Optimizing grinding mill performance through automated monitoring

In the mining industry, grinding mills are among the most expensive assets to acquire and operate in the comminution circuit. Gear and pinion performance is critical to grinding mill operations, and any failure can lead to significant production and financial losses. Gear and pinion failures commonly result from contamination, improper lubrication or misalignment, but these conditions can be difficult to identify without proper inspection or preventive maintenance practices.

Gear and pinion operating conditions affect the gear set profile temperature, and high temperatures can result in premature cracks, wear and potentially preventable failures. Operating temperatures have traditionally been monitored by operators who manually open the gear guard to take gear set readings using a handheld infrared temperature measurement device. This practice is not only labor-intensive and potentially unsafe, but could also provide inaccurate results, as the information gathered from these readings relies on consistent location measurement and reading frequency.

Prevent premature failure

Metso’s automated infrared condition monitoring solution is designed to replace manual readings by using thermographic imaging and sensors to analyze gear set profile temperature and help prevent gear and pinion component damage. The Pinion temperature monitoring system (PTMS) thermographic camera and infrared sensors cover the entire pinion width to provide real-time temperature readings at three different locations across the profile. The readings provide grinding mill operators with precise data that can be helpful when planning shutdowns and maintenance programs.

The system is installed in the gear guard and conveniently located for maintenance. The camera and sensors are contained in a tube for protection from lubrication spray that could prevent accurate temperature readings. The system can be easily fitted to any horizontal grinding mill equipped with a pinion and ring gear to allow online monitoring through a customer’s control system.

One solution, many benefits

Metso’s Pinion condition monitoring system not only helps to prevent premature gear set component damage or failure, but also increases mill availability by identifying temperature increases that can lead to potential problems. In identifying issues before they happen, operators can also reduce mill downtime and maintenance costs that occur with unplanned stoppages.

The enhanced monitoring system’s camera and onboard sensors combine to create a complete solution for an invaluable indicator of critical pinion operating factors such as gear set alignment and lubrication. The system offers a proactive condition-based maintenance approach to maximize a grinding mill’s useful life, increase its productivity, enhance safety and reduce operating downtime.

Web link: Pinion Condition Monitoring – Metso