Challenge details:

The challenge of online condition monitoring for dredge pump-lines in trona mining operations in Africa"s Rift Valley arises from their critical role in transporting excavated material from the lake to the processing plant. These dredgers, located 4 to 8 kilometers from the central plant, face significant accessibility challenges due to their remote placement in the lake, which can become flooded or swampy. Harsh environmental conditions, including high salinity, temperatures up to 42°C, and potential submersion in water, further exacerbate the situation. The standard distance between pumps is 1.2 kilometers, with an ideal pipeline diameter of 10 inches. The pumps being used are Metso or Orion models (150/100). Additionally, pulleys and V-belts are used for efficient power transmission. Accessibility is also hindered by unstable network connectivity and the continuous movement of dredges, which necessitates frequent infrastructure relocation. The current manual condition monitoring system is cumbersome and lacks real-time capabilities, with unreliable sensors and no provision for monitoring lubrication levels or grease conditions. These limitations hinder the efficient monitoring of critical parameters such as flow, density, pressure, vibration, temperature, and current loading. The key performance indicators (KPIs) of interest include Availability, Utilization, MTBF, MTTR, and OEE.

We are seeking a robust, integrated solution to enable real-time data analytics, ensure stable connectivity, withstand environmental challenges, and enhance operational efficiency while reducing downtime.