TCO: Mining Industry

TCO: Mining Industry

Application: Ventilation Fan
Motor Type: AC Induction
Manufacturer: Toshiba
HP: 200
Voltage: 575
RPM: 1800
Enclosure: TEAO

Problem
A gold mine in Ontario, Canada with 50+ ventilation fan motors was experiencing multiple premature bearing failures on many of their motors. This resulted in unplanned downtime costs as high as $60k per hour.

Solution
IPS conducted a root cause failure analysis on one of the motors and found that the failure was caused by electrical currents passing through the bearings. The customer had recently started using adjustable speed drives on some fan motors, which was the source of the electrical currents.

• IPS recommended that the customer replace old bearings with insulated bearings and to install shaft grounding brush in the motor

Savings
• The IPS recommended upgrade of adding the shaft grounding brush and insulated bearings increased the repair cost by approximately $9,000
• The customer has not experienced any repeat bearing failures to its ventilation fan motors- eliminating $291,000 of unplanned lost production (assuming a conservative unplanned downtime rate of $25,000 per hour for a failed ventilation fan and approximately 12 hours to replace the motor)

Download the complete case study and calculations below:

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