Publication: MEJORA EN SISTEMA DE TENSADO EN CORREAS DE LA LÍNEA CRÍTICA EN GRAN EMPRESA MINERA DEL COBRE
Date
2016
Authors
TAN GÓMEZ, WE-SIANG HUGO
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Abstract
El presente informe, tiene como objetivo presentar el estudio de las correas transportadoras CV-110, CV-111, CV-112, CV-113 y CV-114, pertenecientes a la línea crítica del área de chancado y manejo de materiales de una gran empresa minera de cobre. Dicho estudio busca encontrar puntos de mejora asociados a los sistemas tensores de estas correas, orientado a tres aspectos principales: diseño, operación y mantenimiento.Desde la perspectiva del diseño, se calcularon las tensiones y potencias que requieren las correas transportadoras según la norma CEMA y se compararon con los valores que presentan actualmente. De este análisis, se llegó a que las correas están trabajando con factores de seguridad mayores a 10, por lo que están bajo el estándar de la empresa. Por otro lado se detectó que las correas CV-110, CV-112, CV-113 y CV-114 al operar con una flecha de 1%, requieren aumentar el peso de sus contrapesos.Desde el punto de vista operacional, se utilizaron herramientas de análisis de fallas para encontrar las detenciones críticas y sus causas raíces. Dicho análisis arrojó que los sistemas tensores no son equipos críticos, ni tampoco son parte de las causas raíces de las detenciones de las correas transportadoras.Desde la perspectiva del mantenimiento, se analizó la inspección y mantenimiento que se realiza a los sistemas tensores por contrapeso, encontrando un punto de mejora, debido a que las pautas de estos son muy básicas.Por otro lado, también desde el punto de vista del mantenimiento, se analizó la participación del sistema tensor en los mantenimientos que requieren el destensado y tensado de la cinta, detectando peligros para los trabajadores durante la maniobra y una larga duración dentro del mantenimiento. Este es el segundo punto de mejora encontrado.Dentro de las mejoras, se elaboraron nuevas pautas de inspección y mantenimiento, diferenciando entre las correas analizadas, e incorporando la inspección detallada del cable de acero, que constituye uno de los elementos críticos del contrapeso.La segunda mejora consiste en implementar un sistema auxiliar para el sistema tensor, el cual tiene como elemento principal un winche eléctrico, en el que irá enrollado un cable de acero que se conectará en el extremo libre con el contrapeso y la torre. Este cable será guiado a través de un conjunto de roldanas y se acondicionará para su uso con prensas Crosby, guarda cabos, entre otros elementos. Dicho sistema disminuirá el tiempo de destensado y tensado de la cinta a la mitad del actual y eliminará la utilización de las grúas y el peligro que corren los trabajadores.La implementación del sistema auxiliar tensor, tiene un costo de inversión de $177.880.929 [CLP]. Además, los indicadores económicos VAN, TIR e IVAN indican que el proyecto es rentable y de alto rendimiento económico para la empresa.
The present report aims to present the study of the CV-110, CV-111, CV-112, CV-113 and CV-114 conveyor belts, belonging to the critical crushing and material handling area of a large Copper mining company. This study seeks to find improvement points associated with the tensioning systems of these belts, oriented to three main aspects: design, operation and maintenance. From the design perspective, the tensions and powers required by the CEMA standard conveyor belts were calculated and compared with the current values. From this analysis, it was found that the belts are working with safety factors greater than 10, so they are under the company standard. On the other hand, it was detected that the belts CV-110, CV-112, CV-113 and CV-114 when operating with an arrow of 1%, require increasing the weight of their counterweights. From the operational point of view, fault analysis tools were used to find critical arrests and their root causes. Said analysis showed that the tensioning systems are not critical equipment, nor are they part of the root causes of the arrests of the conveyor belts. From the perspective of maintenance, we analyzed the inspection and maintenance that is done to the tensioning systems by counterweight, finding a point of improvement, because the guidelines of these are very basic. On the other hand, also from the point of view of maintenance, the participation of the tensioning system in the maintenance that required the tensioning and tensioning of the belt was analyzed, detecting dangers for the workers during the maneuver and a long duration within the maintenance. This is the second improvement point found. Among the improvements, new patterns of inspection and maintenance were developed, differentiating between the belts analyzed, and incorporating the detailed inspection of the steel cable, which constitutes one of the critical elements of the counterweight. The second improvement consists in implementing an auxiliary system for the tensioning system, which has as main element an electric winch, in which will be rolled up a steel cable that will be connected at the free end with the counterweight and the tower. This cable will be guided through a set of pulleys and will be conditioned for use with Crosby presses, rope guards, among other elements. This system will reduce the time of tensioning and tensioning of the tape to half of the current one and will eliminate the use of the cranes and the danger that the workers run. The implementation of the auxiliary tensor system, has an investment cost of $ 177,880,929 [CLP]. In addition, the economic indicators VAN, IRR and IVAN indicate that the project is profitable and of high economic yield for the company.
The present report aims to present the study of the CV-110, CV-111, CV-112, CV-113 and CV-114 conveyor belts, belonging to the critical crushing and material handling area of a large Copper mining company. This study seeks to find improvement points associated with the tensioning systems of these belts, oriented to three main aspects: design, operation and maintenance. From the design perspective, the tensions and powers required by the CEMA standard conveyor belts were calculated and compared with the current values. From this analysis, it was found that the belts are working with safety factors greater than 10, so they are under the company standard. On the other hand, it was detected that the belts CV-110, CV-112, CV-113 and CV-114 when operating with an arrow of 1%, require increasing the weight of their counterweights. From the operational point of view, fault analysis tools were used to find critical arrests and their root causes. Said analysis showed that the tensioning systems are not critical equipment, nor are they part of the root causes of the arrests of the conveyor belts. From the perspective of maintenance, we analyzed the inspection and maintenance that is done to the tensioning systems by counterweight, finding a point of improvement, because the guidelines of these are very basic. On the other hand, also from the point of view of maintenance, the participation of the tensioning system in the maintenance that required the tensioning and tensioning of the belt was analyzed, detecting dangers for the workers during the maneuver and a long duration within the maintenance. This is the second improvement point found. Among the improvements, new patterns of inspection and maintenance were developed, differentiating between the belts analyzed, and incorporating the detailed inspection of the steel cable, which constitutes one of the critical elements of the counterweight. The second improvement consists in implementing an auxiliary system for the tensioning system, which has as main element an electric winch, in which will be rolled up a steel cable that will be connected at the free end with the counterweight and the tower. This cable will be guided through a set of pulleys and will be conditioned for use with Crosby presses, rope guards, among other elements. This system will reduce the time of tensioning and tensioning of the tape to half of the current one and will eliminate the use of the cranes and the danger that the workers run. The implementation of the auxiliary tensor system, has an investment cost of $ 177,880,929 [CLP]. In addition, the economic indicators VAN, IRR and IVAN indicate that the project is profitable and of high economic yield for the company.
Description
Catalogado desde la version PDF de la tesis.
Keywords
LINEA CRITICA , MINERIA DEL COBRE , SISTEMA DE TENSADO