Current Situation and Issues
The Throughput in a Mining Operation Is Directly Proportional to the Conveyor Belt Systems Performance
Sometimes, the roller has the difficulty to rotate (mainly due to a bearing failure and the constant friction between the roller and rubber belts) often resulting in a fire occurrences. In that case, the plant has to stop production in long term, which causes catastrophic damage to the management. Hence, continuous monitoring of all rollers temperature is required to prevent fire and minimize downtime.
Manual/route-based monitoring with IR thermal inspections
The onset of temperature spikes cannot be predicted.
It could happen after the route has been completed. Also, some areas of the conveyor belt maybe in unsafe places.
Install wireless point sensors at given points
Only a partial health status visibility of the assets within the plant.
Initial cost and running cost increase when a number of wireless point sensors are installed.
Convectional linear heat detector
It can detect when fire-accident actually happens by the short circuit of twisted pair metal wire with melted outer. It can’t prevent fire and locate the location of fire.
They should aspire to move towards digitalizing the inspection and maintenance processes.
YOKOGAWA's DTSX Solution and Benefits
- Ability to monitor long and wide conveyor belts in real-time.
- HMI graphical drawings enable excellent visibility for operators.
- Centralized monitoring and diagnostics permits failure prediction.
- 7-10x lower downtime and 70% OPEX savings compared to reactive and proactive monitoring models.
Comparison of downtime periods for each maintenance way
The Integrated Conveyor belt Monitoring Solution
Features of Optical Fiber Sensing in DTSX System
Temperature distribution monitored every 1 m
- Monitoring distance : to 50 km
- Monitoring temperature : -200 to 300 °C
- Shortest monitoring cycle : Approx. 5 seconds
- Temperature resolution : 0.03 °C
*: each specification dependent on conditions
Main Features
- 24 hours a day, 365 days a year monitoring even in wide areas and ordinarily non-manned areas
- Power supply not required, explosion-proof, not affected by electromagnetic noise
- Flexible installation
- High compatibility with DCS and other host systems (Modbus / TCP)
Customer Case Studies
Quick implementation of new conveyor belt fire detection system
The customer had implemented a Linear Heat Detector (LHD) to detect fires, however the maximum coverage length was 3kms and was furthermore unable to precisely locate the position of fire.
Eventually, the customer came across an unexpected fire accident and needed to replace a fire detection system very quickly.
Yokogawa performed a quick site feasibility study, implemented the DTSX solution with no lead time, and acquired the customer’s firm trust.
Realize managing bioleaching in vast Copper Mines
Bioleaching is a popular organic process to extract metal from low-grade ores. The organic process involves the application of bacteria, which loses its effectiveness at very high and low temperature extremes. The challenge was to measure the thermal profile of phreatic level over a vast area. As it was difficult to measure temperature over a long distance using traditional electronic based measurement, The customer selected Yokogawa’s DTSX. The solution provided a high resolution temperature profile with no need of specialized knowledge. 24/7 access to temperature data from a HMI panel allowed the customer to take necessary actions to adjust temperature levels.
* Some graphs and images are quoted from the eBook ("Digitalize Conveyor Belt Monitoring") created by Frost & Sullivan.
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Contact UsIndustries
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Energie
Dans les années 1970, Yokogawa est entré dans le secteur de l'énergie avec le lancement du système de contrôle électrique EBS. Depuis lors, Yokogawa a poursuivi avec constance le développement de ses technologies et de ses capacités afin de fournir les meilleurs services et solutions à ses clients dans le monde entier.
Yokogawa a exploité le réseau mondial de solutions énergétiques pour jouer un rôle plus actif sur le marché mondial dynamique de l'énergie. Cela a permis un travail d'équipe plus étroit au sein de Yokogawa, en rassemblant nos ressources mondiales et notre savoir-faire industriel. Les experts de Yokogawa dans le domaine de l'énergie travaillent ensemble pour apporter à chaque client la solution qui répond le mieux à ses besoins spécifiques.
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Fer et Acier
Dans l'industrie du fer et de l'acier, il est crucial d'améliorer la qualité non seulement des produits mais aussi des technologies de fabrication et d'exploitation, ainsi que d'aborder les questions d'environnement et d'efficacité énergétique. Yokogawa aide ses clients à créer l'usine idéale et évolue avec eux pour une croissance mutuelle.
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Pâte et Papier
L'industrie du papier et de la pâte à papier est très compétitive et doit répondre aux besoins du marché en constante évolution. Yokogawa contribue à la réalisation d'usines efficaces sur le plan énergétique et durables à l'échelle mondiale.
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Énergies Renouvelables
Les énergies renouvelables contribuent à protéger l’environnement et rapprochent la société et l’industrie de l’objectif de durabilité. Cependant, par rapport aux sources d’énergie conventionnelles, certains défis entravent son adoption rapide, tels que des coûts de production plus élevés et une plus grande instabilité dans l’approvisionnement en électricité du réseau. En tant qu'entreprise leader dans le secteur du contrôle et de l'instrumentation, Yokogawa s'est toujours efforcé d'aider ses clients de divers secteurs à réaliser des opérations stables et à améliorer la productivité de leurs usines. Nous fournissons des solutions pour les applications d’énergies renouvelables dans le monde entier, contribuant ainsi aux objectifs de développement durable.
Les produits et solutions liés
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DTSX1 Fiber Optic Heat Detector
DTSX1 stores the functions required for heat detection in one box. DTSX1 analyzes the temperature data with high accuracy by measuring with fiber optic sensor cable and perform high temperature heat detection.
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DTSX200 Distributed Temperature Sensor
The DTSX200 is a standard version that is ideal for temperature measurement, for medium-sized areas, and for areas where the distance of fiber optic sensor cables is short. It has excellent environmental resistance because it consumes less power and is less dependent on the temperature measurement environment.
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DTSX3000 Distributed Temperature Sensor
The DTSX3000 is a distributed temperature sensor developed in response to the demand that “one unit be used to monitor temperature distribution a longer distance and a wider area”. A flagship model that meets the expectations for long-distance temperature measurement and high temperature resolution.
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Fiber Optic Temperature Sensor DTSX
The DTSX fiber optic temperature sensor, which uses optical fiber for the temperature sensor, quickly detects and locates abnormalities in equipment by monitoring temperatures at production facilities located far away and across wide areas 24 hours a day, without omission. Highly accurate predictive maintenance avoids downtime and ensures stable plant operation.