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Mining, Process Plant, Maintenance & Safety Training
PERFORMANCE ASSOCIATES INTERNATIONAL
Excellence in Mining, Process Plant, Maintenance, and Safety Training Performance Associates International, Inc. (PAI) is the world leader in online and on-site training for the mining industry. We provide organizations with a single source for assessments, skills training, continuing education, safety training and compliance mandates, and more. Our first-class content guides your staff to gain the critical knowledge they need to work safely and efficiently today. Our proven, leading-edge industrial training programs improve performance in existing operations and ensure success during the start-up of new operations. Our training programs have saved companies millions in personnel accident prevention, production loss, and equipment damage. We partner with our customers and consult collaboratively to provide the analysis and content development to meet your needs. Services PAI Offers Plant Operator TrainingOur three-tier concept for effective plant operator training starts with fundamental knowledge and progresses to plant-specific concepts that are reinforced through detailed animations and interactive simulations. Maintenance TrainingWe custom build state-of-the-art maintenance training programs using exploded graphics, explanatory text, detailed procedures, and management systems. Mobile Equipment Operator TrainingOur first-class training program focuses on operator controls and indicators, safety, and performance optimization. It also includes operating, emergency, and troubleshooting procedures.Commissioning and Start-UpWe can identify, track, and control the thousands of activities that must occur for the successful commissioning and start-up of a process plant. There is no shortcut to a successful start-up.Testing and Tracking SystemsWe can help manage and track the performance of employees to improve the overall performance of the mine and plant industrial training programs. Our testing and tracking systems provide invaluable assistance in safety and operational compliance. Introductory and Safety TrainingOff-the-shelf introductory and safety training packages are an excellent source for mine and plant industrial training courses. They provide fundamental knowledge and basic training concepts. Now offering online courses!E-Learning, Animations, and SimulationsOur interactive e-learning keeps trainees focused and engaged. Our experienced in-house multimedia team develops state-of-the-art graphics, virtual and mixed reality training, stunning 3D animations, and technically engineered simulations of real-world scenarios.Other ServicesWe also provide many services relevant to planning, analyzing, and evaluating process plants, including:·         Operations readiness plan.·         Planning studies.·         Quality management.·         Systems implementation.·         Statistical process control.·         Reliability-based asset management.·         Productive capacity studies.·         Surveys and needs analyses.·         Economic life analysis.·         Process control strategies and methods.·         Debottlenecking and process optimization.·         Spare parts inventory and analysis.·         Feasibility studies.·         Consulting assistance.Consulting * Gap Analysis * Content Development * LMS * On-Site * Train-the-Trainer * E-Learning * Process Plant Optimization * Training * Safety * Mine Training * Plant Operator Training * Maintenance * Mobile Equipment * Competencies * Commissioning
Mining, Process Plant, Maintenance & Safety Training
PERFORMANCE ASSOCIATES INTERNATIONAL
Excellence in Mining, Process Plant, Maintenance, and Safety Training  Performance Associates International, Inc. (PAI) is the world leader in online and on-site training for the mining industry. We provide organizations with a single source for assessments, skills training, continuing education, safety training and compliance mandates, and more. Our first-class content guides your staff to gain the critical knowledge they need to work safely and efficiently today.  Our proven, leading-edge industrial training programs improve performance in existing operations and ensure success during the start-up of new operations. Our training programs have saved companies millions in personnel accident prevention, production loss, and equipment damage. We partner with our customers and consult collaboratively to provide the analysis and content development to meet your needs.  Services PAI Offers  Plant Operator Training Our three-tier concept for effective plant operator training starts with fundamental knowledge and progresses to plant-specific concepts that are reinforced through detailed animations and interactive simulations.  Maintenance Training We custom build state-of-the-art maintenance training programs using exploded graphics, explanatory text, detailed procedures, and management systems.  Mobile Equipment Operator Training Our first-class training program focuses on operator controls and indicators, safety, and performance optimization. It also includes operating, emergency, and troubleshooting procedures. Commissioning and Start-Up We can identify, track, and control the thousands of activities that must occur for the successful commissioning and start-up of a process plant. There is no shortcut to a successful start-up. Testing and Tracking Systems We can help manage and track the performance of employees to improve the overall performance of the mine and plant industrial training programs. Our testing and tracking systems provide invaluable assistance in safety and operational compliance.  Introductory and Safety Training Off-the-shelf introductory and safety training packages are an excellent source for mine and plant industrial training courses. They provide fundamental knowledge and basic training concepts. Now offering online courses! E-Learning, Animations, and Simulations Our interactive e-learning keeps trainees focused and engaged. Our experienced in-house multimedia team develops state-of-the-art graphics, virtual and mixed reality training, stunning 3D animations, and technically engineered simulations of real-world scenarios. Other Services We also provide many services relevant to planning, analyzing, and evaluating process plants, including: ·         Operations readiness plan. ·         Planning studies. ·         Quality management. ·         Systems implementation. ·         Statistical process control. ·         Reliability-based asset management. ·         Productive capacity studies. ·         Surveys and needs analyses. ·         Economic life analysis. ·         Process control strategies and methods. ·         Debottlenecking and process optimization. ·         Spare parts inventory and analysis. ·         Feasibility studies. ·         Consulting assistance. Consulting * Gap Analysis * Content Development * LMS * On-Site * Train-the-Trainer * E-Learning * Process Plant Optimization * Training * Safety * Mine Training * Plant Operator Training * Maintenance * Mobile Equipment * Competencies * Commissioning  
Interested in BIG Productivity Gains? Wipe Out Non-Productive Driver and Fleet Time
Command Alkon
There’s some good, solid news for the construction industry: Dodge Data & Analytics Index projects that we’ll have “moderate strengthening” through the end of 2018. But in terms of productivity, we appear to be heading in a different direction. Of note, a recent survey of 600 global construction leaders* compiled by PlanGrid and FMI Corporation mentions: ·         Poor communication, rework and bad data management cost the construction industry; $177 billion annually in labor costs in the United States alone. ·         Construction workers lose almost two full working days per week solving avoidable issues and searching for project information. ·         Each construction project team member spends more than 14 hours weekly on average dealing with conflict, rework and other issues. ·         Almost half of all rework is due to poor communication among project stakeholders, and poor project information, while 26% of rework is due to poor communication or miscommunication between team members caused unresponsiveness of team members; the inability of project stakeholders to collaborate effectively; and the lack of a common platform for all team members to communicate and share project data. ·         The most common goals for technology adoption included providing better access to project data, improving project productivity and increasing the accuracy of project information. ·         Workers are not taking full advantage of mobile devices and IT investments. Stamp Out Non-Productive Driver and Fleet Time for Big Productivity Gains It stands to reason that companies who address productivity issues will not only avoid scrambling for information and wasted hours and energy but also quickly gain competitive advantage. If you’re managing drivers and trucks that wheel in and out of numerous sites during the day or week and aren’t using automatic processes via technology to more efficiently track and manage your fleet, there’s more good news. You can increase driver productivity and avoid the 20-40 minutes per truck per day that’s lost through clocking in and out and other non-productive activities during: ·         Time in Transit ·         Time at the Job Site ·         Time in the Yard Forty minutes per day, per truck may seem marginal at first glance. But 200 minutes/week x 48 weeks/ year = 9,600 minutes, 160 hours or a total of 4,000 hours of inefficiency for a fleet of 25 trucks. Time in the yard is the lever most within a producer’s control and represents over half of the total nonproductive time per truck. So, rather than simply adding incremental trucks and drivers to the fleet to boost productivity (which unfortunately only adds to the total non‐productive hours and fails to improve operational processes), consider a solution that: ·         Uses automatic processes via technology to more efficiently track and manage your fleet. ·         Enables your drivers to punch the clock from in the cab, an efficiency enhancer that alone could save you up to 20 minutes per day (this is time spent in your own yard, under your own watch, that you can act on quickly to recapture those minutes, regardless of what happens away from your yard). ·         Captures a meaningful portion of that lost time from each driver. ·         Provides a constant view into the location and performance of your entire fleet. ·         Is adaptable and helps your teams collaborate in real-time with a “central source of truth” and access to relevant data when you need it. At least 50% of employees’ non‐productive time can be captured back efficiently and effectively when the right combinations of levers are pulled – both in terms of area of focus (i.e., time in yard) and adaptability to each individual customer’s business process requirements. This equates to big productivity increases over both the short- and long-term. Learn more about how Command Alkon’s TrackIt solution offers an industry specific, flexible and fully customizable solution to track your fleet and meet your specific needs, including in-cab time and attendance functionality focused at recapturing lost time in the yard, helping you drive a more efficient fleet and improve your profitability. *500 respondents from the United States and 99 from Australia, New Zealand, United Kingdom and Canada. Of those surveyed, 49% work for general contractor firms, 36% came from specialty trades and 15% were owners. Over 300 respondents came from the commercial sector and the other respondents represent industrial and manufacturing, heavy civil, healthcare, power (oil and gas, and energy), education and government.
Interested in BIG Productivity Gains? Wipe Out Non-Productive Driver and Fleet Time
Command Alkon
There’s some good, solid news for the construction industry: Dodge Data & Analytics Index projects that we’ll have “moderate strengthening” through the end of 2018. But in terms of productivity, we appear to be heading in a different direction. Of note, a recent survey of 600 global construction leaders* compiled by PlanGrid and FMI Corporation mentions: ·        •Poor communication, rework and bad data management cost the construction industry; $177 billion annually in labor costs in the United States alone.        •Construction workers lose almost two full working days per week solving avoidable issues and searching for project information. ·       • Each construction project team member spends more than 14 hours weekly on average dealing with conflict, rework and other issues. ·         •Almost half of all rework is due to poor communication among project stakeholders, and poor project information, while 26% of rework is due to poor communication or miscommunication between team members caused unresponsiveness of team members; the inability of project stakeholders to collaborate effectively; and the lack of a common platform for all team members to communicate and share project data. ·        •The most common goals for technology adoption included providing better access to project data, improving project productivity and increasing the accuracy of project information. ·        •Workers are not taking full advantage of mobile devices and IT investments.      Stamp Out Non-Productive Driver and Fleet Time for Big Productivity Gains It stands to reason that companies who address productivity issues will not only avoid scrambling for information and wasted hours and energy but also quickly gain competitive advantage. If you’re managing drivers and trucks that wheel in and out of numerous sites during the day or week and aren’t using automatic processes via technology to more efficiently track and manage your fleet, there’s more good news. You can increase driver productivity and avoid the 20-40 minutes per truck per day that’s lost through clocking in and out and other non-productive activities during: ·         •Time in Transit ·         •Time at the Job Site ·         •Time in the Yard Forty minutes per day, per truck may seem marginal at first glance. But 200 minutes/week x 48 weeks/ year = 9,600 minutes, 160 hours or a total of 4,000 hours of inefficiency for a fleet of 25 trucks. Time in the yard is the lever most within a producer’s control and represents over half of the total nonproductive time per truck. So, rather than simply adding incremental trucks and drivers to the fleet to boost productivity (which unfortunately only adds to the total non‐productive hours and fails to improve operational processes), consider a solution that: ·         •Uses automatic processes via technology to more efficiently track and manage your fleet. ·         •Enables your drivers to punch the clock from in the cab, an efficiency enhancer that alone could save you up to 20 minutes per day (this is time spent in your own yard, under your own watch, that you can act on quickly to recapture those minutes, regardless of what happens away from your yard). ·         •Captures a meaningful portion of that lost time from each driver. ·         •Provides a constant view into the location and performance of your entire fleet. ·        •Is adaptable and helps your teams collaborate in real-time with a “central source of truth” and access to relevant data when you need it. At least 50% of employees’ non‐productive time can be captured back efficiently and effectively when the right combinations of levers are pulled – both in terms of area of focus (i.e., time in yard) and adaptability to each individual customer’s business process requirements. This equates to big productivity increases over both the short- and long-term. Learn more about how Command Alkon’s TrackIt solution offers an industry specific, flexible and fully customizable solution to track your fleet and meet your specific needs, including in-cab time and attendance functionality focused at recapturing lost time in the yard, helping you drive a more efficient fleet and improve your profitability. *500 respondents from the United States and 99 from Australia, New Zealand, United Kingdom and Canada. Of those surveyed, 49% work for general contractor firms, 36% came from specialty trades and 15% were owners. Over 300 respondents came from the commercial sector and the other respondents represent industrial and manufacturing, heavy civil, healthcare, power (oil and gas, and energy), education and government.
Complimentary Maintenance Management Course
PAUL D TOMLINGSON
Complimentary Mining Maintenance Management Course - Maintenance is always more successful when operations, management and staff departments have a more comprehensive understanding of how maintenance works. Then their roles in the support, cooperation and direction of the interdepartmental maintenance effort can create the circumstances that can yield improvement. Education and training of operations, management and staff department personnel adds directly to the effort of improving maintenance.   Those who perform and control maintenance possess significant diagnostic and repair talent. But these skills do not automatically yield management skills. As a result, maintenance often struggles to limit downtime and meet equipment reliability needs. Within maintenance there are many capable personnel who could easily acquire essential management skills providing training and education are provided. The unfortunate reality is that no such training is being provided. Instead, the unfortunate practice of promotion from within does not always produce capable maintenance managers. Typically, an outstanding craftsman is, over time and attrition circumstances, promoted to maintenance manager. Through no fault of his own he had not acquired the requisite management skills for the job. Nor had training been provided. The end result is poorly managed maintenance that ultimately impacts mine operation performance. This oversight requires correction.   When effective maintenance education and training are available and accessible, those who can influence maintenance improvement will use it. Outstanding craftsman will aspire to efficient supervision and management.Operations managers will connect better maintenance to greater availability.Managers will realize cohesive interaction among departments to assure profitability. Complimentary Mining Maintenance Management Course - Over 600 Society of Mining, Metallurgy and Exploration (SME) member organizations are benefiting from the Mining Maintenance Management Course (see attachment) being offered as a complimentary professional courtesy. If you are member of SME you may access the course: Log into http://community.smenet.org Click: Browse then select link to Mining Maintenance Management Course Library. PPT course topics (01 – 22) appear with Word reference (MIT) files for each course topic. Select and download course topics to make them available to your personnel. If you are not an SME member, the course can also be made available for transmission to your organization. Please inquire.   Paul D. Tomlingson, Mining Maintenance Consultant (Retired) Legion of Honor Member – Society of Mining, Metallurgy and Exploration (SME) Denver, Colorado USA [email protected]                  
Get More Performance Out Of Your Crusher
Stedman Machine Company
Get More Performance Out Of Your Crusher impactor maintenanceThere’s an urban legend out there about the company whose maintenance crew mistakenly installed a new crusher with the rotor spinning backwards. It still worked! And you think you have issues? To get the most from your equipment investment, you need to put in the time. Yes, a crusher costs a bit more than your average automobile, but that doesn’t mean it’s maintenance-free. An automobile needs oil changes too, right? Performing regularly scheduled maintenance on impact crushers is crucial for guaranteeing day-to-day reliability and optimum product output. Did you know you can boost output and quality by doing just a little bit more? Even daily cleanups and inspections can increase service life. It’s a no-brainer, though possibly easier said than done. Here are some steps and practices to incorporate in your ongoing operations and maintenance. Beginning with maintenance team education, parts logs, and general maintenance record keeping, plus troubleshooting, these guidelines will help your crusher go the distance. Training: Proper training for consistent maintenance is one of the most fundamental requirements for successful, reliable production. Begin with the crusher’s operation and maintenance manual. Incorporate the manual’s suggested routine maintenance schedule into the maintenance team’s duties. Appoint a “lead person” for each crusher as the go-to for that machine. This person is the historian for the unique operational adjustments the producer has incorporated for raw feed and product requirements. Daily log (document the following every 8 hours): Amperage draw: See if it changes from day to day. If amperage is exceeding normal levels, it could be a signal of bearing problems, loose belts, or general feed issues. Coast-down time: You’re going to need to know (and log) how long it takes the machine to come to a complete stop after shutdown. Here’s why: If the time starts to shorten, this could indicate a bearing problem. Oil pressure: You’ll want to record performance in a variety of operating conditions. This will allow you to identify trends and help to detect problems before they cause costly damage or downtime. Daily maintenance (every 8 hours): Check oil level, sight glass, grease appearance, and other lubrication schedules. Check high temperature or low hydraulic pressure indicators and switches. Check wear parts. Tighten bolts. Inspect belts. Remove dirt and debris from crusher frame surfaces and areas around the machine. Check intake/discharge chutes for any obstructions and/or build up. Check alarms. If electrical changes are made or programs are altered in automated systems, verify that all alarms and interlocks function properly. Don’t be afraid to replace switches or timers that appear damaged or are in poor condition. This is more economical than a major overhaul, but never disable or alter any alarms or interlocks! Lubrication: Completely drain and thoroughly clean out the inside of the oil tank (if you have one) to eliminate any contaminants before refilling. Find contaminant sources. Contaminants such as dust particles and water can get in where oil leaks out. Inspect hydraulic systems and tag any leaks for corrective action on the very next maintenance cycle. Use the proper grade of oil. Use the proper specification of filters. Keep the oil breathers clean. Understand grease versus oil lubrication. Grease requires less-intensive maintenance than that of oil-lubricated systems. Automatic oil lubrication systems or sealed cartridge bearings are for higher speed crushers like vertical shaft impactors, air swept fine grinders, or high-speed cage mills. Most horizontal shaft impactors, hammer mills, and cage mill applications are below 1,000 rpm and grease is sufficient. Maintain a scheduled oil sampling program. By creating a baseline of normal wear, it helps indicate when abnormal wear or contamination is occurring. The exact condition of a mechanical assembly is reflected in the oil. Belts: Inspect V-belt drives for damaged belts or loose belt tension. By replacing cracked, glazed, torn, or separated belts, plus maintaining proper belt tension, you’ll optimize your plant’s performance. Wear parts: Don’t overextend wear parts. Avoid running them so long that they become too worn. You may find that you can no longer rotate breaker bars or interchange wear plates to lower wear areas — and now, you’ve lost half of the wear. Guards: Rubber and chain curtains located in the feed and discharge openings of the crusher are subject to wear and tear. Since they are a first line of protection, it’s important to inspect them regularly and to establish a schedule of regular maintenance. Electrical: When (or if) electrical changes are made, you’ll need to verify that all alarms and interlocks still properly function. Same goes for programs when altered in automated systems. Always check with the manufacturer before making any modifications. Spares recommendation: Keep the recommended spares on hand and order replacements as soon as they are used. A list of recommended spares may be included with your equipment operations manual. If not, contact the manufacturer for recommendations. Update your equipment: All equipment evolves, and the recommended manufacturer upgrades are a good investment for increased life and better crusher performance. Check with the manufacturer for any possible updates. Unapproved modifications: Manufacturer design engineers have considerable field experience, which helps them as they calculate the design and perform prototype testing. Their engineering tasks include calculating bearing loads and bearing clearances. They’ve also worked to maximize throughput by establishing the most efficient speed and setting combinations to optimize impact on the material undergoing reduction. So when plant personnel suggest modifications that alter the intended design, these changes will more than likely hurt the purpose of the original design. As a result, you’ll have a less productive and reliable crusher due to potential damage and overload. Since the manufacturer has a vested interest in how well the crusher performs, contact them before making any modifications Cage Mill Operation and Maintenance Requirements for optimum production and wear part utilization include the following: sleeve wear patterns cage wear pattern identification To increase multi-cage sleeve life, cage rotation should be reversed regularly, if possible. (Some cage mills can be reversed, while others cannot.) By reversing the cage direction, sleeves will be worn from both sides, thus extending wear life. Wear parts: Index and or replace sleeves periodically. Inspect or replace hopper ring and shaft protector, if needed. Cage rebuilding is an option. Bearings: Follow the manufacturer’s recommended specifications and schedule for lubrications, temperature, and vibration ranges of spherical roller bearings in pillow block housings. Horizontal Shaft Impactor Operation and Maintenance Variables affecting product gradation include the following: Rotor speed – Higher rotor speeds produce finer product output.Breaker bar wear & new edges crush finerBreaker bar changes. Apron gap settings – Closer gaps retain the feed longer producing a finer product. Breaker bar wear – Regular inspection and turning will lower operating costs. Throughput (tons per hour) – Overfeeding a crusher can make the output more coarse, but it also causes a number of wear and longevity issues making overfeeding a major concern to avoid. Moisture – Moisture cushions the impact, producing a coarser product. Apron wear – Worn plates can be replaced or moved to areas of lower wear. Spring bridge operation – Spring set height is critical to maintain proper operation of spring bridges. Spring bridges return the aprons to their original positions after an overload situation. The use of altered or non-specified springs can cause equipment damage or catastrophic failure. Requirements for optimum production and wear part utilization include the following: Protect inlet and outlet. Restrict maximum feed size. Maintain feed rate within allowable limits. Check rotor rotation. Use metal detection (required). Check for wear. Follow recommended breaker bar rotation setting sequence. Check rotor breaker bar, wedge, and stop block or jack screws. Check liners and breaker plates. Vertical Shaft Impactor Operation And Maintenance The vertical shaft impactor uses high rotor speeds (1,000 to 3,000 rpm) to apply high energies to the material, and since Energy + Material = Size Reduction, it can create sand from 2-inch feed. Requirements for optimum production and wear part utilization include the following: optimized parts in rotor tube Limit feed size. Use metal detection (required). Observe any vibrations with the use of continuously monitored vibration sensors. Listen to the equipment, if something sounds unusual, shut down and inspect. Limit recirculating product in a closed system. If using water for dust suppression, introduce it into the discharge area if possible. Introducing water in the intake will increase wear. Place weight match shoes opposite one another. The image above shows rotor tubes indexed 90 degrees providing a new wear surface. Wear parts include the following:recommended parts for vertical shaft impactors Shoes and tubes Anvil ring or other inserts Housing liners Rotor table liners and assembly Spares recommendation: Shoes (one complete set) Table liner Anvils (one complete set) Discharge plate The spare parts inventory shown above is recommended for vertical shaft impactors. Hammer Mill operation and Maintenance Up running hammer mills combine impact and shear to reduce material. Down running hammer mills primarily use shear by immediately taking feed to the screen or grate bars where hammers shear the material, until it passes through the openings. Requirements for optimum production and wear part utilization include the following: Lubricate bearings regularly. Regularly inspection (unclamp or unbolt front upper half housing for access to screens and hammers) liners, hammers, hammer bolts, rotor discs, grate bars, and screens. Spares recommendation: Hammers Screens Liners Grinding plate Summary A partnership begins between the manufacturer and the customer when the crusher is installed in the field. The manufacturer needs the customer’s help as much as the customer needs the manufacturer’s help to achieve the highest performance possible. Maintenance service after the sale, although mentioned last, is a central part of crusher system performance. And just in case, the manufacturer will have the people and the parts available 24/7 to assist with any problems. Regardless of the field application, the training of personnel is key to successfully and optimally operating equipment. For the size-reduction industry, crusher maintenance problems are mostly related to inadequate training. This exists at plants both large and small. The most effective education is a current and ongoing program for crews — and that’s what will result in legendary performance.