Manual IOM Molino Vertical

Installation Operation and Maintenance Manual
Instruction Manual for

CITIC Vertical Stirred Grinding Mill
CSM 1500 Vertical Stirred Mill

Customer: Codelco Chile
CITIC HIC Equipment Serial #2100-301/1

Codelco Equipment Serial #03320-MVX-001
01
O/C: 4501938640 - PM026 - CITIC HEAVY -
Proyecto S19A401
S19A401-PM026-074
CITIC Heavy Industries Co., LTD P.R. China 206 Jianshe Road Luoyang
www.citichmc.com o www.citic-hic.com Página 1 de 137
Content
1 General Information.................................................................................................................... 6
1.1 Operation instructions........................................................................................................... 6
1.2 Confidentiality declaration....................................................................................................6
1.3 Responsibilities..................................................................................................................... 7
1.4 Safety regulation................................................................................................................... 8
1.4.1 Environmental pollution.................................................................................................. 13
1.5 Communication address......................................................................................................13
1.6 Lifting, transport and Storage............................................................................................. 13
1.6.1 Lifting...........................................................................................................................13
1.6.2 Storage conditions........................................................................................................14
1.6.3 Storage period.............................................................................................................. 14
1.6.4 Open-package inspection and y acceptance................................................................ 14
2 Product summary...................................................................................................................... 16
2.1 Design calculation...............................................................................................................16
2.2 Stirred mill performance..................................................................................................... 16
2.3 Meaning of the product type............................................................................................... 16
2.4 Applicable product standard............................................................................................... 16
2.5 Suitable working condition and environment.....................................................................16
2.6 Mill design parameter......................................................................................................... 17
2.7 Summary of the primary structure of the equipment:.........................................................17
2.7.1 Feed pipe assembly...................................................................................................... 17
2.7.2 Liner assembly............................................................................................................. 17
2.7.3 Drive assembly.............................................................................................................18
2.8 Installation procedure..........................................................................................................18
2.9 Others.................................................................................................................................. 18
3 Installation................................................................................................................................. 19
3.1 Installation instruction.........................................................................................................19
3.2 Mill Specification................................................................................................................20
3.3 Tool, Equipment and Manning List.................................................................................... 21
3.4 General description............................................................................................................. 24
3.5 Transportation..................................................................................................................... 27
3.6 Use of Drawings..................................................................................................................38
3.7 Wearing Parts...................................................................................................................... 38
3.8 Recommend Spare Parts according to Table 3.8................................................................ 38
3.9 Specification........................................................................................................................39
3.10 Protection of the Mill parts during storage......................................................................... 39
3.11 Storage of full assemblies................................................................................................... 40
3.12 General properties description............................................................................................ 40
3.13 Working principle................................................................................................................41
3.14 Foundation...........................................................................................................................43
3.14.1 Installation procedure.............................................................................................. 43
3.15 Installation...........................................................................................................................44
3.15.1 General Instruction.........................................................................................................44

3.15.2 Bottom Shell Installation............................................................................................... 49
3.15.3 Completion..................................................................................................................... 55
3.16 Bottom & Upper Shell Assembly....................................................................................... 55
3.17 Drive Frame Assembly........................................................................................................58
3.18 Intermediate shaft assembly................................................................................................62
3.19 Door Installation..................................................................................................................64
3.20 Installation of the Hydraulic Door Jacks............................................................................ 65
3.21 Automatic Grease Assembly...............................................................................................67
3.22 Installation of the Automatic Grease Assembly................................................................67
3.23 Magnetic Liner Segments Assembly.................................................................................. 73
3.24 Screw Liner Assembly Procedure.......................................................................................78
3.25 Screw installation procedure...............................................................................................79
3.26 Control Philosophy............................................................................................................. 83
3.26.1 Mill Drive Motor......................................................................................................83
3.26.2 Gearbox....................................................................................................................83
3.27 Maintenance Frame.............................................................................................................87
3.28 Screw Shaft Assembling..................................................................................................... 87
3.29 Screw Shaft, Digging Shoes & Flyghts Installation........................................................... 87
3.30 Screw Shaft Installation.................................................................................................... 87
3.31 Bottom Shell Assembly.......................................................................................................89
3.32 Performance features...........................................................................................................90
3.33 Technical performance........................................................................................................ 90
3.34 Upper Bottom Shell Assembly............................................................................................91
3.34.1 Structure and Composition of the Shell Assembly..................................................91
3.35 Top & Bottom Shell Assembly and Disassembly...............................................................92
3.36 Check all bolts after installation......................................................................................... 94
3.36.2 Bolt Installation Method............................................................................................94
3.37 Recheck............................................................................................................................... 96
3.38 Main Motor.........................................................................................错误！未定义书签。
3.38.1 Main motor assembly.................................................................... 错误！未定义书签。
3.38.2 Flexible coupling assembly high speed.........................................错误！未定义书签。
3.38.3 Planetary gearbox assembly.......................................................... 错误！未定义书签。
3.38.4 Low speed coupling assembly....................................................... 错误！未定义书签。
3.39 Service tools........................................................................................错误！未定义书签。
3.40 Gearbox lubricating systems.............................................................. 错误！未定义书签。
3.41 Operation of the lubrication system................................................... 错误！未定义书签。
3.42 Temperature control lubrication system............................................. 错误！未定义书签。
3.43 Assembly of the gearbox lubrication system..................................... 错误！未定义书签。
3.44 Commissioning and Operating Instruction for gearbox lubrication system错误！未定义书
签。
4 Commissioning...............................................................................................................................98
4.1 The preparation and checks before the trial run of the mill............................................... 98
4.1.1 Mechanical Unit.......................................................................................................98
4.1.2 Electrical Unit.............................................................................................................. 99

4.1.3 Gearbox lubrication station..........................................................................................99
4.1.4 Commissioning Auditory............................................................................................... 100
4.2 Trial Run............................................................................................................................100
4.2.1 Idle Test Run.......................................................................................................... 100
4.2.2 Tightness test of the mill:...........................................................................................101
4.2.3 Trial run under 30% load........................................................................................... 102
4.3 Data Records for trial run..................................................................................................104
4.3.1 Trial Run Condition....................................................................................................... 104
4.3.2 Trial run items............................................................................................................ 104
4.3.3 Vibrations record........................................................................................................106
5 Operation...................................................................................................................................... 108
5.1 Process description............................................................................................................108
5.2 Mass balance..................................................................................................................... 109
5.2.1 Design values............................................................................................................. 109
5.3 Control system...................................................................................................................112
5.4 Normal procedure for starting and stopping the mill........................................................113
5.4.1 Starting sequence........................................................................................................113
5.4.2 Stop sequence.............................................................................................................116
5.4.3 Short-term shutdown stand-by...............................................................................117
5.4.4 Long-Term Shutdown................................................................................................ 117
5.4.5 Failure shut down....................................................................................................... 118
5.4.6 Emergency stop.......................................................................................................... 118
5.5 Normal Operation..............................................................................................................119
5.5.1 Adjustment of mill load and output........................................................................... 119
5.5.2 Mill Power Control.................................................................................................... 120
5.5.3 Pressure control and percentage of solids to cyclones.............................................. 120
5.5.4 Water dosing processes to tanks feeding cyclones.................................................... 121
5.5.5 Lime dosage in the cyclone underflow...................................................................... 121
5.6 Instrumentation and interlocks..........................................................................................122
5.6.1 Motor interlocks............................................................................................................. 122
5.6.2 System grease interlocks................................................................................................123
5.6.3 Lubrication system interlocks........................................................................................ 123
5.7 Control Principle............................................................................................................. 123
6 Maintenance.......................................................................................................................... 124
6.1 Maintenances plan.............................................................................................................124
6.1.1 Main activities........................................................................................................125
6.1.2 Detention strategy.................................................................................................. 127
6.2 Troubleshooting................................................................................................................ 128
6.2.1 Motor failures...........................................................................................................128
6.2.2 Gearbox failures.....................................................................................................128
6.2.3 Intermediate shaft failures..................................................................................... 129
6.3 Component Changes......................................................................................................... 130

6.3.1 Motor change......................................................................................................... 130
6.3.2 Gearbox change..................................................................................................... 131
6.3.3 Screw liners change............................................................................................... 132
6.3.4 Ball load extraction................................................................................................134
6.3.5 Magnetic cladding change..................................................................................... 136
6.3.6 Intermediate shaft lubrication system drum change..............................................137
1 General Information
1.1 Operation instructions
The sections in this manual are compiled according to the installation sequence of the
mill. Before installing the mill, the whole content of this manual must be read and
understood, to ensure a successful installation. The content of this manual includes
installation, commissioning and operation, mill maintenance, after sales service and
additional information for safe operation.
The storage, handling, transport, commissioning, operation and maintenance of the
equipment must comply with the requirements of this manual. Before using the
equipment, the relevant personnel must read and understand the content of this
manual to ensure correct, effective and safe operation. This manual must be regarded
as part of the equipment and properly preserved.
This equipment can only be operated by trained and qualified personnel.
The operators will need to understand all the functions and warning messages of the
equipment. In order to understand and interpret any emergencies that may arise; all
operators must take part in operational training,
The installation, operation and maintenance of this equipment can be only performed
by trained and approved personnel.
Unqualified personnel must not operate this equipment as personal injury or
equipment damage may occur.
1.2 Confidentiality declaration
This Manual, and the information contained within is confidential to CITIC HIC and
must not be used, copied or disclosed (manually or electronically) in whole or part
without the expressed written permission of CITIC HIC.
The information in this manual is owned by CITIC HIC only, and is issued for
customer use only.
The attached contents including drawings and pictures are copyright to CITIC HIC,
and cannot be copied, duplicated, exhibited or sold.
1.3 Responsibilities
CITIC HIC reserves the right to alter this information as required without notice. In
regard to this document, and the product described, CITIC HIC will not be
responsible for any errors or omissions on technology and editing and will not be
responsibility for any accidents and losses caused due to the use of this document.
THIS MANUAL IS FOR REFERENCE USE ONLY.
CITIC HIC cannot predict all the conditions that may occur during installation and
operation of this equipment. This manual does not include all possible technical and
safety information. If there is any doubt during installation and operation, please
contact CITIC HIC.
The composition and configuration of the plant is the buyer's responsibility.
If discussions’ relating to the configuration or any other aspect of the CITIC supplied
equipment is required; contact our company's projects department or product
application engineers.
CITIC HIC will not take any responsibility for any personnel injury, equipment
damage or property loss caused by the incorrect operation and non-maintenance of the
equipment that is in violation of the requirements noted in this manual.
Any alterations and or modifications of the equipment must be approved in writing by
CITIC HIC. CITIC HIC will not be held responsible of any injury, loss of life and or
equipment loss or damage or any other losses through the use of this equipment.
Without prior written permission, CITIC HIC will not allow any modifications to the
equipment. All modifications on the equipment configuration and structure shall be
carried out by CITIC HIC or the personnel appointed by CITIC HIC.
CITIC HIC will not take any responsibility for any personnel injury or equipment loss
or other damages caused by the use of repaired, refurbished and or use of non-genuine
spare parts.
1.4 Safety regulation

 The design and manufacture of this equipment conforms to regulatory safety
standards and is safe under the correct operating conditions. We consider the
operator’s safety as most important during design. If the equipment is not
operated correctly, not used for the intended purpose suitable application or
operated by unqualified personnel, the equipment has the potential to cause
injury and or damage.
 In view of the safety concerns for your personnel, please read this manual
carefully, and get to know the purpose, limit and relevant potential danger of
this equipment.
• The dangers caused by the following conditions have the potential to
cause serious injury, death and or equipment damage:
• Incorrect operation or operated by unqualified personnel;
• The equipment is used in a manner for which it was not designed;
• Incorrect or faulty installation;
• Failure of power supply;
• Incorrect repairs or maintenance fault;
• Changing data and or operational parameters;
• Use of non-genuine or refurbished spare parts;
• Not adhering to the procedures outlined in the manual;
• Unexpected accidents.
 The operator of the equipment must clearly appoint the persons in charge of
start, operation and maintenance, and must ensure the equipment is to be
operated only under safe working and operational condition.
 Operators or qualified personnel must repair all damage to the equipment and
its ancillaries in a timely manner. If the fault or damage is critical then the
equipment must be shut down by following the correct shut down procedure.
 Unqualified personnel and or non-inducted visitors shall remain behind safety
guarding/fencing at all times.
 During handling and installation, the carrying capacity (SWL) of the lifting
gear must be sufficient to bear the weight of the equipment.

 Signs or labels related to product safety must be clearly displayed, checked
and cleaned regularly. If they cannot be identified within a reasonable distance,
they must be replaced.
 Before each start, all the safety mechanisms must be checked, and all the
protection devices must be operational. If there is an idle/fault condition found
on any safety device, the device must be replaced; if the faulty device cannot
be replaced immediately, the equipment must not be started or must be
stopped.
 Before starting the equipment, clear the area of all equipment, tools and
possible dangerous items that may harm the operators.
 Shut down the equipment prior to any work being performed. All the rotating
parts have to be fully stopped and all energy sources to be locked out in order
to avoid an accidental start up (lockout padlocks and warning signs to be
placed on the main switch and all other energy sources), guards or cover plates
are not to be removed or opened until approved by senior supervisors and
maintenance must not be performed until the equipment has been rendered
safe, stopped and all safety lock outs are in place, checked and signed off.
 Equipment components and safety mechanism must not be removed modified
or bypassed.
 This equipment must not be used in an unsafe condition.
 The work area shall be well lit, free of debris, cleaned of all oil and grease to
provide a safe working environment.
 Lightening arresters must be correctly fitted to any structure to protect the
equipment.
 The operating speed of the equipment is to be within the design parameters
and not to be exceeded.
 All personnel working on the equipment must wear personal safety equipment
and (hair nets if required).
 The working area is to be kept clean and free from debris and rubbish. Failure
to do so may be an infringement upon safety regulations. All safety and guide

signs on the equipment must be clearly visible and kept clean.
 For design and installation of the stair, passageway and platforms: refer to
local regulations and the CITIC HIC annexure. All access doors which allow
entry into the equipment and its ancillaries must be fitted with bolted access
covers and or appropriate guarding. Entry to maintenance and service areas
must be restricted to authorized personnel only.
 Always wear personal protective equipment (PPE’s), Dependent on the work
environment it will be required to wear gloves, protective collision pads,
safety helmet, dustproof mask, safety glasses and ear protection. Breathing
masks or other respiratory safeguards should be used if personnel are exposed
to paints, adhesives, or cleaning agents that will probably cause a respiratory
health hazard.
 The emergency treatment and first aid telephone number shall be marked near
the work area.
 Prior to an emergency situation; the operators are to have first aid and the
firefighting/extinguisher training and must know the location of first aid kits
and fire extinguishers.
 A lifting mechanism must to be utilized when handling/lifting heavy
components prevent personnel injury.
 If the feed chute becomes blocked, follow the shutdown procedure, stop the
equipment and lock out all energy sources to ensure no accidental start up.
Ensure safe working procedures are adhered to when unblocking the feed
chute.
 After shutting down the equipment, ensure that all energy sources are locked
out, potential energy released and equipment tagged.
 The permissible noise level is determined by the statuary regulations and local
authority standards. If noise levels exceed the nominated, correct and
approved Dba hearing protection must be worn.
 The equipment must not be started under any emergency condition.
 Only after the energy sources have been locked out can the maintenance,
cleaning and disassembly of the equipment be performed.
 The equipment is to be provided with the correct maintenance, such as
lubrication and adjustment, but the maintenance must not be performed whilst
the equipment is operating.
 It is recommended that only parts supplied by the OEM (CITIC-HIC
recommended parts) be used.
 A daily log of maintenance/service work is to be completed for future
reference.
 The Floor around the equipment must be made of non-flammable material.
 Protective guards have been supplied to protect personnel from the injury
while the equipment is operating. These guards must be correctly installed and
in place at all times when the equipment is operating. Warning signs must be
posted to warn personnel of any potential hazard. If a hazard is noted it must
be immediately reported to the supervisor.
 Prior to any maintenance; check the equipment to ensure it is not pressurized.
Depressurized equipment as necessary ensuring correct procedures are
followed. Do not relieve pressure in the direction of personnel.
 During installation and disassembly, the technical methods and protective
measures specified in this manual can ensure safety for personnel, property
and surroundings.
 The operator must ensure the storing and operating area, room and building for
the equipment meet the safety requirement specified in this manual and must
provide good ventilation.
 The instructions for disposal of the hydraulic oil and or lubricants must strictly
follow local authority regulations in order to prevent any pollution of the
environment.
 After the initial installation, if the user makes modifications to the equipment
approved by CITIC-HIC in writing, the information in the manual must be
upgraded.
 The equipment operators must undertake training in order to familiarise

themselves with the safe operation of the equipment.
To also understand the relevant dangers and the preventive measures for
correct operation of the equipment.
 The relevant extracts from this manual shall be placed near to the control panel
of the equipment in a durable form and the date of issue shall be marked.
 When starting the equipment; ensure there are no maintenance personnel
working on the equipment. Personnel who will be working on the equipment
must sign in on the register. The equipment is to be tagged and locked out
using locking devices to lock the main switch so as to prevent accidental start.
Upon completion of work; personnel must sign out on the register and remove
their personal “Danger Tags” and or “Locks”
 Electrical equipment must be properly earthed and personnel working with
electrical equipment must follow ISO standard electrical safety precautions.
When welding on or around the mill, the welded piece must be properly
earthed.
DO NOT use the ground point of the system. Electric currents are not
allowed through the mill system. Bearings on motors and pumps can be
easily damaged by incorrect earthing during welding.
Lift and handle the components safely, when lifting the equipment components
the size and weight of the each section must be checked to ensure the safety of
both the equipment and personnel. Lifting apparatus must be checked prior to
lifting any equipment and must be passed by trained personnel specializing in
rigging and crane operations. Estimated weights of components can be found
on the assembly drawings in this manual.
Areas for lifting must be clearly marked and kept clear during lifting and
handling. Warning bells and/or sirens are recommended to alert personnel at
site during lifting.
1.4.1 Environmental pollution

If some material used conflicts with the environmental pollution regulations please
eliminate such material according to the regulations.
If an authorized industrial waste collection and disposal company is contracted, it is
the operators’ obligation to ensure the waste material is disposed of according to local
regulations.
1.5 Communication address

Services & Spare Parts:
CITIC Heavy Industries Co., Ltd.
Address:
AV. Cerro El Plomo 5931, office 1411
Las Condes, Chile.
Telephone: +569 4435 8104
63 Parramatta Road
Australia
Service after sale Tel：+61 2 9737 5600
Fax： +61 2 9737 0133
Website in English:
Http://www.citic-hic.com
Website in Chinese:
Http://www.citichmc.com
webmaster@citichmc.com
1.6 Lifting, transport and Storage
1.6.1 Lifting
 The lifting and transport of the equipment must be performed according to the
local requirements and governing bodies.
 There are lifting holes located on the major sections.
 During lifting, the machined surface of the equipment shall be protected from
impact, the equipment shall be protected from deformation, and the packaging
shall not be damaged.
1.6.2 Storage conditions

 The packed goods shall be stored in a dry ventilated area.
 If the area of the warehouse is sufficient, the packed goods shall not be stacked;
if stacking is required, the upper package's weight shall not exceed 0.5 to 0.8
times the lower package's weight, and the upper package's dimension shall be
equal to or smaller than the lower package's dimension.
 No packaging shall be placed or stacked upside down, and the symbols on the
packages shall be put in positions that are easy to observe.
 The packages for electrical instruments, lubrication equipment and their spare
parts shall not be stacked or placed upside down; they must be stored in a dry
enclosed area.
 Unenclosed or unpackaged equipment may be stored in the open or in the
warehouse with regard to their weather protection level and final assembly
requirements. Unpackaged equipment shall not be stored on top of each other.
 If the equipment needs to be stored in the open, the rain-proof and rust-proof
packing must be checked to see if it is in good condition. Additional rain-proof,
rust-proof and theft-proof measures shall be taken to protect the equipment.
1.6.3 Storage period

Before leaving the factory, unenclosed equipment is protected with the anti-rust oil
which has a life of 12 months. If this period is exceeded, or during this period the
equipment packages is subjected to high humidity, frequent rain, flood or other
corrosions, the packages shall be opened and the contained goods shall be checked,
then repacked with anti-rust protection.
1.6.4 Open-package inspection and y acceptance

After the equipment arrives on site, the open-package inspection shall be performed
within 15 days, the user will inform the manufacturer 7 days prior to the inspection,
the open-package inspection shall be performed by the two parties together, and then a
detailed record of open-package inspection must be signed by the two parties.
After the goods arrive at the appointed station, if there is damaged packaging
discovered, the user must inform the manufacturer immediately and investigate
possible causes of the damage and report the findings to CITIC HIC within 10 days
and provide a report to the insurance company within ten (10) days. If deemed
necessary the manufacturer will appoint personnel to attend site and make a detailed
inspection record with the customer.
2 Product summary
2.1 Design calculation
Note: These specifications are provided for reference only. They were used as design
criteria for the engineering of the grinding system. They do not represent any
guaranteed or warranted outputs or capacities.
Material Processed: Copper concentrate.
CITIC-HIC recommends Cylpebs for the grinding media. Ball charge to be supplied
by customer
Recommended initial load:
Ball Size = 25mm Weight = 175.000 kg
2.2 Stirred mill performance
The Semi Autogenous Grinding (SAG) or Autogenous Grinding (AG) or Ball mills
are used to pulverize mineral ore or other material after it has been crushed to a
nominated particle size by passing through a crusher or similar reduction equipment.
The purpose of the “Stirred Mill” is to obtain a reduced particle size for tertiary
grinding. The “Stirred Mill” is widely used in many industries, such as mineral
concentration, metallurgy, construction and chemical industry. It has many desirable
features including high reduction ratio, high reliability, high adaptability and high
capacity.
2.3 Meaning of the product type
CSM1500 Vertical stirred mill
 CMS: CITIC Stirred Mill
 1500: 1500 kW
2.4 Applicable product standard
The performance of this mill shall conform to the ISO standards.
2.5 Suitable working condition and environment.
Installation condition: Outdoors
Ambient temperature: Range from 0 to 40℃
Altitude: 1500 meters above sea level
Working duty: Continuous
2.6 Mill design parameter

Refer below table:
ÍTEM Data Unit Value

1 Shell Inside Diameter mm 4.800
2 Shell Length mm 4.780

3 Shell Effective Volume m3 95
4 Spiral Rotating Speed r/min 17,6
Power kW 1.500
5 Main Motor Speed rotation r/min 740

Voltage V 3.600
Frequency HZ 50
Quantity 1
6 Model P2NB34
Main Reducer
Transmission ratio 42,353
2.7 Summary of the primary structure of the equipment:

The equipment consists of the following: - shell assembly, magnetic liner assembly,
gearbox, main motor, couplings, reducer lubrication station, drive shaft bearing grease
lubrication station and ancillaries.
CITIC HIC also supplies equipment for installing and maintaining the mill, including:
Screw installation frame, screw installation rails and trolley, hydraulic screw elevation
system, hydraulic power pack, hydraulic torque wrench and all necessary hoses,
fittings, valves and controls.
2.7.1 Feed pipe assembly

Supplied by customer.
2.7.2 Liner assembly

The mill shell is fitted with magnetic liners to which the steel shot attaches to create a
non-wear liner surface which also protects the body of the mill against abrasive wear.
2.7.3 Drive assembly

The drive assembly consists of the main motor, couplings, gearbox, intermediate shaft,
bearings and seals.
The mill is fitted and supplied with a three phase squirrel cage rotor induction main
motor 1500 kW, 50 Hz, 3600 V, 740 rpm. The main drive motor is fitted with
manually lubricated motor bearings.
The gearbox is supplied with a stand-alone oil lubrication system.
The driveshaft is equipped with a grease lubrication station that feeds grease to the
bearings at set intervals.
The customer is responsible for the external pipe installation and layout.
2.8 Installation procedure.
Installation of this mill requires following the same good practices as in the erection
of all types of machinery:
A. Strict adherence to assembly drawings is mandatory.
B. Attention must be paid to proper sub-foundations.
C. Parts must be cleaned and inspected prior to assembly.
D. Parts requiring lubrication must be lubricated.
E. E. Alignment of assembled parts must be correct.
2.9 Others
For the detailed information of main motor system, grease and oil lubricating systems,
main reducer and couplings; please refer to the respective instruction sections within
this manual and “IOM CITIC CHUQUICAMATA PART I y II_ES”, supplied in this
project.
3 Installation
3.1 Installation instruction.
The liners installed this equipment are magnetic. Personnel with cardiac
pacemakers should avoid handling liners and keep clear of magnetic fields.
Electronic equipment such as:
• Phones
• Smart cards
• Credit cards
• Computer disk
• Video, audio and computer tapes
• Computer equipment
Must not come into close contact with magnetic fields.
Keep electronic equipment away from any magnetic field or source.
The instruction manual aims at providing technical guidance for beginners and a
technical reference for the experienced operating personnel. Carefully read this
manual and keep for future reference. The diagrams and instructions in this manual
can guide the operating personnel to carry out appropriate inspection, installation,
operation and maintenance on the mill and its ancillary equipment.
The manual only contains basic operating techniques, which will help technical
personnel to understand the mill and its operation; in place of formal training.
Personnel can gradually improve their skills and master more operating techniques.
Some revised information may not be included in this manual as the design of the
product is updated and upgraded. If conflict arises during actual operation, we will
update and add required information or make some appropriate modification in the
following edition.
CITIC-HIC reserves the rights to terminate the production of this model, modify its
specification or design without prior notice, and does not undertake any consequent
responsibility or liability. This manual is valid on the completion date of its
publication.
If you have any question about the mill or the manual, please contact CITIC-HIC or a
local office to obtain the latest applicable information.
This manual is an overall guidance and general instruction about the technical
specification. For all the necessary technical instructions for the actual equipment
please refer to the installation drawings and technical data provided with the specific
models.
3.2 Mill Specification.
Mill Designation: Stirred Media Grinding Mill
Equipment Tag Number: CITIC-HIC #2100-301/1
(Serial Number)
Screw Speed: 17.6 RPM
Screw Rotation Direction: Clockwise (viewed from the top)
Speed Reducer Size and Type: P2NB Gear Reducer, size 34 with external lubrication
system
Speed Reducer Ratio: 42.353: 1
Mill Drive Motor Size & Speed: 1500 kW, 3600 V, 50 Hz, 740 RPM
Drive Motor Power Draw: 100%
(at recommended speed and ball charge)
Grinding Media: Steel Grinding Shot
Recommended Shot Size & Weight Distribution (shot charge by customer)
Shot Size: Refer to the Process Data Sheet for ball size chart
Shot Charge Volume: 40% maximum (based on mill volume)
THIS MANUAL IS FOR REFERENCE USE ONLY.
3.3 Tool, Equipment and Manning List.

It is the responsibility of the erector to provide suitable tooling, rigging and lifting
equipment. CITIC HIC does not provide any tooling, rigging or lifting equipment.
Prior to beginning the erection all available drawings should be reviewed and the
tooling list checked to ensure all required equipment is on site.
The erector must advise CITIC-HIC’s technical advisor in writing all lifting and
rigging equipment to ensure it all complies with all relative safety regulations and is
of a capacity required to lift all of the equipment safely.
It is the erectors responsibility to discuss with the CITIC HIC technical advisor the
detailed fitting and sequence of the installation and comply with the requirements of
all relevant documents, standards, equipment drawings and all other technical
requirements.
The manual is a guide for the correct fitting/assembly of the mill, and again we
recommend all relevant stakeholders should read the manual to have a clear
understanding of the requirements for assembling and commissioning this equipment.
Approximate Manning and Tooling List:
Manning Level
 2 millwrights
 1 surveyor
 1 Licensed and qualified electrician
 3 to 4 fitters with welding and piping skills
 3 to 4 licensed and qualified riggers
 3 to 4 licensed and qualified scaffolders as required
 10 to 20 trades assistants – site decision on manning levels
The following is a list of the common tools required for mill installation; the erection
company to supply all tools. CITIC HIC will not supply any of the items listed
below. Standard lifting devices and mounting accessory units are provided by the
customers engineering company or the contracted mill erection company and are not
listed in the following table:
Tooling List – Customer Supply

 Calibrated high accuracy optical (dumpy) level – (Leica NAK2 with GPM6 scale
accuracy to 0.2mm/10m and Invar staff is readily suitable for this type of work)
 Calibrated theodolite – electronic preferable - manual if not available
 Check CITIC drawings for specific A/F bolt sizes
 Flogging spanners to suit M36, M42, M48, M56 and M64 hex nuts. Check CITIC
drawings for specific A/F bolt sizes
 2 – 4kg Sledge hammers
 Ratchets handles and extensions for sockets – ¾ to 1" drive
 100 - 150mm feeler gauge set – 0.04mm minimum size required
 300mm feeler gauge set – 0.04mm minimum size required
 300mm feeler gauge set – 0.04mm minimum size required
 Number and Letter metal stamps – 8mm and 10mm
 Calibrated machinist’s level – 150mm minimum @ 0.02mm/m
 Machined and ground parallel strips 300mm long x 50mm wide x 25mm thick
 Stainless steel bevels (straight edges) 1 @ 0.6m, 1@ 1.2m, 1 @ 1.8m – the width of
the straight edge to be 65mm
 1 off 0-25mm, precision @ 0.01mm micrometer
 1 off – 600mm Vernier calliper
 1 off – 300mm Vernier calliper
 Small inside screwed adjustable callipers 100m – 150mm length for checking saddle
to slipper bearing clearance
 2 off - Plumb bobs with a minimum weight of 0.3kg – 0.35kg
 1 off - Calibrated 30m steel tape with 5kg spring balance
 2 off - 10m steel tape measures
 2 off - Engineers square 150mm & large square 600mm
 2 off - Engineers 300mm adjustable square
 2 off - Tungsten tip scriber
 12 off - Flat combination oil stones
 10 off each - Files – round, half round - 2nd cut and smooth cut with handles
 20 to 30 litres cleaning solvent such as Acetone

 50 kg of cleaning rugs
 General fitters tools such as spanners & screwdrivers, electrical screwdrivers,
hammers, cold chisels, tape measures, 1.5 kg club hammer and other hand tools
 Scabbling tools – hand, electrical or pneumatic driven
 Scraping tools
 Lifting chains and slings – of various sizes to complete installation refer to CITIC
manual and drawings for approximate loadings.
 Cranes to lift equipment as required, Check CITIC drawings for loadings.
 50mm cello tape for meshing checks
 Molybdenum disulphide paste for shell and head bolts
 Scaffolds for mill access and cleaning.
 Welding equipment
 Stainless steel shim for packing base plates – 0.05, 0.10, 0.25, 0.30, 0.50, 0.75, 1.00,
2.00 and 3.00mm. Stainless steel shim less than 0.75mm supplied in 300 x 5m rolls.
Stainless steel shim over 0.75mm supplied in 1500 x 1800 sheets
 Oxy acetylene kit
 Power tools (With Safety Tag) – pistol drill with 13mm chuck, hammer drill with
8mm,10mm,13mm and 14mm tungsten tip concrete drills, rotary hammer, 125mm
angle grinder with grinding and nylon buffing wheels
 Die or pencil grinder with rotary burrs.
 Infra-Red Temperature (IR) gun
 Multimeter
 10 off rolls of Denso tape™ – (rust preventive wrapping tape for foundation)
 5 off - tarpaulins 4m x4m and plastic sheeting in 4m wide roll
 24 rolls - Duct tape
 8 off Rolls each - emery cloth P220, P120, P80, P40 and 4 off packets each- Wet and
dry paper 1500, 600, 120 girt
 Filtered high pressure air supply (8 Bar) with blow gun and minimum 30m of Ø16mm
hose
 High pressure air supply (10 Bar) capable of delivering 10.5 to 13 m³ per minute with
30m of Ø25mm hose for cleaning plinths and concrete surfaces
 4 off – M10 turn buckles with hooked ends for tensioning piano wire centrelines
 4 off – M25 turn buckles with plain ends for general lifting and moving
 Cutting shears for shims – bench top model best suited for this application
 2 sets - Two way hand held radio communication for communication between
operators and observers
 Ladders – 5m
 2 off - step ladders – 1.8m
 Nitrile rubber gloves for cleaning
 100m x 0.5mm piano wire
 Laser Alignment equipment
 25 to 50 litres of Acetone
Electrical
 Electrical power for running equipment.
 3 phase MCB 4 Amps, 6 Amps, 20 Amps and 32 Amps
 1 phase MCB 4 Amps and 15Amps
 RCD Single and Three phase
 5 off - Extension Leads – 15m for each load rating with safety
3.4 General description
Drive Assembly
Drive Frame
Drive Shaft Assembly
Screw Shaft
Upper Shell Assembly
Shell Door
Bottom Shell Assembly
Door Open Tool
Magnetic Liner Screw Liner
3.5 Transportation
For transportation, the stirred mill can be dismantled into several sections, which are
then transported as separate packages.
The assembly of parts depends on transport limit conditions and site lifting capacity,
generally, including bottom shell, top shell, screw shaft, gearbox, main motor and
ancillaries.
3.6 Use of Drawings

All the part names and part numbers in the instructions are referred to as an "item".
Each stirred mill is equipped with a spare parts list.
After the stirred mill is shipped, the spare parts list is sent separately, listing all the as
built items, quantity of parts and recommended quantities.
The relevant drawings and parts list are used to order and replace spare parts and
consumables.
3.7 Wearing Parts
Wearing parts and replacement parts for the stirred mill are sold by CITIC HIC. When
ordering wearing parts, the following information must be attached:
1．Type, size and serial number.
2．Description and part number.
3．Quantity of each part.
4．Transportation mode; such as by courier, sea or air.
3.8 Recommend Spare Parts according to Table 3.8
Table: 3.8 Recommended Spare Parts List
Part/Drawing No. Quantity Recommended
Description
Quantity
Drive Motor Bare 1 1
Speed Reducer P2NB-34 1 1
High Speed Coupling 1 1
Low speed coupling 1 1
Reducer Filter Elements 2 6

Thrust Roller Bearing 294/530EM 1 1
Spherical Roller Bearing Radial 240/530ECA/W33 1 2
Axial Clamp Seal W6511030247 2 4
Lip Seal W6511030243 4 4
Seal W6511030245 1 1
Screw Assembly Bare A7555-1P 1 1
Digging Shoe Liner A7555-10 2 4
Flyght Liner A7555-6 6 16
Magnetic Liner 1140 1140
Note: Another complete screw with liners unit can be used as standby to avoid shutdown
delays.
3.9 Specification
The designation of the type is as shown in table: 3.9.
Tabla: 3.9 Designations
ITEM Data Unit Value

1 Shell Inside Diameter mm 4800
2 Shell Length mm 4780
3 Shell Effective Volume m3 95
4 Shaft Rotating Speed r/min 17.6
Quantity 1
5 Power kW 1500
Main Motor Rotating Speed r/min 740
Voltage V 3600
Frequency HZ 50
Quantity 1
6 Model P2NB34
Main Reducer
Transmission Ratio 42.353
Overall Dimensions (mm)
7 15371 H x 5600 W x 5505 L
3.10 Protection of the Mill parts during storage

During long-term storage of stirred mill parts, special protection shall be taken to
prevent damage.
1 ． Large fabrications (upper & lower bottom shell, top shell and screw) shall be
properly protected and stored indoor. They shall not be put directly on the ground but
on the chock or other support. Apply antirust oil to all the machined surfaces. For
further protection, fill crepe paper with oxidation inhibitor treatment in the cavities of
the drive frame. In addition, seal all the openings with a glued board cover. Seal all
the openings to prevent entry of dirt or water. Then wholly cover it with waterproof
tarpaulin and strap it to avoid to exposure to atmosphere and ultraviolet radiation.
2．Small castings (digging shoes and flyghts) can be stored outdoors. It is important
to protect the surfaces from corrosion and physical damage.
3．Motor, gearbox and ancillaries to be stored indoors. Apply antirust oil to external
machined surface. Ensure that there is always antirust oil covering on bearing surface.
Turn motor shaft once a month. In order to avoid damage to air vent, it must face
upward during storage.
4. Do not store parts near high-voltage energy sources e.g. power distribution
boards, arc welders or transformers.
During lifting and storage, be careful to avoid physical damage of parts. Because
climate conditions are varied; contacting the local supplier for proper antirust oil is
suggested. Regularly check stored parts and make sure that they are intact.
CITIC-HIC shall not take any responsibility for the damage caused by improper
measures.
3.11 Storage of full assemblies
If the stirred mill is assembled, but the trial run period delay is greater than 30 days,
the following steps are to be followed:
1. Prior to deliver the flyght shaft assembly is coated in antirust paint.
2. Apply grease to upper journal of flyght shaft.
3. If motor and gearbox are exposed to the atmosphere, cover with waterproof
tarpaulin.
3.12 General properties description
CITIC-HIC uses advanced design methods to manufacture its latest range of advanced
stirred mills, using 3D technological properties equal to internationally advanced
levels. CITIC-HIC has undertaken optimization analysis on the structural integrity,
which offers greater availability and reliability. We uset the latest technology and
combined mechanical, electrical & hydraulic technics to provide closed-loop control.
We can include overall monitoring on the operation of the entire machine, and provide
faults diagnosis & alarm function. We adopt man-machine interface technology with
visual enhancements to make operation and maintenance simple, to reduce labour
strength of operators and maintenance cost.
Through improved design of components, the stirred mill can perform at an optimum
level under harsh operating conditions; it has the capacity to ensure high-yield and
stable quality product.

3.13 Working principle
A detailed description for the structural composition, installation, dismantling
and method of operation relating to the stirred mill is illustrated in Figure: 3.13.1
and details of the main components are as shown in Table: 3.13.1.
The working principle of the stirred mill is as follows: the drive motor supplies
power and transfers this power to the gearbox; the flight shaft is connected to the
gearbox though a low speed coupling.
The rotation of the flight shaft causes the media and slurry to be elevated
ensuring that both the media and solids in the concentrate come into contact
which causes a high grinding situation due to this particle interaction.
Grinding is a consequence of the velocity gradient between the grinding media
and the particles in the slurry which generate stress events.
The rotation of the flyght shaft and digging shoes creates a constant grinding
zone between the media and the solids.
In the gap between the digging shoe and the mill chamber, grinding media moves
in circular motion of different circumferential velocities.
As the material is ground to a nominal size and its specific gravity becomes less
than the liquor allows the smaller solids to discharge through the screens into the
launders.
Table: 3.13.1 General Specifications
Standard Approximate Weight(kg)
Lower Upper
Stirred Mill Screw Drive shaft Screw Liner Main
Total Gearbox Bottom Bottom
Specification shaft unit assembly set motor
shell unit shell unit
240000 14300 30267 19252 14694 16230 28745 14000
Tabla: 3.13.2 Tabla de especificaciones sistema lubricación reductor

Lubrication pump Tank Capacity Air radiator
Motor
Stirred Mill Motor Nominal Fan
power Output Oil Filter Lubrication Speed
Specification power pressure power
(kW) (L/min) size (μm) (L) (rpm)
(kW) (MPa) (kW)
1500 7,5 2,5 143 60 N/A 2,2 1000
Table: 3.13.3 Main Parts List

Nº Dwg No. Name Nº Dwg No. Name
1 A7655-SP Screw shaft assembly 7 A7656-SP Drive shaft
2 A7652-SP Top shell assembly 8 E765 Lubrication station
3 A7651-SP Bottom shell assembly 9 Gearbox
4 A7657-SP Drive assembly 10 Electric drive motor
5 HSS Coupling assembly 11 Service coupling
6 A7654-SP Drive frame assembly 12 Heat exchanger
Fig: 3.13.1 Structural layout of the Stirred Mill
3.14 Foundation
3.14.1 Installation procedure

3.14.1.1 Foundation Requirements
An erection drawing of main parts and components for volume and weight will be
supplied with each mill, for this is A765DZ-SP REV1. A crane is required to be
located near the mill for service and maintenance requirements. Ensure there is
enough space above the mill to remove the main motor, gearbox and or gearbox
support frame when constructing any external structure.

The foundation is always designed by the customer, contractor or CITIC-HIC can
provide this service if required. CITIC-HIC can arrange the design and working
performance of the mill, alternatively CITIC-HIC can also produce general mill
layout GA drawings with foundation, work space requirements and feeding
arrangement.
The following regulations must be observed:
3.14.1.2 Soil for Mill Foundation
1．The foundation geotechnical should meet and conform to the requirements of the
“Cone Penetrometer Testing” method or other recognized soil property tests.
2．The foundation must be prepared to suit the geotechnical conditions.
3. The foundations are to be designed and built by a qualified CIVIL engineering
company. Ensure recommended concrete strength and reinforced steel bar meet ISO
standards.
4. The dimensions shown on the stirred mill foundation layout drawing include such
items as the following:
a. Minimum pier sizes at the base location.
b. Clearance dimensions where needed.
c. Anchor bolt sizes and lengths of projection above the foundation.
d. Minimum grout thickness
3.14.1.3 Loadings
Foundation loadings are provided on the stirred mill foundation layout drawing in
A765DZ-SP REV1 and are summarized in tables 3.13.1 of this manual.
3.14.1.4 Centerlines
After foundation has been poured and all forms removed, establish bench marks for
the mill centerlines.
3.15 Installation
3.15.1 General Instruction

The stirred mill components will be subject to very high loads during the operation
including the screw shaft bearings. All care must be taken at the time of assembly, to
ensure correct centering and the supply of sufficient clean and contamination free
lubricating oil to the operating components. Correct erection procedures and
implementing an applicable maintenance program during the operation will guarantee
bearing surfaces remain free of dirt and dust contaminants. All associated pipe-work
and ancillaries (by others) will require pickling (if not stainless steel) prior to being
put into service. Completely check the lubricant oil circuit components, pipework and
remove all corrosion or debris before erection. Clean and remove all the preservative
oil by pickling. Also linish any slightly damaged machined part in order to get a
proper match at the time of assembly.
For installation of the grinding mill component parts, use the following recommended
procedures in conjunction with the assembly/arrangement and erection guideline
drawings included as part of this instruction manual. Refer to the
assembly/arrangement and erection guideline drawing(s) for components and their
locations.
The foundation (provided by others) must be in conformance with the assembly
drawings A765-1-SP and the anchor bolt locations must be correct. The drawing is
shown below:
All grinding mill components parts must be available at the installation site and
inspected to ensure that no damage was incurred that would impede installation. All
fasteners must be available and properly categorized for efficient structural assembly.
The installation personnel and the crane operator must be aware of all major
component weights. If weights are not stamped on components and are not shown on
drawings, then estimates should be made allowing a considerable safety margin.
Lifting devices, such as cranes, clevises, shackles, spreader bars, etc. must be
available and capable of meeting all required load capacities, local laws and
regulations.
Levelness readings are to be taken on the machined surface of the top flange of the
bottom shell assembly with a precision machinist's level, and the levelness in all
directions should not exceed .001" per foot (0.08mm/m).
Installation check sheets covering the major steps and important points in the
installation process are provided for recording pertinent installation data.
Note:
Before operating this system, refer to the “Operation” section of this manual. The
operation section provides important pre-operation instructions covering the
lubrication of equipment and equipment checks. The operation section also provides
instructions for initial start-up of the system after assembly of the mill is complete and
all equipment checks and pre-operation lubrication instructions have been performed.
The following installation procedure gives the chronological order for installation of
the Stirred Mill components. It includes some installation steps that are also noted in
more detail in separate write-ups. Refer to these procedures for an understanding of
the overall installation process and the individual component description for more
specific installation details.
 All major components are shipped in the vertical position. The bottom shell
bottom section must be lifted using the four (4) clevises and chains attached to
the lifting holes in the vertical support beams. If necessary, a spreader bar
should be used to lift this 25167kg component. Position the bottom section of
the mill shell on the foundation over the appropriate anchor bolts. The anchor
bolts in the foundation should enter through the anchor bolt holes without
interference.
Note:
Do not remove the shipping brace pipe inside the body.
 The mill shell can be brought to the correct elevation and levelness by the use
of shims. The shims should be located in a manner to prevent deflecting the
mill body anchoring feet when the anchor bolt nuts are torqued. If using shims,
compressive loads in terms of "Nm" should be considered.
DO NOT OPERATE THE SCREW WITHOUT WATER AND BALLS IN THE MAIN MILL
BODY.
Fig. 3.15.1 Assembly of the lower bottom shell, upper bottom shell and screw
shaft.
3.15.2 Bottom Shell Installation
The lower housing is the main part of the mill frame and is fixed to the foundations by
anchor bolts, foundations have magnetic wall coverings and an inspection door.
In the following figure you will see details of the construction of the frame for the
lower housing assembly.
Fig. 3.15.2 Structure of the lower housing assembly
1. Prior to installing the sub-sole plates, the foundation surface must be free from any
grease and or debris and dirt. Level and adjust the sub-sole plates for each of the base
plates for the mill. Each sub-sole plate is made up of a pair of the same size mild steel
plates. Position sub-sole plate as close as possible to the foundation bolt sleeves but
allow for grouting formwork. If necessary, final levelling of the base plates can be
done with the use of adjusting shims placed between the sub-sole plate and the mill
base. The adjusting shim is made of different thickness steel sheet; each adjusting
shim does not exceed 2-3 pieces of shim material, stainless steel must be used for all
shims during installation. Ferric or malleable materials are not to be used.
Notes:
a. All shim material is to be supplied by the customer.
b. Equipment weight and operating loads must be transferred into the
foundation through the grout, and not through the shim packs.
c. The shim packs are required to level and bring the mill base up to elevation
for grouting.
2. If the stirred mill is mounted on a concrete foundation, it is necessary to grout the b
shell bottom onto the foundation. Sub-sole plates should be located adjacent to the
foundation bolts. The thickness and shim size is based on the actual installation
finished height. First level the sub-sole plates in both directions. Form work enclosing
the sub-sole plate is required to retain the grout while being poured. Thus the sub-sole
plate surface becomes the mill’s datum plane.
3. The concrete surface must be scabbled, the vertical and horizontal direction should
be kept flat, the contact surface of backing plate unit and concrete should be well
distributed, and the sub sole plates should have not less than 75% of full contact with
the mills base. Shim must not be removable after installation to ensure a suitable
contact between sub-sole plates and the underside of the mill base. Check by pulling
on the shims using a pair of pliers.
4. Levelling will be achieved by the use of stainless steel shim. All sub-sole plates
shall be grouted at the specified positions (for specific height and distance
requirements refer foundation drawing GA), as they will be used as the reference
point for the next stage of construction. The distance between every two adjacent sub-
sole plates shall be 300 - 800mm. Place two sub-sole plates at the position of each
foundation bolt and as required by foundation drawings.
5. When installing the sub-sole plates, all rust, oil and contaminants on surface shall
be removed. Grout the sub-sole plate using a grout specified by the site civil engineer.
6. The grout must be non-shrinking type in order to ensure the contact area of the
sub-sole plate and concrete is up to 75%. The weight and operating load will be
transferred to the foundation through the secondary grouting layer but not the sub-sole
plate. We intentionally reduce the quantity and size of the sub-sole plates in order to
increase the area of secondary grouting layer.
7. Prior to installing the sub-sole plate, scabble the concrete surface of the foundation
in order to ensure good contact between grout and concrete foundation. Remove all
the foreign matter on concrete foundation. Determine the positions for the sub-sole
plates and mark out the foundation. Drill bolt mounting holes according to the
instruction of Fig.2 (a) and Image 2, and fill epoxy resin adhesive into the hole, then
insert the full thread bar and screw on the bottom nut, then install the sub-sole plate.
Level the sub sole plate in two (2) directions and secure using the top nut. During
installation of the sub sole plates refer to the centre height of the mill and allow for
shim packing between the sub sole plate and bottom shell of the mill. Nominally 2 to
3mm.
8. When the elevation of the sub-sole plate is correct, fully secure the top nut. Again
check the elevation of the sub sole plates before pouring grout. Ensure the top nut is
tight.
During the curing of epoxy resin, keep the correct position of sub sole plate. Once the
epoxy resin is fully cured, screw on the top nut; adjust the nut to position the sub-sole
plate 4mm below the design reduced level (RL) for the mill This is to allow room for
adjustment when final levelling. The top surface of sub-sole plate shall be horizontal
in both horizontal axes; the levelness of each sub-sole plate shall be no greater than
0.1mm.
9. After the acceptance of sub-sole plates, formwork shall be constructed according to
Fig.2 (b) & (c) The formwork can be made of plywood or similar material. Use silicon
resin or secondary grouting material to pre-seal the gap between the base of the
formwork and the foundation and then carry out grouting work. Make sure the grout
flows from one direction under the sub-sole plate; do not allow the ingress of air into
the grout by over working. The inside of the formwork should be covered with a
non-adhesive barrier such as duct tape to allow easy removal once grout has reached
75% final strength.
10. During the curing of the grout secure the position of sub sole plate and prevent
any accidental movement. Once the grout is fully cured, remove the form work and
recheck and record the elevation (RL) of the individual sub sole plates. Make up the
required shims for adjustment and final levelling of the bottom shell of the mill. The
top surface of sub-sole plate shall be horizontal in both horizontal axes; the levelness
of each sub-sole plate shall be no greater than 0.1mm.
11. Allow to cure for a minimum of 24 hours, remove the formwork and top nut and
grind off the emerged part of bolt to ensure the flatness of the top surface.
Polish the top surface with a combination stone. Be careful not to allow oil or
lubricates to splash onto the foundation or dry grout as it will affect the secondary
grouting. Clean with Acetone as required. Recheck the level of the sub sole plate
record the details.
12. Fit the bottom shell of the stirred mill. Ensure the bottom shell is vertical to the
foundation, which is checked according to the position of centre line of the internal
bore hole and jointing flange.
13. A gap shall be kept between the bottom shell mounting flange and the top of the
concrete foundation in order to pour the grout. Check the grout manufacture’s
requirements. Internal and external form work is required to retain the grout while
being poured. Torque the bottom shell to the foundation bolt at approximately 30 to
50% of the full load torque. Pour the secondary grout.
14. After the grouting has cured, fully torque the foundation bolts to 100% of the
recommended values.
Note:
a. The machined surface at the top of the Stirred Mill lower shell is to be
leveled within 0.001” per foot (0.08mm per meter). The elevation should
be as required by connecting equipment.
b. Follow the recommendations of the concrete manufacturer during the
preparation and erection. It is very important to keep the stirred mill level in
two directions. The qualified civil engineer shall supply the requirements and
design of the foundation.
c. When customers are required to supply the correct foundation bolts. A
qualified structural engineer’s recommendation on bolt grade is to be specified
for this application. Bolts will also have a suitable thread length to
accommodate the bottom shell flange, a structural washer, two (2) nuts,
shimming and the sub-sole plate.
Figure 3.15.3: Example of mounted sub-sole plate
Figure 3.15.4: Sub-sole plate design
3.15.3 Completion
A recheck of alignments must be performed after grouting to be sure that
misalignment has not occurred while the grout was curing. After the grout has been
installed, checked and all forms have been removed: the surfaces may be painted with
an oil resistant paint. This is to protect the grout from oil contamination as well as to
facilitate the cleaning up of spilled materials.
3.16 Bottom & Upper Shell Assembly
1. Check the fitted bolt holes (refer upper shell assembly drawing) between the
bottom shell and the upper shell. Remove any burrs, marks, rust or dirt on the contact
surface. Ensure each fitted bolt can be tapped into the mating hole. Use anti-seize
paste when checking the fit of the bolt with the matching hole.
A continuous bead of gasket cement is to be liberally applied to the mating upper
flange of the bottom shell.
2. The upper shell section should be lifted using four (4) shackles and chains attached
to the lifting holes on the vertical support beams on the outside of the shell. If
necessary, a spreader bar should be used to lift this 18928kg assembly. Position the
upper section onto the bottom shell section so that the door jamb flange machined
surface on the upper shell section is aligned with the flange machined surface on the
bottom shell section and the six (6) locating fitted bolt holes on the mating flanges are
aligned as shown in drawing A7651-SP. Do not remove the shipping brace pipe inside
the body. Bolt the mating flanges together, and torque bolts to the M42, M48 and M64
bolts based on the torque table 3.37.1 and 3.37.2 of this manual and the below
instructions.
Do not apply white lead to the fitted bolts, use an anti-seize paste.
Keep shell flanges level and parallel when bolting together.
Fit all fixing hardware and torque the M48 fitted bolts (six only per flange), than
torque the remaining bolts to 50% of total value; beginning with bolts located at 180
degrees apart. Then tighten up the bolts which are located 90 degrees apart to the
preceding bolts. Then fasten the remaining bolts with the same torque alternately.
Continue fastening the bolts using the same procedure and turns to ensure that the gap
between flange surfaces is even or until a 0.10mm feeler gauge cannot be inserted at
any point in the flange circumference.
If the gap does not fully close after all the bolts have been torqued may indicate slight
misalignment or foreign material between the flange faces. It would be necessary to
separate the two shell frames and check for any material between the flange faces and
alignment.
3.17 Drive Frame Assembly

1. The drive frame, with the upper drive shaft assembly installed, should be lifted
using four (4) clevises and chains attached to the lifting holes in the vertical support
beam. If necessary, a spreader bar should be used to lift the 30885kg assembly.
Position the upper shell onto the lower upper shell in the orientation shown on the
assembly drawing and secure the bolts.
A continuous bead of gasket cement is to be liberally applied to the mating top flange
of the upper shell.
2. Check and align locating M48 fitted bolts (six only) between the drive frame and
the upper bottom shell. Remove any burrs, marks, rust or dirt on the contact surface.
Gasket cement is to be liberally applied to the upper flange of the bottom shell.
Do not apply white lead to the fitted bolts, use an anti-seize paste.
Keep level so that the connecting flanges are parallel when bolting together.
Fit all fixing hardware and torque to 50% of total value; beginning with the M48 fitted
bolts and then the remaining bolts located at 180 degrees apart. Then tighten up the
bolts which are located 90 degrees apart to the preceding bolts. Then fasten the
remaining bolts with the same torque alternately. Continue fastening the bolts using
the same procedure and turns to ensure that the gap between flange surfaces is even or
until a 0.10mm feeler gauge cannot be inserted at any point in the flange
circumference.
separate the drive frame and the upper shell frame and check for any material between
the flange faces and alignment.
3. Lift the reducer pedestal using the M36 clevises in four (4) holes in the top flange.
Position the pedestal on the upper shell in any of the 45° increments to allow easy
access to grease fittings and entrance for coupling alignment.
4. The coupling half on the output shaft of the motor/gearbox is a pressed fit at the
factory and no further coupling half mounting procedures are necessary. The coupling
half for the upper drive shaft has been factory mounted.
5. Place the gearbox onto the mounting pedestal. The gearbox can be rotated in
increments based on the mounting holes to obtain the most maintenance favorable
position.
6. Align the low speed coupling. Record alignment readings for future reference.
Make sure all mounting bolts are tight when performing coupling alignment checks.
Check coupling manufacturer's manual for alignment limits. Once final coupling
alignments are obtained, it is suggested that the reducer unit be fixed in position on
the pedestal. This may be done by drilling and doweling.
7. Mount the reducer lubrication skid at an elevation below the reducer in a location
close to the reducer. Make the connections to the reducer using pipe. Bypass the
reducer, pickle and flush the piping during initial installation.
NOTE:
a. Do not assemble the high speed motor coupling until the motor has been
bump tested. Motor rotation is clockwise, as viewed from the top when
installed.
8. The high speed coupling halves have been factory installed on the motor and
reducer shafts. Remove the steel bolts with elastic buffers from the coupling halves.
Carefully place the motor on the reducer motor pedestal in a favorable maintenance
position. The motor can be rotated in 45° increments in relation to the reducer. Check
the coupling alignment and record the readings for future reference.
NOTE:
a. At this point, the drive motor should be interlocked with the flow switch
on the reducer lubrication unit. The reducer should not be run without oil
flow in the circulating system.
9. Install the automatic grease lubrication system for the upper drive shaft bearings.
Make the connections as shown on the Automatic Grease
Assembly drawing, and follow the instructions for installation of the greasing system
in the “Automatic Grease Assembly Installation” write-up in this section.
10. Complete wiring to the mill motor, and to any associated equipment.
Check the motor for correct direction of rotation.
11. Energies the main drive motor until operating temperature is maintained. Check
temperature and for vibration during operation, and then assemble the motor coupling
by installing the grid. Pack with grease and assemble the covers and torque the bolts
to the nominated value. After the motor is connected to the reducer, the drive motor
should again be started and run for a short period of time to check the operation of the
reducer and upper drive shaft.
12. Remove the shipping bracing from the lower body. The pipe bracing will have to
be removed, and the inner surface of the mill body ground smooth and painted in
preparation for the magnetic lining installation. See the “Mill Lining Installation”
section for information on the installation of the magnetic liners. The magnetic mill
liners will be installed before the screw assembly.
13. Assemble the screw liners to the screw assembly. See the “Screw Installation”
section for the procedure to assemble the Stirred Mill screw.
14. Install the screw. Refer to the “Screw Installation” section for the screw
installation procedure. The screw weighs approximately 32724kg; care must be used
in the handling of the screw for personnel and equipment protection. Refer to the
torque values noted on the General Assembly drawing when bolting the screw to the
drive shaft.
3.18 Intermediate shaft assembly

The intermediate shaft assembly connects the gearbox to the mill screw shaft in a
direct-drive mode. It includes a connecting shaft, two couplings and hardware. The
transition of the intermediate coupling shaft allows accessibility for the maintenance
of the machine. When repairing the drive unit or the motor unit, it is only necessary to
remove the shaft coupling assembly instead of the entire motor unit to access the drive
shaft for removal. This reduces the maintenance downtime and cost; the direct-drive
shaft has a higher efficiency, and occupies less space. (direct drive can also be
changed for belt drive according to the need of the user). Refer figure 3.18.1 and
drawing A7656-SP for the structure of coupling assembly and its parts list.
Figure 3.18.1: Intermediate shaft assembly layout
3.19 Door Installation

Install the mill body access door. Lift the door by attaching the two lifting lugs
(supplied by CITIC) to the bolt holes in the top flange of the door. Position the door
over the hinges. Insert the hinge pins and adjust the manual jacks on each hinge to
push the door out to the end of the slot in the body portion of the hinge.
This will aid in closing the door.
Before closing and bolting the mill door, apply a bead of silicone sealant around the
door jamb inside the bolt area (between the bolt hole and the inside surface of the
mill). Be sure that no foreign matter is present on the flanges so that a tight seal is
made. Install all guards. When fitting pipe to various components, use care to
introduce no external strains into the system.
3.20 Installation of the Hydraulic Door Jacks

The hydraulic door jacks will be used during maintenance procedures that require the
mill door to be opened. The jacks can be installed after the mill is up and running.
Refer to the “Hydraulic Door Release System” drawing. The four (4) hydraulic jacks
have threaded heads. Screw the jacks into the threaded holes on the mill door flanges.
The hose assemblies come with quick disconnect fittings for ease of connection to the
jacks. Install the hoses and jacks as shown on the “Hydraulic Jack Assembly”
drawing.
Operate the hydraulic pump and jacks as directed in the attached “Hydraulic
Cylinder” instructions in this section.
as
3.21 Automatic Grease Assembly

The automatic grease assembly is an electric driven grease pump system that delivers
lubricating grease to the bearings of the upper drive shaft assembly. Refer to the
maintenance section for details on the operation and maintenance of the automatic
grease assembly.
The components of the automatic grease assembly include the electric grease pump,
the flow control panel, the manifold assembly, the cycle switch assembly, and the
hose assemblies that deliver the grease.
The programming of the grease system control panel controls the amount and
greasing interval frequency. The flow control panel controls and regulates greases to
the electric pump. The manifold assembly splits the grease flow into four paths to the
upper drive shaft bearings. The cycle switch assembly, mounted on the manifold,
allows the grease to cycle through the manifold when it receives a signal from the
PLC.
3.22 Installation of the Automatic Grease Assembly
Refer to the Automatic Grease Assembly drawing. The components of the grease
system must be field mounted during installation. Make the connections as shown on
the Automatic Grease Assembly drawing.
Refer to the “Grease Pump Installation” instructions for details on the installation of
the grease pump.
For additional information review the manual Bijur Delimon S67610
3.23 Magnetic Liner Segments Assembly
The stirred mill has a very strong magnetic liner installed; therefore all loose metal
objects and electronic equipment must be removed from the area.
Personnel who have a heart condition and have pace makers are to avoid entering the
area.
NOTE:
a. Ensure that the port protection plate liners for the recycle port and ball
port outlet are bolted prior to installing magnetic liners.
b. The magnetic liners are to be trimmed onsite to fit the areas around the
recycle port and ball port outlet gate.
c. It is recommended that the magnetic liners be test fitted before any

welding is done for the port protection plates. This will also give an
indication of the proper fitting of the liners, and the need to space the
magnetic liners to fill the area.
d. All liners are to be fitted based on the instructions in the magnetic liner
assembly drawing.
i. Install the magnetic elements as shown on the lining assembly drawing.
Install an element and tap it into place against the steel strip at the door
jamb. Tap gently, using a rubber mallet. Start in the mill body at the door
jamb on the right of the door. Work from the floor upwards until this
space is completed. The Lining Assembly drawing will indicate how
many elements are required. When the body is completed, line the door
using the same procedure.
ii. Fit rubber plugs into the bolt holes located in the port protection plates.
NOTE:
It is very important that all the elements are installed in the same direction. The
four rubber strips on the top of the element will indicate the direction. Have all
the rounded edges in one direction, or all flat edges in one direction.
Door Magnetic Liners

Shell Magnetic Liners
Inlet Port Ball Port
MAGNETIC LINER ASSEMBLY
3.24 Screw Liner Assembly Procedure

NOTE: Refer to the Screw Assembly Drawing and to Sketch 1 on the following page.
1. Remove the front support bar from the trolley.
2. Lower the screw trolley to the drive end of the screw shaft, while the shaft is in a
horizontal position.
3. Screw the trolley to the top flange of the shaft, using the trolley locking plates.
Re-install the front support bar.
4. Lower and bolt on the screw lifting lug to the end of the shaft using the four (4)
holes closest to the key on the shaft flange.
5. Lift the screw and lower into the screw liner installation frame. (ensure the frame is
close to the vertical stirred mill).
6. Using the four (4) M22 x 60mm bolts, screw the trolley to the installation frame
which is capable of supporting 32724kg. The screw will probably need to be rotated
for liner installation.
7. Install the screw wear liners by starting with the end liner.
8. The digging shoe has a weight of 2176kg, and can be lifted using the 50mm
diameter holes in the casting protrusion and the two 60mm diameter lifting holes on
the outside radius.
9. When attaching the digging shoes, locate them at the lower end of the slotted holes
in the rubber covered screw flight. This will allow for an oversize tolerance in the
castings. Under size tolerance can be adjusted for by leaving a gap between the
castings.
10. Install both digging shoes first, and then proceed with the flight liners by putting
one liner on each flight at a time. Each flight liner has a weight of 2211kg.
11. Tighten all nuts (using Molybdenum disulphide on the liner bolt threads only) to
the torque values nominated on the torque table 3.37.1 y 3.37.2 and lock in position
by double nutting.
12. Remove the four (4) M22 x 60mm bolts securing the trolley to the frame.
3.25 Screw installation procedure

NOTE:
a. Refer to the Screw Installation Frame Drawing.
1. Open the mill door; remove the covers on the screw beam pockets on the back side
of the mill body.
2. Install the beams using counterweight as shown on the screw elevation assembly
drawing and bolt securely to the door flange.
3. Align the beams so that they are parallel to each other and in the centre of the beam
pockets.
4. Adjust the nuts on the top of the beam to raise the plate and clamp beam in the
beam pocket.
5. Raise the screw and trolley assembly and position it over the beam with the key
parallel to the door flange. Do not set the screw on the beam at this point.
6. Slowly lower the screw onto the beam and remove the screw lifting lugs.
7. Remove the front support bar from the trolley.
8. Maneuver the screw into the mill and locate directly under the upper drive shaft.
Align the keyway in the upper drive shaft with the key in the screw assembly. This
can be accomplished by manually turning the drive motor by hand at the coupling, or
by removing the motor fan cover and turning the motor and the fan end.
9. Install two (2) long threaded rods (48mm x 1005mm long) in the diagonal holes in
the drive and screw coupling flanges (nearest to the key). Screw one end of the rod
into the saddle on the jack and fit the nut to the other end of the rod.
10. Attach the hose assembly to the two (2) jacks and pump assembly to the assembly
center connection.
11. With the holding valve on the pump closed, operate the pump until the weight of
the screw is taken off the trolley.
12. After the screw weight is supported by the jacks, remove the bolts and plates
attaching the trolley to the flange and remove the trolley rear angle support and move
the trolley out of the way.
13. By operating the pump, slowly raise the screw to the upper drive shaft.
14. Install the M48 screws and screw shaft bolts, nuts, and washers, as shown on the
upper drive shaft assembly drawing and torque to 4136Nm using molybdenum
disulphide paste on the threads.
15. Remove the beams using counter weights; replace the beam pockets cover plates.
3.26 Control Philosophy

Monitoring systems and safety interlocks are provided for the CITIC Stirred Mill.
Actual grinding system control, including feed and process water flow rates, are not in
CITIC’s scope of supply. Systems monitoring the operational condition of the Stirred
Mill drive motor and speed gearbox operation provide alarm and mill trip signals for
the customer’s control system.
The following is a summary of interlocks and condition monitoring systems provided
for the grinding mill by CITIC-HIC.
Refer: Piping & Instrumentation Diagram (P&ID) for detailed information on these
systems.
3.26.1 Mill Drive Motor

Six RTD’s monitoring the drive motor windings’ temperature, and two
RTD’s for the drive shaft bearings provide signals to the customer’s control system to
monitor the operating temperature of the drive motor. The signals should be used to as
warning and operational permissives.
RTD Location: Recommended: Recommended:

Alarm Set-point: Mill Trip Set-point:
Drive Motor Winding 115°C 135°C
Drive Motor Bearings 105°C 110°C
3.26.2 Gearbox
The gearbox has monitoring systems for oil flow, temperature, and differential
pressure across the oil filter. Interlocks include a lube oil pump running permissive to
prevent the mill from being started without the gearbox lubrication system running.
Monitoring System: Alarm & Trip Set-points::

Lubrication System Oil Volume Flow 120 LPM Alarm, 105 LPM Trip Switches
Monitoring System: Alarm Set-point
Lube System Filter Differential delta p > 2 bares
Pressure Switch
Reducer Lubrication System RTD 75°C Alarm
temperature 80°C Trip
3.27 Maintenance Frame
The maintenance frame is to be erected in a clear open space and fixed to a concrete
slab in close proximity to the mill. Refer drawing A765-9-SP.
3.28 Screw Shaft Assembling
The screw shaft includes shaft, digging shoes and flyghts.
Fit the key into the shaft and then the half coupling; tighten the grub screw to lock the
coupling to the shaft.
Fit the CITIC-HIC supplied lifting lug to the coupling so the shaft can be raised and
maneuvered into the maintenance frame.
Sufficient clearance is required around the stirred mill for the screw shaft installation
and for future servicing as it will be required to swing the screw shaft into position
using the mobile crane.
A separate mobile articulated vehicle is used for opening the door when servicing and
when digging shoes and flyghts require replacement.
3.29 Screw Shaft, Digging Shoes & Flyghts Installation
Once the screw shaft has been secured into the maintenance frame, the digging shoes
and flyghts can be fitted.
Attach the spreader bar with outriggers to a digging shoe, adjust to secure the
outrigger to the digging shoe and then maneuver into position.
Once aligned insert fixing bolt and torque to 30% value for possible further
adjustments.
Repeat this sequence until all digging shoes and flyghts are installed.
3.30 Screw Shaft Installation

1. Install the rail into the opening located in the top shell;
2. Fit the trolley to the top of the screw shaft prior to lifting; raise and maneuver
into the mill by the previously fitted lifting plate.
3. Ensure that alignment between the rail and the trolley is achieved.
4. Push the shaft along the rail and into the mill.
5. Align the coupling halves.

6. Jack the two (2) halves together using the supplied hydraulic power packs.
7. Insert fixing bolts; torque to the recommended values.
Figure 3.30.1 Screw Shaft Installation Rails and Screw Trolley
Figure 3.30.2 Screw Shaft Installation Coupling Assembly
3.31 Bottom Shell Assembly

3.31.1 Structure and Composition of the Bottom Shell Assembly
The bottom shell is the main part of the mill frame and is fixed to the foundation by
anchor bolts. The screw shaft assembly is connected to the gearbox through the low
speed coupling causing the screw shaft to rotate. These spiral weldments are fitted
with replaceable cast steel digging shoes and flyghts which not only protect screw
shaft weldments but also agitate/stir the slurry and the media.
The bottom shell forms the base structure which is mounted onto the foundation and
includes magnetic wall liners and an inspection door.
Frame construction details for the bottom shell assembly:
Fig 3.31.1 Structure of the bottom shell assembly
3.32 Performance features
The structure of the bottom shell is optimized and designed by means of finite
element analysis to provide a more stable, reliable and appropriate structure.
3.33 Technical performance
1. The screw shaft is a one piece machined forging which incorporates the helix which
is welded as an integral part of the screw shaft to eliminate the stress centralization
attributed to connection and fit of separate weldments in order to reduce the assembly
steps and enhance the mechanical performance and integrity.
2. The screw shaft is a component that evidences transition in all major rounded
corners to make the stress distribution uniform, therefore minimizing the shaft’s
breaking risk and therefore offering an integral, reliable, long life structural design.
The modular design of the CITIC Stirred Mill allows for many assembly orientations
utilizing standard components.
Four (4) power packs are located in the door frame, which will produce sufficient
force to release the door from the lower body.
The door on the body of the mill opens with very little effort when using the mobile
articulated vehicle with grapple hook attachment.
The mill body interior is protected from wear by a magnetic lining. The grinding
media attaches itself to the magnetic liner and creates a high anti-wearing surface.
The digging shoes and flyghts are (specially) cast steel wear components which are
bolted to the screw helix.
An integral (patent pending) system is designed into the digging shoes and flyghts for
easy installation and removal even if the liners are badly worn.
3.34 Upper Bottom Shell Assembly
3.34.1 Structure and Composition of the Shell Assembly

The shell assembly mainly consists of the bottom shell, upper shell, access door,
magnetic liner, screw with flyghts and digging shoes. (Refer to table 3.34.1 and fig.
3.34.1). This fabricated structural frame unit is also used to support the reducer
pedestal, couplings, thrust bearings and main motor.
Table 3.34.1 Main Assembly Components
Nº Drawing No. Name Nº Drawing Name
No.
1 A7654 Drive Frame 10 A7655 Screw Shaft
2 A7651 Bottom Shell 11 A7655 Flyghts
3 A7652 Upper Shell 12 A7655 Digging Shoes
4 Main Motor 13 A7658 Magnetic Liner
5 Low Speed 14 A7653 Inspection Door
Coupling
6 High Speed 15 A7656 Intermediate Shaft
Coupling
7 Gearbox
8 A7654 Gearbox
Pedestal
Figure 3.34.1 Structure of the Upper Shell Assembly
Refer Upper Shell Drawing # A7652

3.35 Top & Bottom Shell Assembly and Disassembly
Check and align fitted bolts between the bottom shell and the upper shell. Remove
any burrs, marks, rust or dirt on the contact surface. Gasket cement is to be liberally
applied to the upper flange of the lower bottom shell.
Do not apply white lead which will cause inconvenience for later dismantling.
Keep level so that the connecting flanges are parallel when bolting together.
Fit all fixing hardware and torque to 50% of total value; beginning with bolts located
at 180 degrees apart and ensure the fitted bolts are aligned. Then tighten up the bolts
which are located 90 degrees apart to the preceding bolts. Then fasten the remaining
bolts with the same torque alternately. Continue fastening the bolts using the same
procedure and turns to ensure that the gap between flange surfaces is even or until a
0.10mm feeler gauge cannot be inserted at any point in the flange circumference.
separate the two shell frames and check for any material between the flange faces and
alignment.
Repeat this procedure for the drive frame.
Fig. 3.35.1 Structure of the Drive Frame Assembly
Certain pressure is needed to separate the fit between the upper, bottom shells and the
drive frame.
The operating procedure for this is suggested as follows:
1. Remove all bolts from the connection flanges of upper shell and drive frame.
2. Connect the drive frame to an overhead travelling crane or similar type crane and
remove the drive frame by the aid of a steady pulling force by a crane. Be aware that
when the upper shell and drive frame connection is released it will cause the drive
frame to suddenly bounce.
3. After the removal of drive frame, clean and lubricate the machined surfaces at the
joint between upper shell and drive frame to protect them from rusting. Then position
upper shell onto a suitable timber bed and properly protect its machined surfaces.
Repeat steps 1 to 4 as above to remove the upper shell from the bottom shell.
3.36 Check all bolts after installation

3.36.1 Re-check
When installation is complete, clean and repaint as required. Check all bolt torque
values and the connecting parts to guarantee correct installation as per the instructions
and assembly drawings.
3.36.2 Bolt Installation Method
The rotating elements (main motor, gearbox and screw shaft) are connected by bolts
where failures can occur but can be minimised by good maintenance. These bolts are
an integral part of mill structure. The correct preload torque should be used to
maintain the tightness of these bolts such as to ensure that the mill will have a
long-term operation. Loose bolts will reduce the connection intensity, shorten the
operating time and may cause serious damage. The tightness of all bolt connections
are to be checked at timed intervals. Protect the thread surface during transportation
and storage. Use a file to clean any burrs and high spot to avoid the possibility of
increased bolt friction leading to thread damage. Ensure both bolts and nuts are
cleaned and burrs removed. Use Molybdenum disulphide grease on the threads only
for all bolts.
3.36.3 Hydraulic Torque Wrench
Only use a calibrated hydraulic torque wrench. The hydraulic torque wrench will
make a specific bolt reach the correct extension length after torque adjustment.
Calibrate the spanner on site by measuring the elongation of a test bolt.
There are numerous related variable factors that will influence friction and connecting
conditions, there are deviations for preload torque amongst the connecting parts. Use
a calibrated hydraulic torque wrench to largely reduce any deviations.
Tighten to nominated torque table values.
3.36.4 Bolts Tightening Procedure.
Cleaning and Preparation.
Clean all the bolts and studs of dirt, rust, oxide skins, anti-rust, oil, burrs, and check
for thread damage. Do not use bolts and studs directly from the packaging. Bolts,
studs and nuts can be slightly damaged during transportation.
Examine every bolt, nut and stud carefully before they are put into use. The steps are
as follows:
1) Wash by metal cleaning agent
2) Check whether the thread is damaged or not.
3) Clean any notches and burrs.
4) Screw the nut up and down the thread to ensure ease of assembly.
5) Apply Molybdenum disulphide grease.
3.38.6 Installation and Tightening
The bolt and/or the stud should be matched to the originally matched nut when
installing.
The tightening of the preload torque should be divided into 3 steps: firstly, all bolts
are tightened to half torque value; secondly, all bolts are tightened to full (Final)
torque value; third, recheck all bolts at final torque value.
If the bolt pattern is compared to a clock, each step should be carried out by bolting
the clock symmetrically and equally to the required torque in accordance with the
following sequence: 12:00、6:00、3:00、9:00、1:30、7:30、4:30、10:30、2:00、

8:00、5:00、11:00、4:00、7:00、1:00. In order to prevent the bolts from rotating, the
bolt head must be fixed then rotate the nut when tightening. This step is important
during the first 50% torque stage however the final 100% torque may be conducted in
a circular manner to reduce time.
The torque value should be indicated and calibrated on the torque spanner to produce
an accurate torque setting when installing the bolt as indicated in Table 3.37.1 All
results must be logged. Number each bolt while torqueing.
3.37 Recheck
After the mill has operated with a full-load for one week, all rotating connecting parts
of the mill are to be checked with full torque. Recheck them after six months and
check them once at random every six months in the future (several bolts are checked
in each flange). All bolts should be tightened again if the preload torque of several
bolts is less than required.
Table: 3.37.1 Bolt Torque Values

Final Torque Class
Item Location Bolt Size (mm) @75% Proof Load
(Nm) of Bolt
1 Journal bearing housing to drive frame M30 x 200 x 3.5P 983 8.8
2 Roller bearing housing to drive frame M42 x 220 x 4.5P 2,754 8.8
3 RingFeder Locking Ring M24 x 90 780 12.9
4 LS Coupling Flexible to Rigid Flanges M42 x 220 x 4.5P 2,754 8.8
5 Reducer adapter flange to drive frame M56 x 240 x 5.5P 6,650 8.8
6 Bottom shell to upper shell M64 x 200 x 6.0P 10,020 8.8
9 Upper shell to bottom shell M64 x 200 x 6.0P 10,020 8.8
12 Screw shaft flange to drive shaft flange M48 x 500 x 5.0P 4,136 8.8
13 Screw liner to screw shaft flight M48 x 220 x 3.0P 3,900(65%) 8.8
Note: 1. Applies to coarse screw threads

2. Allowance for pre-tightening torque is ±5%
3. Preload shall be calculated based on 0.6σs of material.
4. Coefficient of friction: μ=0.14
5. Given values are bolts with lubricant. Pre-tightening torque for bolts
without lubricant is 133% of value in table.
6. Torque value for inside nut of double nuts shall reduce 5% from value in
table.
Table: 3.37.2 General Bolt Torque Values

Property Nominal Diameter of Bolts
of Bolt M20 M24 M30 M36 M42 M48 M56 M64
Class Tightening Torque TA Unit : Nm
Class 3.6 86 150 297 520 830 1247 2005 3021
Class 5.6 145 298 593 1037 1661 2495 4010 6042
Class 8.8 307 530 983 1845 2754 4136 6650 10020
4 Commissioning
4.1 The preparation and checks before the trial run of the mill.
Do an overall check before the mill is started, the mill cannot be started until the
following requirements are met. Survey the mill elevation before starting the
commissioning procedure and record the details for later reference against foundation
settlement.
4.1.1 Mechanical Unit

Review all completed data records and check sheets and confirm the mill installation
is in accordance with the CITIC HIC manual and all requirements have been met.
Connection of the lubricating pipe line is complete and in accordance with CITIC HIC
requirements.
All instruments and gauges outputs such as the flow meter, manometer, and the
pressure sensors are correct.
4.1.1.1 Shell Assembly
Ensure all the flange bolts are torqued correctly, examine all bolts connecting shell
segment to ensure that their preloaded torque is correct.
Check that there is no debris or other components in the shell assembly. Ensure there
are no loose bolts, nuts or any other parts within the shell assembly.
Check the direction of the spiral and refer to the direction of rotation.
4.1.1.2 Drive Unit
The position and wiring of the sensor for measuring bearing temperature of the
reducers is correct and temperature within guidelines.
The lubricating pipe lines of the reducers are connected correctly; and the lubrication
oil grade and type is correct.
The radial and axial run-out of the coupling at the reducer’s connection with the main
motor is correct and within guidelines.
The fixing bolts on the reducers are torqued correctly.
Re-examine whether the joint bolts on each part have the correct torqued values.
Clear any debris or other objects in or around the drive shaft guard or coupling guards,
which could damage the equipment or personnel when it is running.

Ensure the equipment can operate without interference.
4.1.2 Electrical Unit

Ensure the electrical components of the mill are correctly installed.
All the wiring in the MLCP is connected correctly.
All the wiring of the installation on the site is correct and fitted according to local
standards.
Check the insulation of all the low voltage motors; the insulation resistance should be
more than 2MΩ using a high voltage Megger (insulation resistance tester > 2 times
the motor voltage). Record details of the relevant actual resistance and voltage values
of each test. Ensure the voltage test has also been taken for the high voltage motor/s
and the high voltage cable recently and insulation tested with a Megger insulation
resistance tester using the manufacturers recommended test procedures.
Record details of the test results including all voltage values and insulation values.
Powering up of the mill for commissioning cannot be completed until all mill systems
are passed by the installation company and the customer.
4.1.3 Gearbox lubrication station

1) Check and confirm that each pipe line of the lubrication station is installed
according to the drawing.
2) Check and confirm that there is no damage to any pump, valve or console
instruments; and each valve on the pipe line is set.
3) Check and confirm that the wiring of the relevant electrical control panels and
instruments are correct.
4) Check and confirm that the pipe arrangement between the mill and the lubrication
station has been finished, and have been cleaned by pickling, neutralization, and
flushed; the oil is to meet the ISO4406-18/15standard. Confirm the fall in the return
oil line is correct at between 1:8 and 1:10. No vertical drops of more than 1000mm.
(Detection report should be supplied by customer).
5) Check and confirm that the specified grade and type oil which is filtered has been
filled to the prescribed level at the oil tank.

6) Confirm the direction of pump rotation.
4.1.4 Commissioning Auditory
Check and confirm that the commissioning audit has been completed by the CITIC
representative and the customer’s supervision department.
4.2 Trial Run
The initial mill start-up must be accomplished in steps after the mill has been installed
and checked. Commissioning will involve multiple trial runs. The focus of the trial
runs is to gradually increase the load on the drive train while closely monitoring the
motor, reducer, couplings and drive shaft bearings operating condition to ensure
correct alignment and proper running of the reducer, main motor and shaft. Trial run
“Data Sheets” are provided to record operating conditions during initial trial runs,
which are essential for determining the bases for final mill operating condition.
4.2.1 Idle Test Run

The objective of this test is to verify the correct operation of the motor - reducer and
intermediate shaft assembly.
Verify that the helical shaft is disassembled.
Before starting the main lubrication unit, ensure that all personnel are in the safety
zone of the mill and their exit has been recorded.
People who have a heart condition and have a pacemaker should avoid entering this
area.
1) Start the mill in the following sequence.

- Start the gearbox lubrication station.

- Start the grease system of the intermediate shaft bearings.
- Start the main motor.
Check if the motor rotating direction is correct.

- Turn off the mill if there is any abnormality
Record startup current once the main motors are on and observe if there is anything
abnormal and then go to next step; motor current should be recorded every 15 minutes,
and the mill should be stopped for examination if there are any abnormalities.
2) After running the mill for 4 to 6 hours and no problems occur, record all
parameters every 30 minutes as trial run records, including gearbox bearing
temperatures, motor stator and bearing temperature, main motor parameters, all
lubrication station parameters; all these should be recorded in data sheets and within
its individual specified range. Bearing temperature should not exceed 55OC during
idle run. Most temperature should be in the range of 20°C maximum above ambient
for normal operation. All movable parts should run normally, and bolts not loosened,
check each lubrication unit to ensure there is no oil or grease leakage. If there is any
abnormalities, stop the mill and rectify as necessary.
Mill shutdown sequence:
- Stop the main motor
- Stop the air fan cooling system
- Stop the grease lubrication device (bearings and gearbox)
- Shut down main bearing grease lubrication station when mill temperature lowers
to ambient temperature.
4.2.2 Tightness test of the mill:

When the idle trial run has been approved, a tightness test of the mill will be carried
out.
- Verify which helical shaft is coupled.
- Fill water continuously into the mill shell until water overflows from the discharge
end.
- Verify that there are no leaks in the bolts and seals of the mill housing. Make the
necessary corrections.
- The water inside the mill will indicate if any of the shell bolts needs to be
re-torqued. Loose bolts will damage the integrity of the mill.
4.2.3 Trial run under 30% load

Load testing is a static load test in that the load on the mill is not increased during this
test.
- Fill the mill with water and check for leaks. Make the necessary corrections before
adding iron balls.
- Once the water tightness test has been completed and accepted the mill will be
filled with 30% of iron balls.
- The mill must be started, so that the load is spread across and not in one section of
the shell.
Load trial run with shot and material charge should be for 2 hours as per the procedure
with water until certain parameters such as temperature are stable and all operation
parameters should be recorded every 15 minutes.
NOTE:
Stirring the ball load will produce heat. The ball load must remain submerged in
water to protect the lining of the mill from excessive heat. Add water if necessary
to ensure the ball load remains submerged.
Trial run under load should satisfy following requirements: the mill works normally
and has no periodic shocks; main motor current is kept within specified range; all
parts work normally; no leakage occurs at mill shell bolts and they should be
re-torqued. Check all bolts. Reducer bearing temperatures should be lower than 60°C
and return oil temperature lower than 50°C.

test. Follow the same procedure as above. After the 30% load trial run has been
accomplished, a 60% load (including iron shot and material) trial run should be
carried out in the same sequence for at least 2 hours until certain parameters such as
temperature stay stable, and during this period all operation parameters should be
recorded every 15 minutes.
NOTE:

test. Follow the same procedure as above. If the 60% load test run has been
accomplished, it's recommended to add 30% iron shot and material; the mill must be
inched occasionally when filling with steel shot so the load is spread across and not in
one section of the shell. Than the last 10% load is to be fed through the charging
device and into the mill, which could be adjusted based on mill operating conditions
to optimise material grind efficiency, taking care not to exceed a current consumption
of 225 Amps.
Trial run procedure should be same with 30% load trial run.
The 90% load trial run should run for at least 24 hours until temperature and other
parameters remain stable, and during this operation parameters should be recorded
hourly.
During the 24 hour operational testing additional material may have to be added to
lubricate the shot charge and prevent damage to the flyghts and digging shoes. Ensure
excess material can freely flow from the mill during testing.
NOTE:
Foundation bolts and shell joint bolts which may be loosened during load trial runs
should be re-torqued after trial runs. Check all bolts and nuts, including joint sections.
The mill should be adjusted gradually to full load and rated productivity, after 1 to 3
weeks of operation the mill should be shut down to inspect and tighten all bolts and to
examine the connection between gearbox and main motor couplings.
After six months operation; the pre-tightening torques of all shell and coupling bolts
must be checked.
Torque all bolts as per the tightening procedure. If they are no loose bolts recorded in
the next six weeks, bolts are to be check annually.
CITIC also recommend that special attention should be paid during grinding mill
operation for 30 ～ 60 day to bolts tightening, foundation settlement, concretion and
adjustment should be done to this if necessary. We also suggest all these including
future conditions should be recorded, which may be keys for simple diagnoses and
remedy in future.
4.3 Data Records for trial run
4.3.1 Trial Run Condition

Trial Run Condition:
User Name:
Site Condition:
Site Installation: Indoors Outdoors
Totally exposed to open air: Yes No
Ambient Limiting Temperature: Max. °C Min. °C
Ambient Temperature During Startup: °C
Trial Run Date: /
/
Mill Status Prior to Startup
Mill Empty fitted with magnetic liner. Yes No
Mill Loaded with Charge. Yes No
Charge Weight at Startup. Kg:
Operating Conditions of Mill During Startup.
Batch Feed: Yes No
Continuous Feed: Yes No
4.3.2 Trial run items

Each item should be underwritten by a CITIC HIC engineer or site supervisor for
confirmation of accomplished work or examination points.
REDUCER Initial
Reducer installation and alignment confirmed.
Reducer lubrication station oil tank filled to suitable level.
Parameters recorded in attached table.
MILL DRIVE MOTOR Initial

Main motor installation and alignment confirmed.
Main motor grease lubrication points are filled to suitable level.
Parameters recorded in attached table.
SHOT CHARGE Initial

Charge With Water 30% 60% 90% 100%
Record of shot
charge addition.
Time of Addition.
Initial Shot Charge.
Specification and
Weight.
Table 1: Record of Lubrication Oil (Grease) Used in Each Part:

Unit Name: Type and Manufacturer: Comments:
Viscosity:
Plane bearings
lubrication station:
Reducer lubrication
station:
Main motor lubrication

station:
Table 4: Reducer Lubrication Station Operation Record:

Mill Status: 30% Load □ 60%Load □ 90%Load □ 100％Load □
Time:
MPa Pressure:
Flow:
Pump outlet pressure:
Oil tank temperature:

Differential pressure
of oil filter:
4.3.3 Vibrations record
Table 9: ISO 10816 – 3 Velocity Range Limits (Vibration)

Velocity Velocity Range Limits and Machine Classes
Severity
mm/s in/s Small Medium Large Machines
RMS Peak Machines Machines Rigid Supports Less Rigid
Class I Class II Class III Supports
Class IV
0.28 0.02
0.45 0.03 Good Good Good Good
0.71 0.04
1.12 0.06 Satisfactory
1.80 0.10 Satisfactory
2.80 0.16 Unsatisfactory Satisfactory
4.50 0.25 (Alert) Unsatisfactory Satisfactory
7.10 0.40 (Alert) Unsatisfactory
11.20 0.62 Unacceptable (Alert) Unsatisfactory
18.00 1.00 (Danger) Unacceptable (Alert)
28.00 1.56 (Danger) Unacceptable Unacceptable
45.00 2.51 (Danger) (Danger)
Class I: Machines may be separated driver and driven, or coupled units comprising
operating machinery up to approximately 15kW (approximately 20hp)
Class II: Machinery (electrical motors 15kW (20hp) to 75kW (100hp) without special
foundations or rigidly mounted engines or machines up to 300kW (400hp) mounted
on special foundations
Class III: Machines are large prime movers and other large machinery with large
rotating assemblies mounted on rigid and heavy foundations which are reasonably
stiff in the direction of vibration
Class IV: Includes large prime movers and other large machinery with large rotating
assemblies mounted on foundations which are relatively soft in the direction of the
measured vibration (i.e. turbine generators and gas turbines greater than 10MW
(approximately 13500hp) output.
As reference values, class III machines will be used, with a maximum value of 4.5
mm / s, however, given the particularity of these equipment, it is recommended to
monitor the three mills and define the best acceptable values empirically of
operation.
5 Operation
5.1 Process description
The new regrinding plant will process Rougher concentrates from Plants A0, A1 and
A2, whose process begins with the feeding of the Rougher concentrate to the
4300-DI-101 distribution drawer. This drawer unloads through three (3) modulated
dart valves, and by gravity, the total Rougher concentrate up to the three (3) cyclone
feed tanks 4300-ZM-101 @ 103, that make up each of the three (3) trailer circuits of
the new plant.
Each circuit consists of a hydrocyclone feed
tank, a 4300-ML-101 @ 103 vertical mill of
1,200 kW, and a battery of 10 hydrocyclones (7
operating plus 3 stand by), 4300-CC-101 @
103. This circuit receives the Rougher
concentrate flow from the distributor drawer
4300-DI-101, this concentrate, together with
the product flow of the vertical mills
4300-ML101 @ 103 and the process water
flow added to the tank, form the hydrocyclone
feed pulp which is sent through two pumps to
the battery hydrocyclones at 18 PSI pressure.
The coarse particles, which are discharged by
the cyclone underflow, are sent to the vertical
mill, for reprocessing and return to the classification circuit. On the other hand, fine
particles with a 45 micron granulometry product are discharged by the cyclone
overflow and sent by gravity to the 4300-TK-104 drawer product which receives the
overflow of the three hydrocyclone batteries. From here the flow of pulp, product of
the process of regrinding, it is transported through three (3) centrifugal pumps in
configuration two (2) operating and one (1) in standby, by means of two (2) two
independent pulp lines, to the existing P drawer that feeds the stage of float cleaning.
5.2 Mass balance

The mass balance can be defined as an accounting of inputs and outputs of mass in a
process or a part of it. Before reviewing the mill balance, the following concepts will
be reviewed:
Nominal Flow: Corresponds to the expected annual capacity, considering 365 days
and 24 hours of operation.
Instant Flow: It is the nominal flow with the built-in use, that is, it is the nominal
flow divided by the use.
Minimum Flow: Refers to the flow condition, in which the towing plant would
operate, in the event of an arrest of one of the two mills, due to maintenance or an
unwanted event, which translates into a decrease in flow total rougher concentrate of
approximately 20%.
Design Flow: These values represent the average flow at which the plant must
operate to achieve annual production in the number of effective days or hours of
operation considering the use of the plant and also the design factor.
Utilization: Represents the fraction with respect to the total time of the annual
calendar in which a productive installation is actually in operation, due to the
availability of the equipment. In this case it is considered 92%.
Design Factor: It is used as a backup in the operation, in cases of needing to recover
the production against unforeseen events not contemplated by the factor of use of the
plant and to allow operational flexibility. For specification purposes, the equipment
must be able to operate continuously at design capacity and no other additional factors
should be used. In this case 1.15.
5.2.1 Design values
The design values considered for the mills are those shown in the following
scheme:
These are the values considered for the mass balance that will be shown below:
5.3 Control system
The control system chosen is the DCS Experion with Honeywell C300 controllers.
The screens in Experion follow the same rules as those in the control room and will be
integrated as part of the existing concentrator system.
Figure 5.3 General screen of the regrinding system
5.4 Normal procedure for starting and stopping the mill

This section gives the sequence of the normal procedure for starting and stopping the
mill.
5.4.1 Starting sequence

Start the gearbox lubrication system → start the drive shaft grease lubrication station
→ start mill → start feed system.
Do not start the mill more than twice (2) within one hour when main motor is
hot. Do not start the mill more than three (3) times within one hour when main
motor is cold.
5.4.1.1 Star-up of the gearbox unit lubrication unit

The lubrication system of the gearbox unit must be started first, when the mill is
prepared for commissioning. In general, it makes sense to start the lubrication system
as soon as possible (for example, after performing some maintenance activity on the
lubrication units) to avoid unnecessary cooling of the pipes and bearings.
One (1) of the two (2) gearbox lubrication pumps must be selected as the pump in
service, while the second will be a reserve pump.
Before the gearbox lubrication system starts up, the following interlocks must be
checked:
 The high oil temperature switch (TSH 024) must be turned off
 The high-high oil temperature switch (TSHH 024) must be turned off
The pump in service can then be started from the SCP. The gear unit lubrication
system start indicator on the SCP should flash during the starting sequence. A warning
horn will sound continuously for 10 seconds before the pump starts work.
The indicator “Gearbox unit lubrication stopped” on the SCP will remain on until the
selected lubrication pump is running and the following alarms are off:
 Oil pressure in the reducer: low (PSL 025).

 Oil pressure in the reducer: low-low (PSLL 026).
 Oil flow in the reducer: low (FSL 023).
 Oil flow in the reducer: low-low (FSLL 023).
 Oil flow in the reducer: low (FSL 021).
 Oil flow in the reducer: low-low (FSLL 021).
Then, the indicator will turn off, the lubrication system of the reducer will start to
operate and the display of the SCP will indicate “Reduction lubrication system in
operation”
5.4.1.2 Start-up of the intermediate shaft lubrication unit
The lubrication unit can be started from the local control panel or remotely by a
simple DCS instruction, therefore, before starting the pump from the control room,
ensure that the unit is configured in remote mode Otherwise, you must start from the
button located in the unit cabinet. The layout of buttons in the cabinet corresponds to
the following:
Middle shaft lubrication unit keypad
The greasing unit will activate local indication and alarm signal, when any of the
following failures occur:
 Motor failure (overload) of grease supply pump.
 Motor failure (overload) of grease filler pump.
 The feedback signal of the finished grease supply cycle fails.
 Low fat level in 60 l pond.

The level of grease is controlled by a level sensor, located at the top of the grease
tank.
The sensor signal controls the start and stop of the grease fill pump motor, located in
the 200 L drum.
5.4.1.3 Close up of high voltage feeder circuit breakers
The main motor circuit breaker isolates the mill drive motors from the current. This
switch must be on, grounded and secured before any maintenance work is performed
on the mill.
This circuit breaker must be prepared to close, before the CSM-1500 mill drive motor
can start running.
When the circuit breaker is installed and ready to close, the availability of the
mainstream should be indicated in the SCP.
5.4.1.4 Start mill motor
 Before the mill motor can be started and the “Mill ready to start” signal is
generated, the mill Level 2 and Level 3 permits must be present, the high
voltage switch must be prepared, the system must be running lubrication of the
gear unit and the following interlocks must be disconnected:
 Emergency stop.
 Alarms and control system failures.
 Motor winding temperature: High and High-High (TAH/HH 050 to 055).
 Temperature of mill motor bearings: High y High-High (TAH/HH 056 to 059).
 Gearbox bearing temperature: High y High-High (TAH/HH 011 to 012).
 Shaft bearing temperature: Alta y Alta-Alta (TAH/HH 008 a 010).
 Alarms or failures of the gearbox lubrication system.
 Grease system failure.
 AT switch failure.
At this point, there should be no failures in the mill control system, but it may be
necessary to reset the alarm system in the SCP to reset any faults stored in the system.
If a fault persists, electrical maintenance personnel should check the control room to
detect the cause of the problem.

When the mill motor is ready, then the equipment can be started from the SCP.
Once the start command has been received, a signal is sent to the starter of the main
AT motor to close and simultaneously a signal is sent to the automatic greasing
system to start the lubrication cycle. Then, a signal from the starter device will
confirm that the AT starter unit is closed and a mill start signal will be generated in the
SCP. Next, the SCP will indicate that the mill is working.
5.4.2 Stop sequence

Stop the mill feed → stop the main motor → stop the grease lubrication system of
the motor shaft → stop the gearbox lubrication station.
A simple operator instruction will stop the mill. When a stop signal is received, an
open command is sent to the starting device of the main AT motor and simultaneously
a signal is sent to the automatic greasing system to stop the lubrication cycle.
A signal from the starting mechanism will then confirm that the AT starter is open and
a mill stop signal is generated in the SCP. Then, a signal in the SCP will indicate that
the mill has stopped.
A simple operator instruction will stop the gearbox lubrication system. When a stop
signal is received, the pump is stopped in service. A signal is then generated in the
SCP and it will indicate that the gearbox lubrication system has stopped.
Mill detentions can be separated into three categories: standby detention, long-term
detention and emergency detention. Emergency detentions are analyzed in the
"Emergency conditions" section of the manual. The variable between the other two
types of detentions is their expected duration.
If the detention is expected to be of short duration, the most practical way is to turn
off the mill and place it in standby mode, which leaves the mill ready to be reactivated
when necessary. During a standby stop, the mill must be started periodically so that
the ground product does not settle in the mill.
If the detention is expected to be longer, measures must be taken to clean the mill so
that once it is turned off, the product does not settle or solidify in the body of the mill.
5.4.3 Short-term shutdown stand-by

1. Suspend the mill feed, but continue adding water until the solids content of the
suspension in the mill is reduced to below 5% of its weight.
2. Determine the percentage of solids by using a density rate reading or similar
method.
3. Stop the mill drive motor.
4. Stop the gearbox lubrication pump and automatic greasing system.
5. The mill drive motor must be restarted for about 10 minutes every two hours during
standby shutdown. This is to prevent the ball load from solidifying during the stop.
Make sure that enough water is added to keep the balls submerged during operation.
Make sure the gearbox lubrication pump is in service during mill operation.
NOTE:
During milling or if the mill is operated without new feed and process water, the
balls must be kept submerged in liquid. High temperatures and damage to the
coatings can occur if the balls are stirred without water to dissipate heat.
5.4.4 Long-Term Shutdown

1. Stop feeding, but continue adding water until the solids content of the suspension in
the mill is reduced below 5% by weight.
2. Determine the percentage of solids by using a density cup or similar method.
3. Stop the mill drive motor.
4. Stop the water supply.
5. Stop the gearbox lubrication pump and automatic greasing system.
6. Record the times required for the previous procedure for subsequent references.
Clean the mill with water until the discharge material has been reduced. The rotation
time will be limited within a period of 5 to 10 minutes. Some premature wear and
damage to the mill liners may occur if it operates for any period without power. The
steel balls will be removed from the mill in case of long-term arrest to avoid
permanent deformations in the shell.
Disconnect all power sources from the mill and its auxiliary equipment.
Remove water from the cooling pipe to prevent it from freezing and cracking in it.
Make sure lubrication systems are free of contaminants. Make sure the vents are
working properly and that the heaters are activated on a regular basis to prevent
condensation from forming inside the tanks.
Place moisture absorbing material on all electrical and control panels to prevent
moisture build-up and seal the control panel.
Note: Periodically check the mill, both mechanically and electrically, and
perform maintenance as necessary.
5.4.5 Failure shut down

The detention procedure in case of failures conforms to a normal sequence of
detention and its procedure will depend on the estimated stop time.
The most common failures are as follows:
1. The feed to the mill has stopped or is minimal, which affects the operation.
2. The mill or auxiliary equipment has abnormal vibration.
3. An abnormal noise emanates from the gearbox.
4. There are loose or broken connector fittings.
5. Loose or broken drive unit and main motor fixing hardware.
6. Erratic operation of the gearbox lubrication station or the drive shaft grease
lubrication station.
7. The gearbox or motor bearings have an extreme temperature variation.
8. Main motor operation becomes erratic.
9. The couplings are defective.
10. There is an abnormal discharge of material from the power or discharge ports.
11. The electrical and mechanical control system has a malfunction.
Stop feeding and start the detention procedure. Disconnect all sources of power from
the main drive motor and auxiliary equipment and lock it with locks and warning
advertisement.
5.4.6 Emergency stop

The emergency detention process is the same as the long-term.
5.5 Normal Operation
5.5.1 Adjustment of mill load and output

Maintaining the mill load and monitoring the feed capacity can optimize the grinding
system to improve efficiency. Regularly monitor the feed capacity, ore hardness,
actual power and mill load (medium weight). Visually inspect the volume of steel shot;
the steel shot exiting the mill are to be stowed and counted to determine the steel shot
consumption to grind the required material. Prepare a reasonable shot filling plan
according to above data.
Uniform feeding is one of the most important conditions for getting the highest output.
Therefore, the operator shall adjust the feed volume carefully and aiming for a high
yield and stable output. The water content of the feed will affect material motion in
the shell notably; thus influencing handling ability. The shot diameter can be
increased or reduce to maintain the optimum ratio for material volume.
The feed rate will determine the material dwell time within the mill if other conditions
remain unchanged. In the case of other parameters being fixed, the discharge can
become coarser with increased feed and finer with reduced feed.
The ratio of the grinding media affects the discharge particle size distribution. The
discharging particle size will become finer when increasing the medium shot ratio;
decreasing the shot ratio will increase the discharging particle size. The shot ratio size
is an important means of adjusting the mill output and power draw.
The quantity and graduation of the steel balls can be adjusted according to the feed
material and the particles of the product (P80). Regularly add steel balls to maintain
optimal performance. The specification of additional steel balls shall be calculated as
the maximum diameter based on the original maximum size of the balls.
Make sure all equipment protections are in place during operation to avoid any
damage. Locate notices in case you require personal protection items.
The stirred mill has a very strong magnetic liner installed; therefore all loose
metal objects and electronic equipment must be removed from the area.
Personnel who have a heart condition and have pace makers are to avoid
entering the area.
5.5.2 Mill Power Control

The operation strategy of the Vertical Mills, consists in maintaining the nominal
power or amperage, by means of the dosage of balls, when the amperage is of 80 to
90%.
Ball recharge control is based on the power records (indirectly) or on the basis of the
Amperage (directly) of the 4300- ML-101 @ 103 mills, whose decrease allows the
need for recharging to be noticed in order to keep stable the power level in the mills or
manageable according to the operational conditions.
In addition, there is a monitoring of the granulometry of the product of the overflow
of hydrocyclone batteries, through its online monitoring, by means of the particle size
analyzer 4300-PS-101, which will allow to monitor the three overflow lines of The
Plant and thus handle the operation of each mill, to ensure the size of the trailer
product.
5.5.3 Pressure control and percentage of solids to cyclones

Of the two variables, pressure and percentage of solids, which influence the cutting of
a hydrocyclone, the latter is the most important and easiest to control. The
hydrocyclone pressure will be given by the number of hydrocyclones open or in
service, for a given flow rate. Since the speed of the pump is controlled to maintain
the drawer level, there is not enough flexibility to determine the number of
hydrocyclones in operation.
For the reasons indicated, the typical cut-size control strategy will be controlling the
percentage of feed solids to the hydrocyclone battery. The higher the dilution, the
smaller the cut size and vice versa. It is important to visualize this relationship
between percentage of solids in the feed, cut size, circulating load and percentage of
solids in the overflow of hydrocyclones.
From the above it follows that the typical control strategy applied to the mill
discharge drawer subsystem - feed pump - hydrocyclone battery is summarized in:
• Control the flow of water to the discharge drawer of the mills or pumping
hydrocyclones, depending on the percentage of feed solids to the mill and the
cleaning float stage.
• The percentage of solids in the hydrocyclone feed should be in the order of
33% by weight. The exact value will depend on the fresh load, the hardness of
the mineral, the circulating load and the cut size accepted.
5.5.4 Water dosing processes to tanks feeding cyclones

The process water flow added to the 4300-ZM101 @ 103 hydrocyclone feed drawers
is associated with density measurement through a DPCell and flow system using an
electromagnetic flowmeter, whose resulting information allows determining the
percentage in solids that feeds the cyclone, and thereby regulate the process water
flow necessary to reach the set point of solid percentage set by the operator, provided
that the percentage in operational solid is greater than that set by the operation.
The design condition of the cyclone feed considers a percentage in solids of 33%, a
value that must be set as a set point to add or not add water to the tank, the above will
mean that, for ideal balance conditions, the maximum total flow of process water
required for classification in the towing process will be 193.5 m3 / h, equivalent to a
flow of 64.5 m3 / h per circuit.
5.5.5 Lime dosage in the cyclone underflow

The lime slurry supply is projected from a start in the current manifold that supply the
existing pumps of the TK-1 and TK-2 and TK-3 pond. From here, two projected
centrifugal pumps will be fed (1 operating and 1 stand by) that will distribute, through
a new loop, the lime slurry in the underflow drawers of the three cyclone batteries
4300-CC-101 @ 103.
The control of this dosage is regulated from the online measurement of the pH in the
overflow flow of the hydrocyclone batteries, for this the control room operator will
enter the set point value of the target pH to be reached in the product of grinding, and
the dosage of whitewash will adjust according to the value of the variable. As an
information, it can be noted that the average consumption in the current towing
process is between 0.36 to 0.18 kg of lime / t of ore, variability associated with the
type of ore to be processed and the product quality of the concentrate of Cu to obtain
in the next concentration stage.
5.6 Instrumentation and interlocks
The instrumentation considered in this circuit will be sufficient and necessary to allow
the measurement of the variables required to implement the control loops that allow to
meet the objective defined for the grinding, that is:
• frequency inverter for drive pumps,
• particle size analyzer,
• flowmeter and densimeter,
• level sensors, which allow interlocks to be established to protect both
equipment and people.
The interlocks associated with the trailer will be those associated with each vertical
mill, and those corresponding to the secondary equipment, such as:
5.6.1 Motor interlocks
5.6.2 System grease interlocks
5.6.3 Lubrication system interlocks
5.7 Control Principle

The supply scope excludes electrical control section. Specific control principle and
requirements: Refer < Stirred Mill Controls Functional Description>.
6 Maintenance
Maintenance can be divided into two basic forms, preventive maintenance and
corrective maintenance. Preventative maintenance is organised to keep equipment
functioning and or extend the life of the equipment and avoid unscheduled or
unexpected shut-downs. Whereas corrective maintenance is a repair based process to
get the equipment working and is predominantly unscheduled and disruptive.
Maintenance can include monitoring and detection systems, collection of performance
data, inspections and adjustments. Successful mill operation will largely depend on
schedule maintenance and intercepting failures before they occur or develop into
operational failures.
To obtain the best benefits of predictive maintenance, it is recommended to use a
system of complementary techniques, such as vibrations, thermography and oil
analysis. Keeping careful records of these and establishing trends of the set of
variables in order to achieve more accurate diagnoses of the current and future state of
the machine.
Develop a credible maintenance and lock out procedure and plan, including
inspections, data monitoring with regular reporting intervals and incorporate these
functions into a preventative maintenance plan. No matter how well a preventative
maintenance plan is implemented, corrective maintenance shut downs are to be
expected from time to time.
6.1 Maintenances plan
The maintenance matrix plan is composed of:
• Routine preventive maintenance.
• Scheduled Maintenance throughout the year with or without plant detention.
• Scheduled maintenance with plant detention.
The specialties included in our maintenance plan include mechanical, lubrication,
electrical, instrumentation and predictive specialty activities.
6.1.1 Main activities
System Activity
Activity Description Frequency Condition
Components duration
Screw liners Change liners 24 a 48 hrs by condition Stop
Thickness measurement liners Screw 16 hrs Monthly Stop

Inspection (high T °, vibrations, leaks and abnormal
Mill 30 min Daily Run
sounds)
Vibrations, temperature and thermography 2 horas Weekly Run
Vibrations, temperature and thermography 45 min Weekly Run

< 25°C to 3.000 hrs
Main motor Bearing lubrication 45 min Stop
<40°C to 1.500 hrs
Static motor analysis 1 hora Yearly Run
Oil change 8 hrs Yearly Run
Inspection (flow controls, T °, P °) 45 min Weekly Run
Change filter and dirt inspection to detect traces of metal
45 min By condition Run / Stop
Gearbox or dust
Drain reducer and oil pipes, circuit cleaning 6 hrs Yearly Stop
Oil analysis 1 hr Monthly Run

Inspection Automatic grease system (T ° bearings,
2 hrs Weekly Run / Stop
instruments)
Inspection Grease supply and pressure gauge to verify
1 hr weekly Run / Stop
Shaft bearings regulator setting
Remove expelled grease 1 hr Monthly Stop
Grease drum replacement 1 hr By condition Stop
Check after 2-3 weeks
of operation, re-tighten
Torsion or elongation of bolts 8 hrs Stop
after 6 months and then
Shell once a year
Wash and inspect the mill shell 12 hrs Every 3 months Stop
Visual inspection of structures 1 Weekly Run
6.1.2 Detention strategy

To determine the strategy of plant detentions is considered, the most disadvantageous condition according to the following variables:
• Plant detentions are necessary due to the change of liners.
• Mill detentions should be considered, coinciding with the detention of one of the concentrators.
• Benchmarking wear rate other miners.
• Benchmarking stop time due to change of screw liners.
• 12 hour monthly detention.
• 10% unplanned detentions.
BENCHMARKING
Liners Procedure Discharge and Time liners Total

Company Mill Liners change Changed liners Special tools
duration download balls Cleaning Time change time
Enlainadora
Cadia VTM-3000-WB 8 months To floor 11hrs Mill interior 2 End Liners 5 hrs 16 hrs
RME
2 End & 2 Wear
Cobre A VTM-1500-WB 7 months To floor 6 hrs Change screw - 18 hrs 24 hrs
Liners
Cerro 2 End & 2 Wear
VTM-1500-WB 7 months To box 10 hrs Mill interior Truck crane 14 horas 24 hrs
Verde Liners
2 End & 4 Wear
Cobre B VTM-1250-WB 6 months To floor 12 hrs Mill interior Telescopic crane 16 horas 28 hrs
Liners
Consequently, the following plant availability is estimated considering the above:
DETENTION PROGRAM
Annual Detentions Qty. Detention Hours Total hours
Liners change 2 30 60
Monthly detentions 10 12 120
Unforeseen (10%) 12 18 216
Total, annual detention hours 396
Total, annual hours available 8760
Availability 95%
6.2 Troubleshooting
6.2.1 Motor failures
Failure Probable cause Action

High motor coil • Unbalanced phase • Correct imbalance
temperature • Incorrect power factor • Adjust power factor
High bearing temperature Insufficient lubrication Add grease
Low power after adding

Screw wear Replace liners
balls
Excessive vibration Misalignment of couplings Check alignment
6.2.2 Gearbox failures
•Cooling • Check Cooler

insufficient • Check valve
• Malfunction thermostatic
High temperature
of the cooler • Check for leaks
• Problem with the lubricant
reducer • Check the reducer
• Line leaks • Change lines

• Dirty filter • Change filter
• Chiller blockage or breakage • Check cooler
Low oil flow
• Relief valve in poor • Check / replace relief
condition valve
• Flowmeter Failure • Check flow calibration.
• Replace line.
Low Pressure Oil Flow • Broken line
• Confirm pressure with
Indicator • Pressure switch failure
pressure gauge
6.2.3 Intermediate shaft failures

•Perform vibration
measurement
•Check condition of seals
•Inadequate lubrication
High temperature in in bearings and bushing
•End of life of mechanical
bearings or bushings •Check for leaks
elements
lubricant in lines or clogs
•Perform bushing
measurement with feeler
•Line leaks •Change lines

•Dirty filter •Change filter
•Block or break lines •Check cooler
Low grease flow
•Relief valve in poor •Check / replace relief
condition valve
•Flowmeter Failure •Check flow calibration.
6.3 Component Changes
6.3.1 Motor change

 De-energize corresponding equipment to intervene. Install personal security
lock
 Prepare / install work surface for electrical cable disconnection, debris and
bolt removal fixing the motor base.
 Disconnect control power and motor power cables.
 Prepare a chain sling with 4 branches of equal length, with shackles of
diameter ¾ ”. Engine weight 10500 kg.
 Install ring on the main hook of the Crane Bridge and the branches with
shackles of ¾ ” placed on the hooks of the branches install them on the lifting
ears of the electric motor. Proceed with slow movements of lift, to the slight
and even tension of the branches of the chain sling.
 Remove Motor-Reductor coupling covers.
 Loosen and remove the 16 fixing bolts from the base of the electric motor to
the reducer.
 Proceed to slowly lift the electric motor until the electric motor base is
removed from the radial socket of the pedestal. Subsequently with normal
movements, move the equipment by touching the respective sirens of the
Crane Bridge to a safe, previously established work surface.
 Posing an electric motor on a prepared pedestal and removing the engine
strobe maneuver.
 Install a scrubbing maneuver on a replacement electric motor to be installed.
Move to the physical place of the intervened equipment.
 With slow movement, bring and present the motor mounting flange on the
support pedestal, align perforations and holes with thread. Once aligned, fit
and position the electric motor on support stand. Maintain a scrubbing
maneuver, slightly tense.
 Install all loose mounting bolts of electric motor base. Torque 4 bolts. Check /
correct alignment of reduction motor shafts. Subsequently torque all bolts.

 Remove engine bleed maneuver.
 Install coupling, install rubber stops according to the specific sequence.
 Connect power cables for control and motor power.
 Remove installed work surface for electrical cable disconnection, debris and
bolt removal fixing the motor base. Order and cleanliness of the work area.
 Remove personal security lock. Energize intervened equipment when
requested.
6.3.2 Gearbox change

lock.
 Prepare / install work surface for electrical cable disconnection, debris and
bolt removal fixing the motor base.
 Disconnect control power and motor power cables.
 Prepare a chain sling with 4 branches of equal length, with shackles of
diameter ¾ ”. Gear unit weight (without oil): 11800 kg
 Install ring on the main hook of the Crane Bridge and the branches with
shackles of ¾ ” placed on the hooks of the branches install them on the lifting
ears of the electric motor. Proceed with slow movements of lift, to the slight
and even tension of the branches of the chain sling.
 Disconnect oil supply and return lines from the gearbox lubrication system.
 Position crane bridge with hook on reducer with chain sling. Install the
stripping maneuver to the Reducer - Pedestal Bracket assembly considering at
least 3 branches.
 Loosen the 40 fixing bolts of the Reducer with the pedestal.
 Remove bolts and upper coupling cover. Loosen and remove the shirt fixing
bolts.
 Proceed to slowly lift the Pedestal Support - Reducer assembly until the
machón is disconnected. Subsequently with normal movements, move the
assembly to a safe work surface, previously established.

 Remove the 40 reducer base fixing bolts to the support pedestal. Remove stand
pedestal and install it in spare gearbox. Install and torque.
 Move to the physical place of the intervened equipment. With slow
movements present in mounting position, align perforations and holes with
wires. Pose reducer and torque bolts. Check / correct alignment of Reducer
Shaft - Shaft Connector. Then fix and torque all bolts.
 Remove the stripping maneuver from the Pedestal Support - Reducer
assembly.
 Connect the oil supply and return lines of the decoupled lubrication system.
 Install and torque the shirt fixing bolts. Install the rubber blocks with the
device designed for installation. Install top cover with its respective fixing
bolts to Drive coupling sleeve.
 Install a scrubbing maneuver on a replacement electric motor to be installed.
Move to the physical place of the intervened equipment.
 With slow movement, bring and present the motor mounting flange on the
support pedestal, align perforations and holes with thread. Once aligned, fit
and position the electric motor on support stand. Maintain a scrubbing
maneuver, slightly tense.
 Install all loose mounting bolts of electric motor base. Torque 4 bolts. Check /
correct alignment of reduction motor shafts. Subsequently torque all bolts.
 Remove engine bleed maneuver.
 Connect power cables for control and motor power.
 Remove installed work surface for electrical cable disconnection, debris and
bolt removal fixing the motor base. Order and cleanliness of the work area.
 Remove personal security lock. Energize intervened equipment when
requested.
6.3.3 Screw liners change

Remove the mill balls. Refer to the "Ball load removal procedure" in the maintenance
section of this manual. Screw liners can be replaced with the screw either in the mill
or moved to a work area. If the screw is to be removed from the mill, follow the
instructions on the assembly drawing for transporting the screw.
Worn coatings can be removed by adhering clamps to the hoist ring incorporated into
the liner near the shaft, removing the bolts from the liner and dragging the liner out of
position.
The cast liners are heavy and present a hazard to the maintenance personnel.
Adequate lifting facilities must be available and safety precautions taken to avoid
injury to personnel and damage to the liners.
When replacing digging shoes or flyghts ensure the rubber underlay is replaced
if damaged.
New liners can be lifted into position by putting eye bolts in the liner lifting holes that
are located on a bolt circle greater than the screw diameter, and using the lifting eye
for a three point lift, positioning the liner using a fork truck or hoist.
When installing new liners always start with the end liner and locate it in the lower
extreme of the elongated holes in the screw. That will establish the position of the end
liner while leaving the maximum amount of space to install the wear liners above the
end liner.
If the screw was removed from the mill, re-install it following the “Screw
Installation” procedure contained in the Installation Section of the manual.
With the screw in position, the mill door can be closed. Before closing and bolting the
mill door, apply a bead of silicone sealant around the door jamb inside the bolt area.
Be sure that no foreign matter is present on the flanges so that a tight seal is made.
With the door closed and bolted, water should be added to the mill to confirm that the
door is sealed completely. This should be done before any balls are introduced to the
mill.
Add the ball charge and follow the commissioning procedures contained in the
Operation Section of the manual to bring the mill back into operation.
6.3.4 Ball load extraction

lock.
 Download Balls to floor or with drawers. The use of drawers allows a more
orderly removal of balls and a reload of these faster.
Ball to floor Ball to box
 Before starting to extract the grinding balls from the equipment, the pulp
present in the mill must be diluted. With the mill running, rinse the mill with
water to reduce the percentage of solids to approximately 5% or less.
 With the mill still running, loosen the locking bolts in the ball discharge port
located at the bottom of the access door. Only turn these screws once or twice.
If necessary, use screw jacks to remove the valve shaft from the mill body
Manual valve Manual valve
 Arrange a container to collect the balls located in front of the discharge port.
Pull the valve handle from the mill's discharge port so that the water and the
balls come out. Consider all necessary safety measures to avoid exposing
personnel to the ball and water discharge line.
 When the ball container is full, push the handle toward the mill to stop the
flow of balls.
 With the mill still running and having added rinse water, replace the filled ball
container with an empty one in front of the door and repeat the above
procedure.
 When about 70% of the ball load has been removed or the flow of the balls is
slower, stop the mill motor. Leave the ball port valve open for the remaining
water to drain.
 Locate several ball containers in front of the door to collect the balls when the
door is opened.
 Remove the bolts from the access door flange; drain the hydraulic jacks from
the door flange with the pump supplied with the screw transport system.
Hydraulic jacks and pipes should have been previously filled with oil and
purged lines to remove air.
 When the hydraulic jacks are being extended, the manual jacks installed at the
articulation points must extend simultaneously between them to keep the door
vertically and in the most open position allowed by the hinges, in other words,
must remain butt so that there are no displacements of the door that hinder its
closing later.
 After the door opens, wash the remaining balls with high pressure hoses or
remove them with shovels and rakes. A mini loader (Bobcat) can be used to
help clean the balls and the area in general.
 The load of balls in the mill at maximum operating power and with new
coatings on the screw is about 127,000 kg. With the screw linings worn and
operating at full power, the ball load could be up to 10% heavier. The reason
for this is that, as the screw wears out it becomes smaller in diameter and
requires a higher ball load to reach the same power. The height of the ball load
will indicate when the screw needs new liners.
6.3.5 Magnetic cladding change

 For the disassembly of the magnetic cladding, use a wooden wedge and a
rubber mallet
 Start from the top down by prying the wedge and releasing the pieces.
 Remove all irregularities and excess welding from the surface of the inner
shell.
 Clean and prepare the surface of the steel shell by removing any trace of
grease, oil and dirt that exists in the shell. The surface must be free of grease,
pores and / or oil.
 Wash the shell surface with solvent.
 Separation bars must be installed.
 If the steel separation strips are in place, continue, but repair the steel
separation strips.
 Fit the first section of the cladding against the vertical steel support strip to the
right of the mill door opening.
 Ensure that replacement linings are available, located near the base of the
lower section of the mill.
 In case the liners differ slightly in size and do not fit properly between the
vertical steel bands, the steel band may require removal and reinstallation.
 • Ensure that the liners are in the correct direction and position with respect to
their profile.
6.3.6 Intermediate shaft lubrication system drum change

A record should be kept of the amounts of fat supplied in order to project consumption
and not have supply problems. Before using the feed system from the barrel to the
60-liter tank you must ensure the following conditions:
 Keep the barrel clean, the grease should not be contaminated with impurities.
 Before installing the pump, there should be no contact between the tube and
the bottom of the barrel.
 Clean the outlet filter periodically.

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Manual IOM Molino Vertical

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Installation Operation and Maintenance Manual

Instruction Manual for

CSM 1500 Vertical Stirred Mill

CITIC HIC Equipment Serial #2100-301/1

3.15.1 General Instruction.........................................................................................................44

4.1.2 Electrical Unit.............................................................................................................. 99

6.3 Component Changes......................................................................................................... 130

THIS MANUAL IS FOR REFERENCE USE ONLY.

1.4 Safety regulation

gear must be sufficient to bear the weight of the equipment.

to do so may be an infringement upon safety regulations. All safety and guide

 The equipment operators must undertake training in order to familiarise

1.4.1 Environmental pollution

1.5 Communication address

1.6 Lifting, transport and Storage

1.6.2 Storage conditions

1.6.3 Storage period

1.6.4 Open-package inspection and y acceptance

2.6 Mill design parameter

ÍTEM Data Unit Value

2 Shell Length mm 4.780

5 Main Motor Speed rotation r/min 740

2.7 Summary of the primary structure of the equipment:

2.7.1 Feed pipe assembly

2.7.2 Liner assembly

2.7.3 Drive assembly

THIS MANUAL IS FOR REFERENCE USE ONLY.

3.3 Tool, Equipment and Manning List.

Tooling List – Customer Supply

 20 to 30 litres cleaning solvent such as Acetone

Drive Shaft Assembly

Bottom Shell Assembly

Door Open Tool

Magnetic Liner Screw Liner

3.6 Use of Drawings

Reducer Filter Elements 2 6

Tabla: 3.9 Designations

ITEM Data Unit Value

3.10 Protection of the Mill parts during storage

stable quality product.

240000 14300 30267 19252 14694 16230 28745 14000

Tabla: 3.13.2 Tabla de especificaciones sistema lubricación reductor

1500 7,5 2,5 143 60 N/A 2,2 1000

Table: 3.13.3 Main Parts List

Fig: 3.13.1 Structural layout of the Stirred Mill

3.14.1 Installation procedure

support frame when constructing any external structure.

3.15.1 General Instruction

3.15.2 Bottom Shell Installation

Fig. 3.15.2 Structure of the lower housing assembly

Figure 3.15.3: Example of mounted sub-sole plate

Figure 3.15.4: Sub-sole plate design

3.17 Drive Frame Assembly

Check the motor for correct direction of rotation.

3.18 Intermediate shaft assembly

Figure 3.18.1: Intermediate shaft assembly layout

3.19 Door Installation

3.20 Installation of the Hydraulic Door Jacks

3.21 Automatic Grease Assembly

For additional information review the manual Bijur Delimon S67610

3.23 Magnetic Liner Segments Assembly

recycle port and ball port outlet gate.

c. It is recommended that the magnetic liners be test fitted before any

Door Magnetic Liners