REAL-time data is being used to capture information that optimises the performance of pumping operations in underground mines
RMI Pressure Systems, which specialises in the design, manufacture and application of high-pressure reciprocating pumps, has developed Supervisory Control and Data Acquisition technology that helps improve pump performance.
It can also predict breakdowns by detecting changes in system performance at an early stage.
RMI Australia sales and services director Huw Dodds said pump stations ran in demanding conditions at high pressures could pose risks to workers and the product itself if not carefully monitored and controlled.
He told Australia’s Mining Monthly that RMI’s SCADA system was an active performance management software that helped ensure long-term efficiency of the pumps’ mechanical systems through data-driven, demand-based responses to system requirements.
Data
“The SCADA system constantly monitors the pump and system health, allowing an early response to any operational deviation,” Dodds said.
“This remote monitoring also makes for safer working conditions, as workers do not need to be near the units to check on their performance.
“The SCADA system will show any alarm activation from the pump station, which keeps downtime to a minimum as fault finding is simplified.
“The SCADA system will also capture data on the operating conditions of the pump station and log this data for later review. Any anomalies in pressures or temperatures can be identified and attended to in a scheduled review – preventing any failures and loss of production for the mine.”
Optimal performance
Dodds said being connected ensured the company could review how the system was operating and make adjustments to suit, thereby increasing uptime, lowering maintenance costs and reducing project risk.
“With the availability of variable speed technology, demand-based control can be leveraged to achieve optimal performance,” he said.
“This is an important advance on the older generation of constant or fixed speed drives.”
Dodds said the data gathered was primarily to ensure the pump station was performing optimally and identify any problems that could lead to unscheduled stoppages.
“The actual running conditions are therefore monitored against a benchmarked – or ‘normal’ – data set, and any substantive misalignment between the two sets triggers an alert to the mine engineers,” he said.
“This could indicate, for example, that something on the pump station was starting to wear, or even that there was an issue with the system downstream.”
Dodds said pump users seldom shared efficiency-related data in the public domain, so it was difficult to be specific about performance improvements in any given application.
“However, there is a strong drive in the sectors we serve to improve efficiencies in energy and water usage – as part of ESG policies and targets – and they select RMI pumps to help them achieve this,” he said.
Innovation
Dodds told AMMthe product came about through the company’s commitment to innovation.
“RMI invests its R&D in value engineering, developing new pumping system applications and technology – including software and more efficient, cost- effective solutions,” he said.
“While we do not link our R&D spend to turnover, RMI is always working on new and innovative ways to improve our product range – and we use the latest technologies in this pursuit. Our dedicated team of R&D engineers are continually improving our offerings, by focusing on the applications in which they are used.”
Dodds said the feedback loop between RMI’s field service technicians and its design engineers ensured products were always being improved to help ensure future versions had higher uptime levels.
“RMI gathers feedback from all of our customers on an ongoing basis and this data is used in strategic planning for product improvements and development,” he said.
“This process supports our central aim of ensuring that customers have the best experience of our products. In this way, customers drive our design improvements, which often involves introducing new technologies.
“We also review our previous builds to see what continues to work well, what can be changed and what, if any, new design elements can be carried over into future system builds.”
Expansion
RMI’s S Series range of pumps are already operating in Australia as the main emulsion pumps on a pump station.
There are two models in RMI’s S Series range – the Trimax three-plunger pumps and the Quinmax five-plunger pumps.
“The Trimax system has three running pumps and the Quinmax system only two – and the choice depends on the duty,” Dodds said.
“An important consideration may also be the electrical supply. Where this supply is limited, then multiple Trimax pumps would make more sense, as they use a smaller motor than the Quinmax pump.”
Dodds said company might seek further opportunities to expand in Australia.
“Traditionally, our focus has been on building and servicing longwall pump stations and salvage units for the operation and relocation of roof supports used in underground coal mines from our manufacturing facility in Cardiff, New South Wales,” he said.
“While we will continue this work, we are also looking at other mining applications that use either high-pressure water such as hydro borehole mining or hydraulically driven applications such as paste backfill.”
As a long-time partner to customers in the mining sector, RMI Pressure Systems will be welcoming visitors to its exhibition booth at the US Coal Show Longwall Edition in Pittsburgh, Pennsylvania from 9 to 11 May, 2023.
The US Coal Show – previously the Longwall USA Exhibition & Conference – is the country’s leading conference for longwall mining, giving valuable exposure to RMI Pressure Systems’ century-old brand. According to Gary Punton, General Manager of RMI Inc, the product focus at the event will be RMI’s Quinmax S500 and the updated Trimax high pressure reciprocating pumps.
“We will be showcasing our long history of supplying high quality pressure pump systems to the longwall mining industry,” said Punton, “as well as the benefit to customers of our US-based warehouse and our manufacturing and overhaul facility – which boasts full load-testing capabilities.”
He noted that while metallurgical coal prices were more buoyant, segments such as lower grade steam coal were not as fortunate. Cost factors would therefore continue to maintain the industry’s focus on low capital and operating expenditure, while demanding trouble-free operation of equipment in longwall panels.
“With our latest technological, energy saving and cost-efficient solutions – backed up by our first-class aftersales service – RMI will use the US Coal Show as another valuable opportunity to grow our brand in this market,” he said.
RMI has for decades served the longwall sector with efficient and reliable pump stations and controls. These provide uninterrupted hydraulic power for roof support actuation, and are also used for water jetting for dust suppression.
With a product development and manufacturing hub in Manchester, England, RMI has operations in the US, China, India and Australia. It also serves markets in Europe, the Middle East and Africa. Its in-house research and development capability drives the continuous innovation of its products and solutions.
RMI Pressure Systems will showcase their Quinmax S500 high-pressure reciprocating pump at the US Coal Show Longwall Edition in Pittsburgh
About RMI For companies in the mining and heavy industry sectors looking for quality, robust high-pressure pumping solutions, RMI Pressure Systems designs, manufactures and supports world class reciprocal pumps that last. Through stringent quality processes and extensive testing protocols, we produce pumps that give customers optimal uptime and life-long productivity. With over a century of engineering experience, we have the global expertise to ensure our customers of high-pressure pumping solutions and support that promote profitability and sustainability. Our high-pressure pumping technology delivers 95% energy efficiency and saves water. This aligns with the growing concern in our markets with environmental sustainability, supporting customers who are working towards lower resource consumption and reduced carbon emissions.
High pressure reciprocating pump specialist RMI Pressure Systems has promoted Sabrina Zhang to the role of Director for Aftermarket Sales, Services and RMI Operations in China.
Zhang has been with Armstrong – RMI’s holding company – since 2013 and previously held the role of Senior Manager for Commercial & Aftermarket. In her new role, she will be developing RMI’s aftermarket sales and services in China, including new and rebuilt pumps, part sales and service contracts. She will also be growing the company’s field technical services, proposal generation and service execution – while coordinating with business functions such as supply chain, procurement and engineering.
“For more than 30 years, RMI has been a leader in producing premium quality emulsion pump stations and water pump stations for underground mining applications in China,” she remarked. “We are proud of being a well-known brand in China with a top-class reputation.”
She is confident that RMI will continue to satisfy existing customers and win more business, despite strong competition from local pump manufacturers in recent years.
“Customers value our quick lead times in product supply, combined with our professional upgrade and overhaul services, as well as our prompt field support response,” she said. “Importantly, our team is also implementing exciting localisation strategies to further improve our service to the market in China.”
Zhang will report directly to Joe Keenan, RMI Pressure Systems’ Global Managing Director for Industrial Fluid Flow Solutions.
About RMI Pressure Systems
For companies in the mining and heavy industry sectors looking for quality, robust high-pressure pumping solutions, RMI Pressure Systems designs, manufactures and supports world class reciprocal pumps that last. Through stringent quality processes and extensive testing protocols, we produce pumps that give customers optimal uptime and life-long productivity. With over a century of engineering experience, we have the global expertise to ensure our customers of high-pressure pumping solutions and support that promote profitability and sustainability. Our high-pressure pumping technology delivers 95% energy efficiency and saves water. This aligns with the growing concern in our markets with environmental sustainability, supporting customers who are working towards lower resource consumption and reduced carbon emissions.
RMI Pressure Systems is pleased to announce that Joe Keenanhas joined the company to serve as Global Managing Director, Industrial Fluid Flow Solutions.
Keenan brings with him over 25 years of experience in the mining industry, having held senior positions with companies around the world, including Orica Mining Services, where he served as Senior Vice President for USA and then President, Latin America.
Keenan graduated with a BSc in Geology from Laurentian University in Canada and then later received his MBA from Edinburgh Business School. In 2008, he attended the Leadership program at INSEAD Business School in Singapore and, in 2010, completed the Advanced Management Program at Harvard.
As the global leader for the RMI Pressure Systems’ mining and industrial business, and head of the North American Gas Transmission business, Keenan will oversee the sales, engineering, product management, operations and services functions in the UK, EMEA, USA, China, India and Australia.
“I am looking forward to working with this incredibly talented and diverse team and continuing the growth of this iconic brand. The business has aggressive growth plans and a deep R&D pipeline which is grounded in the voice of our customers. I feel confident that the business has the right market focus and technical expertise to drive RMI forward,” Keenan notes.
Joe Keenan, middle, is joined by the global RMI Pressure Systems management team, from left to right – Kathryn Poke, Gautam Putcha, Sam Bennett, Richard Mayhew and Anup Putcha
The future of RMI Pressure Systems in the Chinese mining sector looks even brighter following the company’s achievement of MA certification to manufacture its world-renowned pumps locally in China.
Sabrina Zhang, Director for Aftermarket Sales, Services and RMI Operations in China, said this is a game-changing development that will open the door to increased sales of its quality equipment. RMI Pressure Systems is a global leader in high pressure and high volume fluid pumping stations, with over a century’s experience in designing, manufacturing and supporting this technology.
“RMI has been a leader in supplying premium quality pump stations to Chinese underground mines for more than 30 years,” said Zhang. “Our local manufacturing capability – certified by the MA Centre – will give us greater opportunity to build on our strong reputation in China.”
The MA Centre is the Chinese agency responsible for approving and certifying the safety of mining products before they can be used underground. RMI’s success in the Chinese market has to date been based on a relatively small number of international public tenders, she pointed out. With the MA certification, the company is now enabled to participate in potentially hundreds of local tenders each year.
“Our certified manufacturing facility in Shanghai allows us to approach the whole market, which is a very exciting prospect for us,” she explained. The facility – owned by RMI’s holding company Armstrong Fluid Technologies – is now certified to produce 15 different models of high pressure pump. The rigourous certification process has taken about a year, according to RMI Commercial Director Robert Yang.
“The MA process included the preparation of extensive documentation, as well as site inspections of our facilities,” said Yang. “We were also required to test the flow and pressure of our emulsion pumps and water pumps in our facility.”
The certification binds RMI to manufacture and assemble its pumps in strict compliance with the specifications set out in the documentation, he adds. There is also a facility inspection conducted by the MA Centre every 18 months, to confirm that it remains in line with requirements.
While the market for high pressure pump systems in China has become increasingly competitive, Zhang highlighted that RMI’s pump range remains well known for its quality design, reliability and low total cost of ownership.
“RMI pump systems that we sold to customers over 10 years ago are still being used productively underground, which is testament to their quality and cost-effectiveness,” she said. “This compares very favourably with many competitors, whose pumps may only last two to three years – just enough to complete one or two longwall panels.”
She also pointed to the value of having a three-year duration between overhauls, rather than the much shorter intervals required by some suppliers.
Boosting its localisation strategy with the recent MA certification, RMI is also working more closely with customers to service its existing large pump systems in China. The company emphasises to its customers the importance of scheduled maintenance, providing specially designed component modules and kits.
“This takes the guesswork out of maintenance, as customers will know when certain components need to be replaced,” she explained. “For instance, we recommend that a Grade A overhaul is conducted after each longwall panel, which focuses on the fluid end components.”
Simplifying overhauls for optimal reliability
Regular servicing is the basis of reliable pump operation, so RMI Pressure Systems makes this easier with its overhaul guides for customers with a PM program that is used for the installed base.
To make the overhaul process simpler for customers, RMI has packaged specific service and maintenance kits for each pump, containing the genuine spares that each grade of overhaul will require. When purchasing an RMI emulsion pump or water pump, customers receive a manual which makes it clear which kit to order, and even contains the RMI part codes.
Sabrina Zhang, Director for Aftermarket Sales, Services and RMI Operations in China
Robert Yang, RMI Commercial Director Robert Yang
About RMI
For companies in the mining and heavy industry sectors looking for quality, robust high-pressure pumping solutions, RMI Pressure Systems designs, manufactures and supports world class reciprocal pumps that last. Through stringent quality processes and extensive testing protocols, we produce pumps that give customers optimal uptime and life-long productivity. With over a century of engineering experience, we have the global expertise to ensure our customers of high-pressure pumping solutions and support that promote profitability and sustainability. Our high-pressure pumping technology delivers 95% energy efficiency and saves water. This aligns with the growing concern in our markets with environmental sustainability, supporting customers who are working towards lower resource consumption and reduced carbon emissions.
Mines and industry rely on critical high pressure pump technology to keep operations safe and efficient, which makes rigorous testing of this equipment an essential part of the manufacturing process.
According to Kathryn Poke, director of engineering at RMI Pressure Systems, dedicated test cells in the company’s Manchester production facility support a range of technical tests to ensure final product quality. RMI Pressure Systems is a global leader in high pressure and high volume fluid pumping stations, with over a century’s experience in designing, manufacturing and supporting this technology. With a primary manufacturing facility in the UK, the company has operations in China, the US, India and Australia – supporting equipment in countries around the globe.
Poke said that RMI Pressure Systems’ quality and testing regime means that new equipment and components can be put through as much as two million pump cycles – over periods of up to 160 hours – to prove their integrity.
“In robust and continuous applications such as longwall coal mining, our customers rely on our high pressure reciprocating pumps to deliver optimal uptime and safety,” she said. “Similarly, our steel industry customers look for quality and reliability in de-scaling and forging applications.”
In these demanding and often hazardous environments, pump pressures can reach 350 to 400 bar – making any leaks or defects potentially disastrous. She highlighted that RMI Pressure Systems’ meticulous testing regime has been critical in building the company’s quality reputation for over a century.
“Before delivery, all of our equipment is put through its paces in our test cells,” she explained. “These well-resourced facilities measure and record temperatures, pressures, speeds and other indicators – generating data that is carefully reviewed and analysed by our engineering team.”
She emphasised that the test cells run alongside the company’s manufacturing processes, which are accredited in terms ISO9001 quality standards. This ensures that the extended periods of testing do not compromise RMI’s production rates. The test facility can accommodate three RMI high pressure pumps at a time.
“This means that our customers are confident that RMI equipment is ready to go when it is installed and commissioned on site,” said Poke. “There is no run-in time or bedding down to be done, so the pumps’ contribution to productivity and uptime will be immediate.”
Experts from RMI Pressure Systems are available to assist with installing and commissioning the equipment, giving customers peace of mind and ensuring optimal performance. The company’s manufacturing quality is also enhanced by its careful selection of suppliers and components; these are chosen on their excellence, and regular quality assurance processes are applied. Cycle testing of components is also conducted to ensure a quality finished product.
“Our inspection team tests new components extensively against the conformance criteria before giving it the thumbs up,” she said. “Staying up to date with technology allows us to improve designs, software and materials of construction wherever possible; each improvement, though, needs to be thoroughly tested before we introduce it to the market.”
RMI Pressure Systems’ meticulous testing regime has been critical in building the company’s quality reputation
RMI Pressure Systems’ meticulous testing regime has been critical in building the company’s quality reputation
Dedicated test cells in RMI Pressure System’s production facility ensures final product quality
Dedicated test cells in RMI Pressure System’s production facility ensures final product quality
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