A ‘filter optimisation program’ carried out by Cummins Filtration and Komatsu at Anglo American’s Dawson coal mine in Queensland has realised major cost savings through use of new technology Fleetguard filters to extend service intervals.
Cost savings of 60%, through reduced filter and oil consumption alone, were confirmed following a 12-month field test involving a Komatsu 830E haul truck powered by a Cummins QSK60 HPI engine.
Applied to the fleet of 14 Komatsu 830E trucks at Dawson mine, savings in excess of $220,000 per year would be realised while slashing downtime for servicing by 74% or 439 hours.
Add in the reduced labour costs resulting from the 439 fewer hours of servicing time, and total savings would exceed $250,000 across the fleet of 14 trucks.
All 14 Komatsu 830E trucks have since been fitted with the new technology filters.
The Dawson mine project was part of a global program by Cummins Filtration aimed at delivering cost reductions to mining companies in the wake of plummeting commodity prices.
“Our objective with the Dawson field test was to demonstrate that new technology Fleetguard filters provide both better protection and lower total cost of ownership for mine operators,” says Gary Ross, director of global high horsepower business for Cummins Filtration.
The testing confirmed a service life of 1000 hours or greater for all primary filter products. In all cases, the historical filter service intervals at the mine for the Komatsu 830E were exceeded.
For example, conventional fuel filters were being changed every 500 hours. The target interval for the field trial with new technology filters was 1000 hours and the actual interval achieved was 3316 hours. A new interval of 2000 hours was set to fit in with existing servicing strategies.
New service intervals were also established for the:
The new technology Fleetguard filters fitted on the test truck to achieve the extended service intervals were: Dual Tall Industrial Pro fuel/water separators with NanoNet media; a SpiraTec rotor for the Cummins Eliminator centrifugal oil filtration system; NanoForce air filters; and ES (Extended Service) water filters.
“The field testing was carried out scientifically so there could be no doubts about the validity of the results,” says Gary Ross.
Data loggers and pressure transducers were fitted to the air, fuel and lube oil filtration systems. Pressure readings along with truck operational data from the engine ECM (load factors, fuel consumption etc) were downloaded at 5 sec intervals for live monitoring by Cummins engineers.
An alarm system, on detecting any potential issues, notified on-site personnel.
Both laboratory and on-site analysis of the filters, fuel and oil was also carried out to confirm media integrity, oil stability and fuel cleanliness levels.
John Soar, principal mechanical engineer for Anglo American Coal Australia Asset Management, confirms the validity of the testing. He says the testing was “innovative” and showed the new technology filters to provide “exceptional enhancements at basically no additional cost”.
“It is always best with testing such as this to have the OEMs (Original Equipment Manufacturers) involved…there was a lot of value in us being able to work with Komatsu and Cummins,” he says.
Scott Keevers, Komatsu 830E fleet project manager at Dawson mine, was the site person responsible for the field test and subsequent implementation of the new service intervals. “The post implementation cost savings for the fleet to date are consistent with the field test data and advertised benefits,” he confirms.
Warren Smith, a man with extensive experience working for mining companies and contractors in Australia prior to joining Cummins Filtration as global mining program manager, believes a new era has arrived in maintenance cost reduction through use of new technology products.
He says that trials around the world have proved that using oil analysis, data loggers with telematics support and visual inspections, service intervals for new technology filters can be extended to suit the equipment and environment on each customer’s site.
“Some of these trials have delivered results beyond our 1000-hour target and the customers have seen the benefit in a significant reduction in parts cost and maintenance time,” he says.
Cummins and Komatsu wish to thank the Anglo American management team at Dawson mine for allowing the stringent testing to be carried out and also for authorising the implantation of the new technology Fleetguard filters.
Murray Clifford
Manager – Communications & PR
Cummins South Pacific