72 Man-hours 2 men 3 days

 

Civil Structures

1. Check all the levels top of concrete for and record the exact RL’s.
2. Check bolt locations to drawings.
3. After Checking against civil drawings note any discrepancies in the mechanical check sheet
4. Once RL’s have been checked and approval to preceded given Scabble all the Plinths.

24 man-hours 2 men 1 day

 

Baseplates

1. Baseplates and machinery must be erected on prepared foundations and aligned to the prescribed centre lines and elevations as shown on the erection drawings.
2. Baseplates and machinery shall be properly levelled, aligned, set and adjusted on packers and shims.
3. Packers shall be of sufficient size to sustain an effective load bearing area. They shall be of one piece thickness.
4. Shims shall be of the same size as the packer. The maximum thickness of shim shall be used to reduce the number of shims required at any one point to a minimum.
5. Set up sub soles using grub screw jacks with pin points to hold position in concrete check the RL’s in all directions and sign off the check sheet, all to be done using a Machine level and piano wire to ensure all points equal.
6. Form up around sub sole plates and pour 2 pack impact resistant Epoxy grout to sub soles and allow 12 hours before applying any load to the soles.
7. Fit and shim main sole plate on sub soles
8. Check center lines measurements to ensure square ( piano wire)
9. Remove Polystyrene formers from Concrete and install hold down bolts in holes in concrete casting. secure plate with the bolts flog down but do not tension.
10. Recheck for level and recheck center lines

48 Man-hours  2 men 2 days

 

 

Mill shell Assembly

 

Shell Components and installation Jacking and support frame  

1. Assemble components for the mill in close proximity to the structure to allow a single lift into position, allow for temporary supporting structures and jacks to be fabricated to suit the Mill weight and size Mill end plates and shell section weight in at many tonnes each. An 11 metres diameter mill end plate will weight around 40 tonnes
2. Develop a rigging study to meet the requirements of the lift and locate the assembled unit within the parameters of the lift study radius. Special lifting lugs will be required for the installation of the shell dependant on the size and configuration of the unit.
3. Setup the area with support frames Place support cradle for shell in position correctly to centre line and le vel, ensure that sufficient packing is allowed to lower the shell to final height after all components are fitted.
4. When assembling the mill shell ensure that all mating surfaces are clean and debris free, clean and lubricate all bolts and nuts prior to use with a thread lubricant to ensure uniform tensioning of the bolt, where specified torque setting are required check the calculation or request confirmation from the clients representative that the torque levels allow for lubricated threads.

Setup area including clean all surfaces and fixings 4 men 60 hours  240 Man-hours

Rigging including study, JSA, Fitting lugs and setting up support frames 4 Men 24 hours 96 hours

Bolting up and torquing Bolts 4 men 48 hours 192 Man- Hours

 

 

 

 

Girth Gear

1. Fit the girth gear, this will come in sections to be bolted to the Shell during installation
2. Set up a dial gauge on the mill girth gear and rotate the mill using the inching drive to check for displacement in the gear.
3. Shim or tension bolts to true gear up ( again Old Mill more critical- New usually OK)
4. Complete as far as possible gear lube spray piping

240 man-hours 3 men 80 hours

 

Bearings

1. Fit the Bearing Cradle/pedestal using the same setup procedure stated above for Sole plates
2. Rolling element type bearings must be installed in accordance with the manufacturer’s recommendations.
3. All sleeve bearings, motor and driven equipment bearings shall be opened and inspected before equipment is lubricated or placed in operations
4. All shafts and bearings shall be maintained in a clean condition during installation and covered whenever work is not proceeding. A Typical Mill journal bearing, is a cylinder which surrounds the shaft and is filled with fluid lubricant. This fluid supports the shaft preventing metal to metal contact.
5. Clean all flanges and bolt holes on bottom and top halves of shell.
6. Remove all the temporary inner shell support structure with the exception of the two horizontal pieces and fit external restraints on shell at four points.
7. After thoroughly cleaning the two bottom quadrants of the inlet (feed) end bolt these together and fit to the shell using tapered drifts and appropriate bolts .
8. Torque up shell to end plate bolts as per instructions and checking with the Micrometer tension device.
9. Repeat the previous instructions for the discharge end.
10. Clean and fit feed end trunnion
11. Clean and fit Discharge end trunnion. A final check to be made and recorded of the shell concentricity and centre ready to allow it to be placed on bearing pads when these are ready. Remove the two horizontal inner shell supports.
12. Clean and fit both bearing housings ensuring alignment and level is correct (assuming that the bearing pads are fitted to housings).
13. Once cradles/ Pedestal is set up the assembled bearing shell is lowered in to position
14. If practical use a third party bearing manufacturer to Lock up and set bearings, if not stay within the manufacturer’s installation methodology. Bearings are processed with a rust inhibitor prior to shipment from the factory. This protection should not be removed until installation. At that time, the bearing should be disassembled and all parts thoroughly cleaned with a lint-free cloth and a solvent such as mineral spirits.  The bearing is then reassembled.
15. Once bearings have been installed into housing use bearing blue
16. rotate mill using turfers then jack the mill up to view pattern of bearing blue locate and mark all the high spots and using a white metal scrapping tool trim down all high spots
17. Continue this process until satisfied that a minimum of 80% + coverage of the bearing.
18. Clean the bearing shells and apply suitable oil to the bearings to allow inching of the mill shell through the remainder of the processes.
19. Lower the mill into the bearing
20. Fit the bearing cap and nip up but do not tension yet
21. Setup and level Base plates 4 men 2 Days  96 Man-hours
22. Installing bearing pedestal 4 men plus a rigger 16 hours  80 man-hours
23. Setting up bearing liners including shell bearings bluing and scraping 4 men 60 hours   240 man-hours
24. Connecting lube connections 2 men 60 hours   120 Man-hours
25. Truing up bearings 4 men 48 hours plus rigger for 18 hours  210 man-hours
26. Closing up the bearings including all checks 3 men 36 hours plus a rigger for 12 hours 120 man-hours

 

Lubrication

Typical Mill Lube system schematic

Install the mill hydraulic pumps, oil reservoirs, piping systems, heat exchangers and filters, test bump the motors and align and couple the motors to the pumps. Setting up both high pressure and low pressure Hydraulic systems

1. The type and grade of lubricant required for a particular item of equipment shall be as recommended by the equipment supplier
2. All lubricating oil supply and return piping shall be completely flushed before connecting to any equipment. Oil sumps shall be cleaned and filters checked prior to filling with clean oil.
3. All internal surfaces of lube lines shall be treated by pickling.
4. All pressure lubrication systems, including oil flow and pressure indicators, shall be run and checked prior to the main equipment being operated.
5. Flush systems using filters and temporary pumps
6. When system is passed as clear connect up the mains system.
7. Check cleaning of the bearing housings, pads and trunnion bearing surfaces.
8. Check bearing clearances and record.

Process installation of lube oil mechanical components 3 men 48 hours 144 man-hours + 48 hours for double pinion

Installation of piping systems 2 men 96 hours  192 man-hours + 36 hours for double pinion

Dry commissioning of system 2 men 18 hours 36 man-hours + 12 hours double pinion

First fill lubricants and flushing the system 3 men 24 hours 72 man-hours + 24 hours for double pinion

Process 2 men 12 hours   24 man-hours

 

Pinion Installation

    

1. Set up sub soles and sole as above for pinion mount.
2. Place the pinion
3. Using Feeler gauges check to ensure a root gap of 6MM both ends move pinion into position as close as possible.
4. Blue the Teeth on girth gear and roll mill using the turfers and check the coverage of the bearing blue. All high spots are to be sanded down using a 5” grinder and a sanding disc, this is especially required when installed used equipment.
5. Once True check the clearance and backlash by inching the mill shell using the turfers.
6. Repeat this process for the second pinion on a twin Pinion Drive

168 man-hours  3 men 4.5 days

 

Gear Box

1. Setup the Sole plates for the gear box in the same manner as the setup for the mill and Bearing pedestal.
2. Check and set gearbox CL and RL and ensure all levels and alignments are true.
3. Shim back and front of Gearbox to bring pinion to within 0.010” max tolerance below 0.005” good, less the better
4. Install Gearbox lubricating system to manufacturers specifications

68 Man-Hours  3 men 2 days

 

Install Inching Drive / Barring gear

1. Install the Inching Drive unit ( Barring Gear) running through the typical leveling and alignment processes although the alignment of this unit is not as crucial, as the drive connection is removed unless inching for maintenance is required, install and fit the drive coupling to facilitate the remaining installation.

24 man-hours  2 men 1 day

 

Couplings

1. Coupling alignment and float tolerances shall be in strict accordance with manufacturer’s recommendations.
2. Check type of coupling,
   1. Motor to Gear box may be a tyre Coupling which consists of 2 flanges, 2 taper core locks and 1 flex tyre.
   2. Gearbox to pinion may be a Chain, Grid or Cone ring coupling
   3. Once Coupling type is known and the Installation data is available Lock down but not tension until checks have been completed and the drive unit has been through a directional test bump which will require the coupling to be disconnected for the test.

54 man-hours 2 men 2.2 days

 

Repeat the process for double pinion drive

Motor Installation

1. Use the Same procedure as above for Motor sole plates, level shim and align.
2. Place motor Base and level
3. Place motor on base
4. Install the coupling to the manufacturers recommendations
5. Align the drive shafts as per the supplier data sheet, leave uncoupled for test bumping.
6. fit brake unit after motor fitted.

84 Man-Hours  3 men 2.5 days

 

Repeat the process for double pinion Drive

Fastening and Fixing

1. Flog down , torque up all bolts
2. Unless otherwise specified or approved, all bolts, studs and nuts shall be of steel. Where they will be subjected to high pressure or temperature, bolts and studs shall be of an approved alloy having suitable characteristics, and nuts shall be of different composition to prevent seizure.
3. Thread exposed to water or weather and subject to future disassembly for maintenance or replacement shall be lubricants with graphite and oil before tightening unless otherwise indicated by “corrosion resistance” of materials.
4. After tightening, the threads on all bolts and studs shall extend at least four threads beyond the inside face of the nut and project one thread beyond the outer face.
5. A plain parallel washer shall be fitted under each nut, except when subject to vibration or movement, when spring washers or nylon insert lock nuts shall be used.
6. Where additional bolting is required or equipment has been left undrilled, unless required to be reamed or for fitted bolts, the holes shall be drilled 1.5mm larger than the bolt size.
7. The preferred thread is ISO metric to AS 1110-1984, AS 1111-1980 and AS 1112- 1980.

180 man-hours  4 men 4 days + 20 hours for double pinion

 

Grouting

1. If satisfied that all checks have been completed and the process to date is signed off by the clients representative setup for Grouting of all equipment mounts.
2. Grout to be formed up for all sole plates
3. Use the nominated Grout as specified by the clients representative or the contract installation specification
4. Grouting shall be carried out in accordance with Technical Specification Structural Steelwork Erection.

108 Man-hours  2 men 4.5 days

 

Safety Guards

1. Safety guards shall be installed for all exposed moving parts such as chain drives and exposed couplings.
2. The guards shall be of substantial construction and rigidly fixed. They shall be easily removed and fitted with gates or doors where access is required for inspection and maintenance.  Care must be taken to ensure that stationary points requiring access, such as grease nipples, etc, are readily accessible without the removal of guards.

108 man-hours   2 men 4.5 days

 

Liners

1. As the system is now live Tag out the equipment and disconnect the main drive coupling at the Motor, set-up turfers to rotate and hold the mill in position.
2. Place extraction fans in the mill discharge end to ventilate air through the unit while work is underway.
3. Put enclosed work space procedures into place, with a sign in board and permanent trained monitor.
4. Set-up for installation of the mill liners according to the requirements of the type being used.
5. Establish a method of moving the liners into the mill by way of a cable feed structure or mono rail, allowing each liner or lifter to be hooked onto the system and fed into the men working inside the mill.
6. For rubber mill liners generally two men inside the mill fit each components and one man outside the mill fits washers nuts and rattles the bolts.
7. In most instances the liners can be installed by turning the mill in 30 to 45⁰ rotations as sections are completed.

564 Man-hours  7 men 84 hours  

 

Commissioning, Inspection and testing

1. After the equipment has been installed, the following shall be performed and recorded
2. Check installation for conformance with the design and specifications
3. Checking alignment of all couplings, drives, gears etc.
4. Checking freedom of shaft rotation.
5. Checking tightness of seals.
6. Make and record tests such as pressure.
7. Check that lubricating equipment is working correctly
8. Check that all moving parts are properly protected
9. Check cleanliness of equipment and systems
10. The above shall be performed without energising the plant or equipment.

114 Man-hours  3 men 3.2 days

1. When construction is completed, tests which require energising of all plant and equipment shall be carried out. These shall be the initial operational tests of the equipment under minimum load conditions and then at full load conditions.
2. All run-in tests shall consist of continuous operation until all bearing temperatures and equipment vibration reach a steady state condition, within tolerances.
3. Check direction of rotation of all equipment, initially with the equipment uncoupled and then ensure speeds are in compliance with design. Ensure that equipment operates with minimum vibration
4. Check operation of hydraulic and lubrication systems. Oil supply to gears and bearings shall be confirmed to be of proper volume.  Gear spray systems shall provide full coverage of the face of the gears.

180 Man-hours   3 men 5 days

1. Checks shall be made between all moving parts to be sure there is no interference and that clearances are to required tolerances.
2. Ensure that all instrument devices (zero speed switches, alignment switches, emergency stop switches etc) are operating properly.
3. Simulate plant or equipment operation ( No Load ) and make other adjustments as required.
4. Supervise the first fill of mill charge.

144 Man-hours  3 men 4 days