Bengalla Mining realises multiple benefits of tailored hose solution

Bengalla reduces downtime caused by hose failure by implementing a tailored Onsite Hose Solution from WesTrac and Caterpillar.

Hoses and couplings come in varying shapes, sizes and degrees of quality.

But problems with just one small hose can bring the biggest, most technically advanced equipment to a standstill, impacting productivity until suitable repairs can be arranged.

Operators are starting to understand that not all hoses and couplings are equal, and that has led Caterpillar and WesTrac to collaborate with customers to develop tailored hose solutions, providing the parts, tooling and access to technical data to carry out hose repairs and maintenance requirements onsite.

In addition, the total solution comes ready to use in fully equipped, converted shipping containers, fitted out as dedicated hose assembly workshops. That includes work benches, storage cabinets, hose testing capabilities, electrics including air conditioning and even data connectivity to enable access to online tools, guides and hose databasing.

The solution is not only designed to cater for Cat equipment but allows operators to carry out hose repairs for other makes and models as well.

It is a solution that has helped New Hope Group’s Bengalla Mining Company in New South Wales realise considerable benefits quickly. According to Reliability Analyst Anton Nicholl, the onsite hose workshop started paying dividends from its first live use, allowing a brake cooling hose on a Cat 777G water cart to be repaired within 15 minutes.

“When considering all the implications of a downtime event such as this, we saw cost savings of more than $500 and reduced turnaround time from around three hours to 15 minutes,” Anton said.

“With those sort of cost savings for Cat equipment alone, I’d expect the workshop to effectively pay for itself over the next two to three years, but take into consideration the other OEM equipment and the reduction in downtime events through shorter wait times and better reliability, and the payback period would be halved.”

Caterpillar Component Application Specialist Jaime Ruiz says the group is the only equipment manufacturer that makes its own hoses and couplings, thus ensuring quality control through the entire process.

“We own everything from selection of materials to design, to manufacturing and testing,” Jaime said. “There are plenty of hoses and couplings on the market but they are not the same. Many hose suppliers use products from different manufacturers, introducing variability in tolerances and quality controls.”

The Bengalla solution, which is the first of its kind in the world, was designed with material flow and operator comfort in mind from the beginning. According to Jaime, that includes consideration for the height of storage cabinets and tool access points, ensuring nobody has to lift loads beyond approved manual handling guidelines.

Hose solution customers are provided with access to required technical specifications and much of the tooling included in the containers is also data enabled, ensuring operators can assemble accurately first time, every time.

Rob Leiss, WesTrac Business Development Manager – Hose and Couplings, says every solution is customised to meet individual requirements.

“The solutions are all very much tailored to different customer needs, so there’s nothing generic about them,” Rob said.

“Depending on the size and scope of the operation, that can range from a container of ready-made assemblies to suit a small number of machines, right through to the Bengalla-style solutions which ensure customers have everything available to be entirely self-sufficient.

“A large proportion of Bengalla’s fleet is non-Cat equipment and as part of the agreement, WesTrac has committed to converting all machines onsite, regardless of make and model, to use Cat hose and couplings.

“That removes a significant pain point for the customer who might otherwise have to reverse-engineer any non-Cat hose requirements.”

Rob added that providing access to Caterpillar hose information and reference systems allowed customers to ensure replacement assemblies were built to original specifications rather than being visually constructed on the fly.

According to Anton, while it is early days, the benefits of the comprehensive hose solution are becoming rapidly evident. He points to four core areas where that is occurring:

1. Quality control – having the responsibility/accountability of an onsite solution ensures Bengalla’s own standards are adhered to (such as the ability to mitigate risks such as fatigued hoses).
2. Cost savings – Bengalla is likely to realise about 40 per cent reduction in hose manufacturing costs compared to using OEM supplied hose assemblies, however the biggest cost saving is the reduction in down time. If a Tier 1 machine has a breakdown, fitters can radio the hose workshop in advance for a replacement hose, which can be made and ready for fitting by the time they arrive at the workshop
3. Capability of manufacturing non-CAT hoses – when it comes to mining machinery, Bengalla runs Caterpillar, Komatsu, Hitachi, Letourneau, Penske, Cummins and a range of fixed plant equipment. Having the capability to manufacture hoses for all onsite equipment enables major reductions in downtime events, enabling the site to meets its objectives of producing ‘Safe, Productive, Profitable Coal’.
4. MDG41 compliance – the precise construction of the hose and couplings using quality assured parts helps Bengalla adhere to the NSW MDG41 standard for hydraulic/fluid power systems.

The Bengalla solution also includes a Cat Hose Assembly Pressure Test unit, with all assemblies being tested to ensure 100 per cent integrity in the workshop before being fitted to equipment.

A label printer is also included with hose and coupling solutions so that every hose assembly can be labelled with vital information such as assembly date, part number and the name of the person who made it.

Rob admits that with Bengalla being one of the first sites to implement such a comprehensive hose solution, there were some initial learning experiences for all parties.

However, he says the level of collaboration and willingness to solve any problems as they arose has resulted in a robust and highly successful outcome.

Anton agrees.

“The world class hoses and couplings, training and the specialised equipment provided make the overall solution incredibly user friendly,” he said.

“This gives us confidence that the solution will add to the reliability and longevity of our fleet and fixed plant equipment.”

Cat hose solutions are available to suit any size operation across mining, construction and other applications. Benefits will vary depending on the nature of the operation and equipment being utilised.

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