TN1293 : Risk Analysis of Shovel Failures and a Risk-baxsed Maintenance Planning (Case Study Sarcheshmeh Copper Mine Shovels)
Thesis > Central Library of Shahrood University > Mining, Petroleum & Geophysics Engineering > MSc > 2026
Authors:
Mahdi Barani [Author], Mohammad Ataei[Supervisor], Ramin Rafiee[Supervisor], [Advisor]
Abstarct: In the mining industry, risk assessment and management of heavy mining equipment are essential for ensuring workforce safety and maintaining production continuity. Harsh operating conditions and the high dependence of production processes on these machines make equipment failures and operational malfunctions significant sources of production interruptions, increased maintenance costs, and potential accidents. Therefore, the application of systematic risk assessment approaches plays a critical role in supporting decision-making processes related to safety and maintenance management. This study focuses on the failure risk assessment of electric rope shovels operating in the Sarcheshmeh Copper Mine, where failures of heavy equipment can lead to costly downtime and reduced operational efficiency. For this purpose, failure data from ten shovels, including P&H 2100XP, P&H 1900AL, and WK-12C models, were collected and analyzed. Following data organization, the shovels were categorized into seven major subsystems, namely mechanical, electrical, hydraulic, pneumatic, travel, operational, and cab/body systems. Subsequently, a risk matrix approach was employed to evaluate the likelihood of occurrence and the severity of failure consequences. The results indicated that most failures were concentrated within the orange (high-risk) and yellow (medium-risk) zones, while a considerable proportion fell within the green (low-risk) zone, requiring periodic monitoring. No failures were identified within the red (critical-risk) zone. In terms of failure frequency, shovels No. 2209 and 2210 of the P&H 2100XP fleet exhibited the highest number of failures and were therefore assigned the highest maintenance priority, whereas shovel No. 2208 of the P&H 1900AL fleet experienced the lowest failure frequency. baxsed on the risk assessment results, an operational frxamework was developed for the targeted allocation of maintenance resources to critical shovels and priority failure modes. By emphasizing high-risk failures, revising maintenance procedures, and maintaining continuous monitoring of low-risk failures, the proposed frxamework contributes to reducing unplanned downtime, improving equipment availability, and controlling maintenance costs.
Keywords:
#Shovel #Failures #Risk Matrix #Risk-baxsed Maintenance Plan #Sarcheshmeh Copper Mine Keeping place: Central Library of Shahrood University
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