1. On-site performance
What problems will the mining area see?
- Old generators can originally bring old production capacity. Once new crushing, pumping stations or workshop equipment are connected after capacity expansion, there will be more faults and trips.
- At the scene, it is often said to repair it first and continue using it, but the same type of alarm, oil leakage, high temperature or startup failure occurs repeatedly.
- The spare parts procurement cycle is getting longer and longer, and maintenance personnel have to wait for spare parts, materials or external support when they arrive at the site.
- Fuel consumption is higher than before, sound, vibration, smoke and the number of shutdowns are all increasing, but the production plan continues to increase the load.
2. Risk causes
The reasons behind the power layout
Older machines are often configured for past loads and production cadences. After the production expansion, more equipment will be operated simultaneously, the startup impact will be greater, and the continuous operation time will be longer. The old machines may no longer be suitable for the new working conditions.
Equipment aging will bring about a series of chain problems: the fuel system, cooling system, control system, power generation end and wiring harness may all enter a high-fault stage, and it cannot be restored to the new machine state by replacing a small part.
It is easy for the site to fall into a temporary maintenance cycle. Every time there is a shutdown, I want to save the unit first, but I don’t judge whether it can still bear the current load. In the end, maintenance becomes the norm and production passively waits.
3. Scope of influence
Production suspension, fuel consumption, maintenance, safety and environmental protection will all be magnified
- Expansion equipment has been invested, but the power supply cannot keep up, and the new production capacity cannot be released stably.
- Added repairs, oil filters, temporary parts, outside services and alternative power supplies, actual costs exceeded early estimates.
- Old machines have high fuel consumption and low efficiency. Long-term self-generated power mining areas will continue to pay additional fuel costs in daily operations.
- Frequent downtime will disrupt production, drainage, maintenance and personnel arrangements, making it difficult for the management team to form a stable production rhythm.
4. How to avoid before construction
What do mine owners need to confirm in advance?
- Before expanding production, review whether the old machine is still suitable for the current load. Don't just check whether it can still be started.
- Evaluate operating hours, fault records, fuel consumption records, maintenance records, spare parts availability and recent repair costs together.
- Distinguish between temporary maintenance and renovation: If the old machine is no longer suitable for the new load, plan for replacement, paralleling or partitioned power supply as soon as possible.
- Reserve transitional power supply and critical load protection in the production expansion plan to avoid the entire mine being forced to stop when the old machine is withdrawn or overhauled.
5. On-site confirmation information
The closer the information is to the scene, the faster the plan will be implemented
- Old generator brand model, capacity, operating hours, years of operation, recent maintenance and overhaul records.
- List of main equipment, simultaneous operation relationships, startup methods and changes in daily operating hours before and after expansion.
- Past faults, alarms, trips, downtime, repair costs and spare parts waiting records.
- Whether there are spare units on site, parallel conditions, low-voltage cabinet interfaces, fuel consumption records and future expansion plans.
