Testimonials
Tahmoor Colliery improved wire rope maintenance using Viper WRL's Mid Wire Rope Lubricator, enhancing safety, efficiency, and cost-effectiveness.
key takeaways
Challenge
Manual lubrication of wire ropes was time-consuming, messy, and posed safety risks. It resulted in uneven application and minimal penetration, reducing rope protection and lifespan.
LE solution
Viper WRL introduced their Mid Wire Rope Lubricator and rope cleaner, automating the lubrication process. This system improved application consistency, safety, and efficiency.
Results
The Viper WRL system reduced annual costs by $9,870, saved 40 man-hours every 8 weeks, and added 16 hours of production bi-monthly. It also significantly improved safety and rope longevity.
Dramatic reduction in Equipment Down time 16 hours of extra production every two months, not including change time due extension of Drift Rope operational life.
Customer Profile
Tahmoor Colliery is an underground coal mine located in Tahmoor, in the Southern Highlands region of New South Wales, Australia. The mine extracts coal from the Bulli coal seam. Most of the mine's product is hard coking coal used for steel making, with a small quantity of steaming blend coal used for power generation also being produced. Both products are exported to Europe and Asia.
The majority of the coal is extracted from the mine using the longwall mining system, with a much smaller part coming from mine development. The CHPP is able to process 650 tonnes per hour and separates the coal into the higher quality coking blend and lesser quality steaming blend, while removing rock and other foreign materials through various screening and cyclonic processes.
Tahmoor Coking Mine operates 24 hours a day. Water and coal contamination on wire ropes are typical in this application.
Application
As part of an ongoing programme of improving their maintenance practices, Viper WRL Pty Ltd was contacted to discuss improved processes for the Cleaning and Lubrication of their 1600m, 52mm Underground drift Wire Ropes.
Challenge
Before contacting Viper WRL, the only option available to the maintenance team at Tahmoor was to manually lubricate the drift rope. This process was not only time-consuming and messy but also required the staff to directly interact with the rope, increasing the risk of injury. Additionally, manually lubricating wire ropes does not achieve the same end result, often resulting in uneven application and minimal penetration of the lubricant into the core of the rope. This reduces the effective protection the rope has once it is placed in service, leading to reduced wire rope life.
LE Solution
Viper WRL introduced the Viper Mid Wire Rope Lubricator to the maintenance team at Tahmoor along with the Viper WRL rope cleaner.
Results
The maintenance team was impressed with the Health, Safety, and Environmental benefits of using the Viper WRL. It wasted no lubricant, didn’t leak meaning no mess, was lightweight allowing for safe application, and the rope could be lubricated at a safe distance, ensuring every gram of grease went on the rope.
The Tahmoor maintenance team observed several benefits from using the Viper WRL, including significant improvements in safety, efficiency, and financial savings.
Before the Introduction of Viper WRL – Manual Lubrication
– Labour: Two men, working 12 hours each (24 hours in total), were required to manually lubricate the rope with paint brushes.
– Lubricant Use: Approximately ten 20 kg pails of grease (a total of 200 kg of grease on each occasion), resulting in 800 kg per year.
– Frequency: The lubrication process occurred every three to four months (four times per year).
Cost Breakdown:
– Lubricant: US$275 per 20 kg pail x 10 = US$2750 per lubrication session.
– Four times per year = US$11,000/year.
– Labour: Two men, 12 hours at US$60/hr (24 hours in total) = US$1440 per lubrication session.
– Four times per year = US$5760/year.
Annual Cost: Approximately US$16,760/year to manually lubricate the drift rope.
Using the Viper WRL
– Lubricant: VCG-1 grease 190 kg drum = US$4520. This drum lasts twelve months (two lubrication sessions).
– Annual cost = US$4520/year.
– Labour: Two men, 4 hours at US$60/hr (eight hours in total) = US$480 per lubrication session.
– Twice per year = US$960/year.
Annual Cost: Approximately US$6890/year to lubricate the drift rope using the Viper Mid Mk II Wire Rope Lubricator.
Annual Savings: Approximately US$9870/year.
Benefits of Using the Viper WRL Package
– Dramatic Reduction in Equipment Downtime: 16 hours of extra production every two months, not including changes due to the extension of drift rope operational life.
– Reduced OH&S Issues: No personal contact with potential broken wires during manual lubrication.
– Man Hours Saved: 40 hours saved every 8 weeks.
– Reduced Risk of Drift Rope Failure: The potential risk of drift rope failure was dramatically reduced.
The transition to the Viper WRL for Tahmoor was an easy decision, given the reduced risk of drift rope failure and the multiple benefits it provided.