CRUSHING PLANT EXPERTISE WORKFORCE SOUTH PACIFIC LIMITED Crushing Circuit Maintenance Services
CAPABILITY STATEMENT PROCESS DESIGN CRITERIA Design Criteria Information Typically, the information required to develop crusher process design criteria includes: • • • •
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Geographic data Civil design criteria Structural design criteria Mechanical design criteria
Climatic data Process design data (process description, ore characteristics) Electrical/instrumentation design criteria.
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Flowsheet Some sample flowsheets are provided in Figures 3, 4, and 5 showing crusher circuits. Figure 6 shows a typical three stage closed crushing circuit with its ancillary equipment. PRIMARY CRUSHER
COARSE ORE STOCKPILE
CLOSED CIRCUIT
DOUBLE DECK SCREEN
SECONDARY CONE CRUSHER
OPEN CIRCUIT PRODUCT
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Figure 3 Two stage open/closed circuit
PRIMARY CRUSHER
COARSE ORE STOCKPILE
DOUBLE DECK SCREEN
3 STAGE CLOSED CIRCUIT
DOUBLE DECK SCREEN
TERTIARY
DOUBLE DECK SCREEN
TERTIARY
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Crusher plant maintenance WFSP adopts an Asset Management and Quality Assurance approach to assist clients develop well planned crusher preventative maintenance programs - the strategic benefits of this approach ensures less wear and tear, change-outs and lowering of operating costs per tonne of ore crushed.
Workforce South Pacific Limited (WFSP) partners with other contractor specialists, to provide complete maintenance services across the crushing circuit (crusher plants, apron, vibrating /grizzly feeders and conveyors). In partnership with other companies, we have an established SBU – MINING MAINTENANCE BUSINESS for aligning our crusher circuit maintenance operations across two business units – CRUSHER MAINTENANCE and GRINDING MAINTENANCE UNITS. WFSP also places extra management focus on our HSE compliance obligations and have an established HSE Unit that cross-manages HSE management operations for the entire SBU. Our Crushing Maintenance Unit (CMUnit) manages operational business units across our maintenance services portfolio – ¤Crusher Plant Maintenance ¤Feeder Plant Maintenance and ¤Conveyor Plant Maintenance. Through our CMUnit we partner with clients to ensure optimal crushing capability to reduce the particle size
of run-of-mine (ROM) ore to such a level that grinding can be carried out until the valuable mineral (gold/copper bearing minerals) and gangue are substantially produced as separate particles.
Our expertise covers all components to the crusher circuit including: ü ü ü ü ü ü ü ü
Crusher wear parts Feeder wear parts Lubrication systems Visual inspections Vibrating screens-all types Conveyor skirting and adjustment Conveyor belt repair/ change out Electrical & instrumentation maint/repairs.
3 • We also provide expert maintenance across all additional and optional equipment for crusher operations: • Rock breaker • Overhead crane • Freight elevator • Service air compressor • Sump pumps • Air vacuum clean up systems • Rock grapple • Conveyor belt magnets • Conveyor belt metal detectors • Belt monitoring systems • Belt feeders • Screw feeders • Bin ventilators • Dust collection/suppression system • Eccentric trolley removal cart • Man-lift elevator • Air cannons • Water booster pumps • Service trolleys • Conveyor gravity take-up service winch • Conveyor belt rip detector • Conveyor belt weigh scales • Vibratory feeders • Lime/cement silos • Sampling stations.
Primary crusher general maintenance Jaw crushers provide much of the primary crushing (along with gyratory crushers) at the commencement of the ore processing circuit and therefore perform a vital first stage ore breaking function to the communition process. Gyratory crushers are another popular primary stage plant for most large mining operations, which depend on gyratory crushers to reduce the material to a manageable size suitable for the crushing or processing plant.
Through our partner alliances, we team with clients to implement comprehensive maintenance, repairs and overhauls. Primary crusher general maintenance Jaw crusher plant maintenance, repairs and overhauls - within our CMUnit -Crusher Plant Maintenance, we team with clients’ crusher operators to implement comprehensive asset management programs including general scheduled maintenance as well as undertake required repair and overhaul services (removals/installations): þ þ þ þ þ þ þ þ þ þ þ
Stationary Jaw Die Replacement Stationary Jaw Die Key Replacement Swing Jaw Die Replacement Swing Jaw Guard Replacement Cheek Plate Replacement Flywheel Pulley/Sheave Tension Rod Toggle and Toggle Seat Replacement Thrust Shaft Hydraulic Adjusting Cylinder Replacement Swing Jaw.
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Our Crushing Maintenance Unit -Crusher Plant Maintenance provides effective asset maintenance services to deliver operating benefits to clients.
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Primary crusher general maintenance Gyratory crusher plant maintenance, repairs and overhauls –we provide full programmed maintenance and general repair services through our CMUnitCrusher Plant Maintenance. We provide effective asset maintenance services to deliver operating benefits (optimized performance/reduced downtime/less costs) – through additional focus around: ! ! ! ! !
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Spider bushings – we ensure optimal clearances and regular lubrication for main shaft integrity Hydraulic cylinders – we conduct regular balance checks of the cylinder nitrogen pressure for main shaft performance
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Concave liners – we ensure minimal reline changes through attention to vertical/horizontal spacing and effective fastening of back material (where designed)
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Lubrication plans – we comply strictly to OEM oil specifications and service schedules
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Spider installations – we ensure OEM procedures for correct pre-assembly/reassembly operations are carried out
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Pinion-shaft assembly maintenance – we adhere to proper installation procedures for replacing primary relief valves and lubrication of pinion assembly.
Rebuilding and hard-facing- gyratory crushers - in addition to general preventative maintenance to primary crushers, we also provide specialized welding maintenance services. We observe industry standards for monitoring of wear, warpage and employ applicable alloy selection, to assist clients economically maintain their crushers: ✔ We apply proper wear thresh holds (50% remaining manganese) to gyratory mantle and bowl liners before we initiate rebuilds ✔ Where possible, we rebuild mantles on extra shafts to increase the economic life of gyratory crushers, eliminating costly need for rezincing or re-Nordbacking and (where possible) we apply automatic welding techniques. Secondary/tertiary crusher maintenance Roll crusher plant maintenance, repairs and overhauls –another service provided through our CMUnit- Crusher Plant Maintenance, is our support to clients is our service and repairs to their secondary stage crushing assets. We implement preventative maintenance programs to OEM specification standards on all maintenance and repairs:
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Roll crusher plant maintenance, repairs and overhauls inspection program: þHammers þInside liners þBolts þRotors þScreen grates þBearing housings þLubrication systems þHydraulic systems þAuxiliary equipment þHigh wear points þDrive components þMaterial flow þOil gauge ports þAir relief valves þWelding/hard surfacing þDrive system þFlexible coupling þGuards and shields.
Secondary/tertiary crusher maintenance Cone crushers plant maintenance, repairs and overhaul – our secondary & tertiary crusher plant management programs extend our maintenance capabilities across the spectrum of our clients’ crushing assets. Through our CMUnit- Crusher Plant Maintenance, our experienced maintenance teams support clients to boost production performance and product quality performances. We undertake scheduled servicing, maintenance and repairs on all components: ✓Bowls and hoppers ✓Hydraulic Adjustment Motor ✓Main Shaft ✓Gear and Pinion ✓Countershaft ✓Eccentric Thrust Bearing ✓Eccentric Bushing ✓Tramp Release Assembly ✓Locking Bolt
Rebuilding and hard- facing roll impact crushers Our highly experienced welders apply (where possible) automatic and semi-automatic welding processes as required for manganese steel-produced crusher roll shells, impactor bars and other reduction components otherwise we follow recommended welding practices for other base metals:
• In partnership with clients, our welders develop a regular schedule for roll maintenance (preventative) • If wear is below standard specifications, we apply recommended build-up weld patterns on rolls using matched alloys • We apply industry standards to roll hard facing (7080% overlay wear), before restoring to size with recommended alloys.
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Maintenance safety We implement mandatory safety procedures in all our crusher maintenance and repair operations – in meeting our compliance obligations to each stakeholder- mining clients, WFSP internal safety management plan and OEM safety procedures .
Within our HSE Unit - our compliance programs are implemented across multiple jurisdictions– WFSP HSE policies/procedures, clients site based regulations/guidelines and plant specific OEM safety procedures: þ Hazards /advisory statements þ Lockout/Tag out standards/procedures þ OEM pre-start/operating procedures þ OEM machinery installation safety þ OEM Maintenance and repair safety þ Hoisting and handling safety.
Maintaining apron (crawler tractor-type) feeders A key focus within our CMUnit –Feeder Plant Maintenance, is the preventative maintenance, repairs and overhaul of apron feeders, which we implement in supporting our clients to manage their circuit based assets. Our experienced teams undertake both scheduled (planned) shutdown maintenance services as well as unscheduled (emergency break downs) repairs: •
Repairs/maintenance on hydraulic and mechanical drive units on all feeders including both drive and power units
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Head shaft bearing and sprockets installations/removals/reversals
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Installation/removals of tail traction wheels
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Track chain installation/removals including links, pins, walls, wear plates, lube systems and bushing for tight sealing along with chain
take up tasks •
Undertake tasks for installation/removals of all impact rails, rollers, and pans including securing pans onto links.
Maintaining vibrating/grizzly feeders We also provide maintenance support for all vibrating and grizzly feeder plant utilized across all crushing stages (primary, secondary, tertiary). We provide preventative asset maintenance benefits to clients to reduce their feeder operating downtime and increase run of mine processing capabilities. We carry out all scheduled OEM service and maintenance operations and undertake major repairs and overhauls to all feeder (VF, VG, VFG, VFGB, VFGP) installations: ✔Installation/removal of springs and bars on all feeder units ✔Vibrating mechanism unit - sleeves replacement, stroke adjustments, eccentric shafts, roller bearings ✔Maintaining the motor base unit including shaft, bearing and belts ✔Remove/install coil springs ✔Remove/install/adjust grizzly bars ✔Remove/install wear plates.
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Our maintenance support for crushing plant, feeders, conveyors and belts, allows us to provide a complete ‘whole-of-circuit’ servicing capability.
Maintaining conveyor belts Conveyors belts are another key plant installation that we provide essential asset maintenance services on - we provide general (scheduled) servicing and maintenance to all conveyor installation and belts from within our CMUnit -Conveyor Plant Maintenance. Our maintenance support for mining operations conveyors and belts, allows us to provide a complete ‘whole-ofcommunition’ servicing capability: CONVEYOR IDLER INSPECTION þ þ þ þ þ þ þ
CONVEYOR IDLER MAINTENANCE
Regularly scheduled inspections of conveyor systems Locate and eliminate noticeable vibrations Check idler rolls are all turning freely and smoothly Remove and replace any rolls not operating properly Watch for unusual wear patterns on the idler rolls Check idler alignment and adjust as required Check for material build-up on idler rolls.
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Inspect the belt for breaks Center the belt on the idler Check material loading on the belt Adjust rubber skirts on chutes and skirt plates Adjust belt cleaners Check to see that all idler rolls are rotating Maintain OEM lubrication cycle/specifications.
Crusher Plant Maintenanc
Workforce South Pacific M: +61 498 613 986 (AUS) M: +675 7227 4392 (PNG) E: chris@spworkforce.com.au W: www.spworkforce.com.au
Feeder Maintenance
Conveyor Maintenanc
MINING MAINTENANCE Workforce South Pacific Limited is your crushing maintenance partner – delivering strategic asset maintenance services across the ‘whole-of-circuit’ plant infrastructure.