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OUTOTEC CUSTOMER eNEWSLETTER 1/2014

Editor: Laura White, laura.white@outotec.com

SOUTH EAST ASIA PACIFIC

CONTENTS• Analyzingtheanalyzer,page1• MillMapper™casestudy,page4• PASARcasestudy,page5• Thedealwithdilution,page7• Businessnews,page10• Productnews,page12

requires a bespoke response. The skilled technicians who install these systems and ultimately man the help-desk can resolve many problems via telephone and email. This, however, is totally reliant upon the relay of exact and accurate information from site.

Maintainingthemaintenance!As mentioned, analyzers, such as the Courier systems, are designed to work unattended, providing continuous assays. Whilst the site personnel checking these read-ings may be proficient in their understanding of the data, they may not have the technical skill or understanding to rectify issues that occur with the system itself.

ANALYZING THE ANALYZERTroubleshooting complex, sensitive analyzer systems is best left to the experts. Here’s how to get the best from your analyzer...

TEXT BRIAN MCPHERSON & ROB WHEELER

An increasingly common tool at modern sites, process automation analyzers provide fast and accurate moni-toring of mineral process streams. Highly complex and sensitive systems, such as the Courier 6i SL for example, are capable of measuring up to 24 sample streams, providing 12 simultaneous assays. The results from each sample can be measured within 15 to 60 seconds (model dependant) with elements assayed ranging from calcium to uranium. This valuable information allows total control of the circuit.

However, in managing this level of complexity, very few standard solutions exist when it comes to troubleshooting. Equipment set-up and software are particular to each site - what works for one site, will not necessarily work for another. Furthermore, with the transient employ-ment nature of sites and the simple fact that automation systems are designed to work without operator involve-ment, there is little need for site personnel to become familiar with all aspects of analyzer systems.

In most cases where issues occur, troubleshooting is best left to the experts as each individual problem generally

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This is where a comprehensive maintenance contract comes into effect. If technical help is only a phone call away, resolution time in man hours alone can be drasti-cally reduced. Errors such as an incorrect normalizing factor (a key part of analyzer stability) can be identified and resolved in a matter of hours, as opposed to several days. Additionally, associated costs, such as a technician site visit or the analyzer being out of commission longer than necessary, can often be avoided.

What is important to note however is that total transpar-ency is key to obtaining the correct assistance from the help desk. Technicians are fully aware of the difficulties facing site personnel who may not have the necessary knowledge and training to deal with complex analyzer systems. Yet one of the greatest challenges facing the technician is the need for correct and accurate informa-tion and the reluctance of site to relay actions they fear may be seen as irrelevant or incorrect.

CaseinpointWhile common scenarios are unusual given the amount of variable factors involved, some similar occurrences have been encountered by our analyzer technicians across several sites. One of the most generic issues involves system resets by site. Each incident occurred after analyzer alarms, (which can indicate anything from incorrect readings to temperature malfunction), following which, site personnel attempted to rectify the issue by carrying out an alarm reset. When this did not achieve the result expected, in each case, site persisted without technical assistance.

Generally, inside the panel of most Outotec analyzers are alarm reset, system reset and reboot switches. The alarm reset switch is not to be confused with the system reset or reboot switch which have entirely different functions and effects. The reboot switch on the interface computing unit does not toggle back to its original setting, as do the other switches. Instead, when used, it pauses the system

to allow program information to be downloaded. When in this position, all subsequent action will result in failure to reset the system until taken out of reboot mode.

On calling the Outotec help desk, the technicians discussed the events and the steps taken by site to allow the most appropriate action to be determined. In each of these occurrences, site insisted the reboot switch had not been used. In one case, a technician visited site and was able to immediately identify that the reboot switch had been used and resolved the problem. Had the information regarding use of the reboot switch been forthcoming, the system would have been up and running far earlier and saved site the associated costs.

InstallationadviceAnother general issue seen on several occasions high-lights the importance of adhering to advice on correct installation, particularly layout and position. From a long-term maintenance point of view, correct location can greatly improve the longevity, accuracy and wear of the analyzer. Poor location has a detrimental impact on the analyzer – chemical leaks, for example, from ceilings can corrode the exterior, causing faults. Exposure to excessive heat can affect the ability of the machine to be maintained at the right temperature.

In one such case, due to excessive heat, the air condi-tioning unit which provided cool water to the x-ray tube was unable to maintain its temperature. As opposed to contacting the help desk, attempts were made by site to cool the Courier by opening the side doors. In these circumstances with a temperature differential, condensa-tion can form inside the unit and as in this case, run into the spectrometer channels.

When site contacted the Outotec technician, inaccurate and varying normalizing factors were reported, making it impossible to gauge correct readings. Without being advised of the temperature issue it appeared the channel

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was faulty. However, upon inspection, the problem was actually from water surrounding the element specific crystal, interfering with the reflections.

Such issues really drive home the need to utilize technical assistance at the onset of problems, as early intervention can keep maintenance costs down and avoid unnecessary downtime.

RemotelydoesitOne method of reducing costs is by employing preventa-tive measures as opposed to resolving matters when things go awry. Where analyzer systems are concerned, a growing trend is to install remote access referred to as a Virtual Private Network (VPN). Successfully utilized at sites globally, this allows remote analysis by a highly experienced technician who can quickly identify existing and potential problems.

For example, on reviewing an NF ABS alarm from one site via remote VPN access, readings showed that the normalizing factor was well over 1.0. The Outotec tech-nician responded by readjusting the linear correction coefficient (LCC) to bring the figure back within range. Downtime, recoveries and man-hours are just the tip of the cost saving iceberg that can be addressed in this type of off-site response.

TrainingWhere such complex and continually evolving technology is concerned, a maintenance contract is imperative. Furthermore, by incorporating a day’s training, site personnel’s knowledge of the analyzer and sampling system will only serve to strengthen maintenance. With greater understanding through high quality, customized training, much more can be done at site by remote instruction. With the on-site training offered

by Outotec for instance, the technician will review the analyzer event log to obtain a history of faults and alarms. The cause of these can then be explained to site personnel and they will receive training on how to address such occurrences in the future.

Additionally, misconceptions about the analyzer can be allayed, such as the concern of radiation exposure upon opening the inspection doors to access the probe set. Most sites will not consider opening the inspection doors due to a lack of understanding of the equipment. While correct care and precaution by trained site personnel should always be taken, most modern analyzers are designed with safety as paramount. With the Courier range for example, there are two redundant safety systems, therefore no single component failure can cause a hazard. Also, what is seldom realized, is that powering down removes the possibility of inadvertently being exposed to harmful x-rays.

InshortAnalyzers are complex, sensitive systems and a valuable asset in your plant. When employing technical assistance to resolve your analyzer and sampling systems issues, only accurate and full disclosure of actions and events will result in the most appropriate resolution. Technicians will not judge or undermine site personnel for lack of knowledge, but are completely reliant upon local eyes and ears to help ascertain the best way forward, particularly considering the vast amount of variables that must be considered.

Including a maintenance contract for your analyzer and sampling system will pay for itself in the long run and when selecting a supplier, ensure technical assistance via a help desk which incorporates remote access and training, are available.