Mining and condition
monitoring solutions
Boosting reliability, enhancing safety
and optimizing maintenance costs

The opportunity
Mining is a vital to many global industries. From airplanes to fuels to communication infrastructure, mining and minerals areindispensable raw materials. As we look to the future, mining’s role will become increasingly crucial, enabling much of the world’scarbon neutrality. For example, minerals are needed for green energy storage systems, such as batteries that power electricvehicles. Those needs will elevate demand for rare earth minerals, with 500% growth forecasted by 2050 (World Bank Group).
As demand and corresponding pricing reach new highs, mining production capacity becomes more essential than ever. This,in turn, elevates mining operation’s reliance on its machinery. Downtime is more expensive. Uptime is more valuable. In orderto profitably capture this burgeoning opportunity, mining operators must navigate new production optimization challenges.

The challenge
Data suggests that many mining operations are under optimized in key areas :70%							operating efficiency due to breakdowns and stalled production
which translates to real potential for increased productivity and throughput				30-50%of mining operations’ costs are spent on maintaining plant, fleet and equipment
so the magnitude of improvements for cost recovery and profitability is significant

3-5X 						cost for urgent repairs and corrective work vs. planned maintenancemade evident by tracking the percentage of work orders through the planning office

In mining operations, the majority of these challenges stem from reactive, time-based maintenance approaches that create
higher order costs and increased risk levels. Thus, maintenance is an underleveraged opportunity, ripe for operational optimization.

The solution
Proactive maintenance via condition monitoring solutions enables mining operations to use data-driven insights to manage
operations and reach the proper balance point across competing priorities:

OutcomeEnablerMaximize ‘smart’ uptime

Understanding asset health, asset life

Minimize downtime

Preventing unplanned downtime before it occurs

Ensuring/enhancing safety

Automating machine monitoring to reduce risk

Meeting regulatory complianceTracking key metrics

Minimizing maintenance costs

Repairs made at lowest possible cost (before damage escalates
prior to full failure and scheduled during planned outages)

Condition monitoring
Condition monitoring obsoletes reactive, time-based maintenance approaches which are based on calendar intervals or
running hours. Time-based approaches are only valid for about 15% of operational assets, and are poor “predictors” of failure
for many assets, resulting in two major issues. First, the majority of assets are getting “maintained” when they don’t need to be,creating a wasteful, overspend in maintenance. Second, it doesn’t prevent full failures and can allow asset issues to escalate
to unplanned downtime, causing costs to escalate in kind.

2Failure is a process

By contrast, condition monitoring supports a proactive approach, based on the premise that failure is a process, not an event. The
Extended P-F curve depicts this concept by delineating a distinct span of time between the potential for failure and functional failure.
Potential for failure is detected by monitoring asset health by measuring properties, such as, vibration, temperature, efficiency,
oil chemistry/particulates, and other physical parameters. Together with tailored algorithms, customized configurations andset points, these parameters can identify both root cause failure mechanisms, in progress as well as irreversible physicaldamage that has already started. As a result, failure can be averted, sound data-driven decisions made and repairs
scheduled at the most advantageous times and lowest possible costs.

The Extended P-F Curve

Root cause failure
mechanism in play

Irreversible damage – inception
to failure progression

Actual damage starts
P-Proactive

FunctionalHealthGoodNo damage
No degradation

P-Preventive$$$Damage causing
conditions exists
Damage is present
and is progressing

FailedTime
Monitoring methods that alert on
conditions that lead to damage,before damage actually starts

TimeSource: “Reliability-Centered Maintenance” by John Moubray, 1992.

Monitoring methods
that alert to the fact thatdamage has started
and is progressing

FFailure

Consequence-Based Technology Implementation

Cost consequences of unexpected failure

In terms of proactive condition monitoring, all assets are not created equal. Each asset has its own warning duration before
failure and asset failure can also result in varying consequences, described below as Important, Essential, and Critical. For criticalassets with shorter warning durations, operators monitor their performance with a continuous, on-line condition monitoring
system. For essential assets with a longer warning duration, periodic on-line systems work well. Lastly, important assets that also
have a longer warning duration are typically monitored with walk-around portable devices. Matching asset characteristics andimpact on production is important for aligning the proper condition monitoring approach and achieving production optimization.

Expected early warning duration

3Bently Nevada helps customers get started
Unreliable and underperforming assets have enormous consequences. Industry studies show that the average facility spends
approximately 5% of its Replacement Asset Value (RAV) on maintenance each year. In comparison, best performers spend 60%
less—just 2% of RAV—while enjoying better uptime, efficiency, and profitability. It’s not simply about spending less on maintenance,
it’s about working differently—and smarter—to achieve more reliable mining operations.
Bently Nevada helps mining manufacturers with a 5-step process:412345Equipment
data library

Asset criticality
ranking

TechnologyPeople

Methodology

1. Build equipment data library.
Constructing a complete master list of equipment, including nameplate data, equipment class and subclass ID field tags.

2. Rank order assets by criticality.
Create relative rankings for asset by weighted criteria such as impact on safety, environment, production, maintenance costs,and product quality.

3. Assign technology.
Based on asset rankings, align technology and monitoring intervals using criticality and failure modes. Develop an on-line
monitoring plan.

4. Align people.
Identify resources with specific roles, responsibilities leveraging in-house and outsourced capabilities. Outline training andculture needs.

5. Adopt methodology.
Establish work and information flow processes; policies and procedures (in-house and outsourced), organizational structureand key performance indicators5

Bently Nevada integrated plant-widesolutions for mining operations

Screening

Screens

Surface Mining

Trucks/Haulers

Crushing

Conveyors

Cone Crushers

Dragline Excavators

Milling
Underground Mining
Blowers

Fans/Pumps
Winches

SAG Mills
Screening Machines
Ball Mills
Bar Mills
Pumps

Flotation

MotorsCompressors
Pumps6Storage
Drying Plants

Compressors

Thickeners

Blowers

MotorsConveyors

Refining

Blowers
Compressors
Conveyors

Power Islands
Turbines

Generators
Pumps

Acid Plants
Blowers

Compressors
Pumps

Electrolysis Plants
Pumps

Port Area

Car dumpers
Stackers
Reclaimers
Ship loader
Conveyors7

Bently Nevada service menu
Key benefits
Be proactive, get it right the first time

Implementation
services• Ensure your assets are protected andmonitored when you’re ready to startup• Avoid costly delays and rework• Use one source to design, plan, manage,and execute the installation• Prevent startup trips due to improper
installation and configuration

Up to$1M/day

100%

Cost mitigationfrom lostproduction,
secondaryprocess &equipment
damageService work
guarantee
1 year warranty
standard on
all service work

Keep your system healthy and optimized

Proactive
support• Prevent instrumentation related false trips• Avert and minimize potential data loss events• Keep up to date and compliant with the best
technologies available• Access the expert support you needwhen you need it mostGenerate actionable insights you can trust

Asset healthand consulting• Understand your asset health to optimize
outage and maintenance planning• Plug in to our global network of machinery
experts with remote monitoring• Get professional OEM agnostic machinery
diagnostics when and where needed• Customize analytic development andtuning to pinpoint specific conditions
Stay ahead of evolving cyber threats• Ensure your system is up to date and protected
as threats continually evolve

Cybersecurity1

Training
and education• Identify and mitigate cybersecurity risks
to your operation• Keep your system both secure and accessible
with advanced security technologies andarchitectures by leveraging data diodes anddatabase replication
Augment critical skills that amplify yourmachinery management capabilities• Enable your personnel to operate and maintainyour monitoring and protection system• Enable your operation to maximize the value of
your system by leveraging expert product andapplication training and knowledge

80%

Machineryalarms andevents due toinstrumentation>90%

Typical reduction
in non-actionable
alarms and events

100% ROI

5-10X

Savings froma single machine
often results infull monitoring
contract
paybackand more

Cost reduction
for well planned
maintenanceoutage vs.
unplanned reactive
outage29%

243 days

Patchmanagement
can reduce
your attack
surface up
to 29%

Average time
lapsed before
detection thata system iscompromised

400+

Customer courses delivered eachyear in 10 languages and to over
45 global locations

1. https://www.us-cert.gov/sites/default/files/documents/Seven%20Steps%20to%20Effectively%20Defend%20Industrial%20Control%20Systems_S508C.pdf

89

Why partner with Bently Nevada?
We are a trusted partner with a proven track record anddeep expertise. For six decades the Bently Nevada experts
and offerings have supported the most demanding proactive
maintenance applications across multiple industries. Ourquantified results speak volumes, and we create significant
benefits for our customers. Even as we protect and monitor
your machinery, we constantly strive to refine and improve
our offerings—and help enable your success.
We design and deliver integrated solutions for all of yourmonitoring needs—including sensors, distributed and rackbased monitors, software, and supporting services—with thefollowing goals:• Increased availability and production• Reduced risk in safety, environmental, andasset performance
Quantifiable, proven results:• 60+ years of innovation in asset protection,
condition monitoring• 240+ international patents, including 150+ U.S. patents• 350+ international patents pending,including 95+ U.S. patents• 8+ million sensor monitoring points• 1,600+ System 1 software users worldwide• Extensive services support provided globally• Lowered maintenance costs

You can rely on us
For more than 50 years, we’ve been supplying condition
monitoring solutions to machinery-intensive industries.
We also bring two decades of experience implementing
reliability improvement projects. Customers turn to us fora simple reason: lasting value. Our solutions demonstrate
their worth, day in and day out, and often result in expanded
implementations because of their proven ROI. We combine
the highest quality products and responsive customer
support with a service team that takes the time to understandthe uniqueness of your plant, your personnel, and your goals.

Our products can be found in many of the world’s mining
plants. Today, many of those same plants are turning
to Bently Nevada for a more comprehensive solution totheir needs, moving beyond just machinery protection
instrumentation on a few assets to plant-wide strategies
and systems for improved environmental compliance,safety, asset production, quality and reduced operationand maintenance costs.

Please contact us here to speak with a subject
matter expert about your specific needs.

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BHCS15044D(09/2021)

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