EVO system halves maintenance downtime

Routine maintenance is required on a P&H 4100XPC electric rope shovel after every 30,000 hours of operation.

These machines – which are used on coal in Australia – require maintenance in which the upper section is lifted off the car body to machine bearing surfaces and inspect and repair structural components.

Weighing approximately 907,000kg, lifting the upper car body requires a significant amount of force and control.

The maintenance team at Joy Global (now part of Komatsu) reached out to Enerpac to deliver a shovel lift system to undock a P&H 4100XPC shovel in approximately one hour and be transported on the highway without oversized load permits.

The EVO synchronous lift technology involved in this lift provided the speed and safety that were critical components in reducing labour and equipment.

Solution

The EVO system included four 450-tonne cylinders with 72 inches of stroke (approximately 1829mm), an EVO synchronous control unit and four custom 8000 series hydraulic pumps.

Each pump was built to operate in extremely cold or hot environments. Enerpac Australasian Mining and Heavy Lift Solutions Manager Warren Baltineshter said the company had previously built a similar shovel lift system for Joy Global’s maintenance team in Chile. 

“The second-generation system built for Joy Global’s service team in Gillette, Wyoming provided significantly more speed,” he said.

The EVO synchronous control unit enabled a single operator to control the entire lift and ensure each lifting point remained within 9.525mm. The shovel was successfully undocked in approximately one hour and the entire system was transported on the highway without oversized load permits.

EVO lift system

Enerpac EVO synchronous lifting systems replace manual control of hydraulic heavy lifting with PLC control of multiple cylinder lifts, offering accuracy, safety and productivity benefits for precision lifting of heavy resources industry machinery.

The EVO system is the evolutionary result of Enerpac’s 25 years of experience in specialised hydraulic engineering and lifting technology, using digitally controlled hydraulics to accurately and safely lift some of the largest and most challenging structures on earth.

Recent examples range from 1360-tonne grinding mills in Western Australia to the super lifting and launch of a 39,000-tonne floating oil production system in Malaysia for the Gumusut-Kakap offshore field.

The latest EVO synchronous system offers eight standard hydraulic control modes and can control four, eight or 12 points with one hydraulic power unit (HPU). A master control unit is also available that offers daisy chain control of multiple EVO systems, giving a maximum of 192 lifting points.

“With synchronous lifting, one operator controls the entire precision lifting process, during which the status of every lifting point is constantly monitored and displayed,” Mr Baltineshter said.

“Time saving is another advantage of synchronous lifting. The process does not have to be stopped after any incremental value, checked, manually re-measured and corrected. The EVO system carries out these actions during the entire lifting process. Depending on the application, time savings up to 60 per cent can be achieved.”

latest news

Gold Fields lifts Invincible

South African mining giant Gold Fields has tipped dramatic developments at its Invincible underground mine, flagging its importance to ensuring St Ives’ longstanding production.

Read more

Rejigged Paladin back on the boards

Investor sentiment around the beaten-down uranium market will be tested today when a restructured Paladin Energy rejoins the boards of the Australian Securities Exchange.

Read more

FMG’s Nev moves on at the height of his power

Outgoing Fortescue Metals Group boss Nev Power bristles at the suggestion he is retiring.

Read more

Quake cuts Newcrest H1 profit to $98m

Gold miner Newcrest's first-half profit has been halved to $98 million as a result of an earthquake that halted production at its Cadia mine last April.

Read more

Miners of a different kind

In Australia’s gold mining capital a new type of digger is emerging.

Read more

Dividend up, profit down at Evolution

Gold miner Evolution Mining’s first-half profit has slid 10 per cent to $122.5 million but the company has lifted its dividend.

Read more

 

industry insight

A rival to the throne?

Over the last couple of years, lithium and its use in rechargeable batteries has taken the mining

...
Products & Technology

Delivering Collahuasi improvements

People & projects

KCGM’s move 30 years in the making

Occupational safety & health

EVO system halves maintenance downtime

interview

Mentality needs to change

For many years Australia’s mining industry has been a leading contributor to economic growth and wealth. 

Read more