A Review of Reliability and Fault Analysis Methods for Heavy Equipment and Their Components Used in Mining," Energies, MDPI, vol. 15(17), pages 1-27, August.
    9. Balaraju Jakkula & Govinda Raj Mandela & Suryanarayana Murthy Chivukula, 2022. "Reliability, availability and maintainability (RAM) investigation of Load Haul Dumpers (LHDs): a case study," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 13(1), pages 504-515, February.
    10. Amin Moniri-Morad & Mohammad Pourgol-Mohammad & Hamid Aghababaei & Javad Sattarvand, 2019. "Reliability-based covariate analysis for complex systems in heterogeneous environment: Case study of mining equipment," Journal of Risk and Reliability, , vol. 233(4), pages 593-604, August.
    11. Barabadi, Abbas & Barabady, Javad & Markeset, Tore, 2014. "Application of reliability models with covariates in spare part prediction and optimization – A case study," Reliability Engineering and System Safety, Elsevier, vol. 123(C), pages 1-7.
    12. Masoud Naseri & Javad Barabady, 2016. "On RAM performance of production facilities operating under the Barents Sea harsh environmental conditions," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 7(3), pages 273-298, September.
    13. Ali N Qarahasanlou & Abbas Barabadi & Yonas Z Ayele, 2018. "Production performance analysis during operation phase: A case study," Journal of Risk and Reliability, , vol. 232(6), pages 559-575, December.
    14. Regattieri, A. & Manzini, R. & Battini, D., 2010. "Estimating reliability characteristics in the presence of censored data: A case study in a light commercial vehicle manufacturing system," Reliability Engineering and System Safety, Elsevier, vol. 95(10), pages 1093-1102.
    15. Railh Gugus Tresor Massonini Ngoma & Cety Gessica Abraham Mahanga Tsoni & Xiangrui Meng & Sumaiya Bashiru Danwana, 2023. "The Impact of the Mining Equipment, Technological Trends, and Natural Resource Demand on Climate Change in Congo," Sustainability, MDPI, vol. 15(2), pages 1-28, January.
    16. Jacek Paś, 2023. "Issues Related to Power Supply Reliability in Integrated Electronic Security Systems Operated in Buildings and Vast Areas," Energies, MDPI, vol. 16(8), pages 1-22, April.
    17. Jarosław Brodny & Magdalena Tutak, 2019. "Analysing the Utilisation Effectiveness of Mining Machines Using Independent Data Acquisition Systems: A Case Study," Energies, MDPI, vol. 12(13), pages 1-15, June.
    18. Barabadi, Abbas & Barabady, Javad & Markeset, Tore, 2011. "Maintainability analysis considering time-dependent and time-independent covariates," Reliability Engineering and System Safety, Elsevier, vol. 96(1), pages 210-217.
    19. Barabadi, Abbas & Barabady, Javad & Markeset, Tore, 2011. "A methodology for throughput capacity analysis of a production facility considering environment condition," Reliability Engineering and System Safety, Elsevier, vol. 96(12), pages 1637-1646.
    20. Panagiotis H. Tsarouhas & George K. Fourlas, 2016. "Mission reliability estimation of mobile robot system," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 7(2), pages 220-228, June.
    21. Nupur Goyal & Mangey Ram & Ajay Kaushik, 2017. "Performability of solar thermal power plant under reliability characteristics," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(2), pages 479-487, June.
    22. Kartick Bhushan & Somnath Chattopadhyaya & Shubham Sharma & Kamal Sharma & Changhe Li & Yanbin Zhang & Elsayed Mohamed Tag Eldin, 2022. "Analyzing Reliability and Maintainability of Crawler Dozer BD155 Transmission Failure Using Markov Method and Total Productive Maintenance: A Novel Case Study for Improvement Productivity," Sustainability, MDPI, vol. 14(21), pages 1-17, November.
    23. Zbigniew Krysa & Przemysław Bodziony & Michał Patyk, 2021. "Discrete Simulations in Analyzing the Effectiveness of Raw Materials Transportation during Extraction of Low-Quality Deposits," Energies, MDPI, vol. 14(18), pages 1-19, September.

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