MANUAL1 - Copia - 2

Description of
Grinding Mill
Equipment
2.7.2 Ring gear seal
Figure 15. Ring gear seal
The gear guard is equipped with felt seals that seal radially against rolled “runner” rings
that bolt to the sides of the ring gear. The felt seal is stationary and clamped to the
sidewalls of the guard by a number of retainer segments. The retainer segments on the
upper half of the guard have an integral dust shield, which shrouds the seal-riding
surface. In some mills the felt seal arrangement is swapped for an oil seal arrangement.
2.7.3 Pinion seal
The gear guard is furnished with felt or hose type pinion shaft seals. The seals are
stationary and run on the pinion shaft.
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Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Outotec Document ID:
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Description of
Grinding Mill
Equipment
2.7.4 Pinion shaft end cover
Figure 16. Pinion shaft end cover
The pinion shaft end cover is supplied to provide guarding of the rotating shaft end. In
addition, this cover can be fitted with sensors and a toothed wheel for use in locked
charge detection. Refer to Operation section of this manual for more information about
this assembly.

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Description of
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2.7.5 Infrared sensor assembly
Figure 17. Infrared sensor
Where fitted, the infrared sensor assembly monitors the pinion face temperature
gradient. The sensors are oriented on a radial plane to the pinion in a location which
keeps the sensors away from lube splatter. Instrument air is constantly blown across the
sensor lenses to prevent debris from accumulating. The sensors are wired to
transmitters which send a 4-20 mA signal to the mill control system for monitoring of
absolute and differential temperatures.

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Description of
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2.8 Mill lining assembly
Figure 18. Mill lining assembly
The mill lining assembly is designed to protect the structural components of the mill
from impact forces and abrasive wear while aiding in the grinding process. The lining
assembly consists of a rubber backing, shell liners, discharge trunnion liner and head
liners.

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Description of
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2.8.1 Rubber backing
Figure 19. Rubber backing
The rubber backing is made of non-reinforced vulcanized rubber which is cemented to

the interior surfaces of the mill. The rubber backing helps to seat the liners. Additionally,
the rubber backing provides protection against corrosion and abrasive wear for the
structural components of the mill.

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Description of
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Equipment
2.8.2 Shell liners
Figure 20. Shell liners
The shell liners are the main wear component of the lining system. They consist of two
main components: wear plates which protect the main structure, and lifters for lifting the
charge. The liners are attached to the mill by bolts, which pass through the mill shell,
and hold the liners in position. Gaskets are provided for the fasteners to prevent slurry
leakage around the bolts.
It is critically important for the longevity of the mill to ensure there are no circumferential
pockets behind the liners that could lead to slurry racing.
WARNING
Slurry racing is very destructive and can lead to catastrophic failure of the mill structure.

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2.8.3 Feed end and discharge end head liners
Figure 21. Feed end and discharge end head liners
The head liners, similarly to the shell liners, consist of plates and radial oriented lifters,
with the same fixation type. (Note: Rod mills do not have lifters in the feed or discharge
head lining.) The liners are attached to the mill by bolts, which pass through the mill
head, and hold the liners in position. Gaskets are provided for the fasteners to prevent
slurry leakage around the bolts.
2.8.4 Discharge grate (if provided)
The discharge end of grate discharge mills has liner grates which help to retain material
(balls/rocks) which are larger than the grate aperture in the mill. After the material flows
through the grate openings it is elevated and discharged via the pulp lifter vanes. The
grates and pulp lifters are attached to the mill by bolts, which pass through the mill head
and hold them in position. Gaskets are provided for the fasteners to prevent slurry
leakage around the bolts.

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Description of
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Equipment
2.9 Mill feed assembly
Figure 22. Mill feed assembly
The mill feed assembly consists of a feed trunnion liner, feed chute, feed trolley with
rock box (where integrated, typically SAG and AG mills only) and the inlet seal with
slurry slinger. The purpose of the mill feed assembly is to provide the customer with an
interface for introducing process material into the mill.

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Description of
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Equipment
2.9.1 Feed trunnion liner
Figure 23. Feed trunnion liner
The mill trunnions are designed as needed for the mill bearings and create an opening
which is larger than needed for the feed spout. This opening may be reduced by a
casting designed to allow fitment of the feed seal.

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2.9.2 Feed assembly
2.9.2.1 Feed spout or feed chute
Figure 24. Feed spout
A feed spout consists of a curved pipe which is cast from wear resistant material. A feed
chute is a fabrication which is lined with wear resistant liners. Feed material enters the
spout or chute and the material is fed into the mill via gravity or pressure or both.
A steel collar, concentric with the feed head opening, is compression fitted on the end of
the feed spout/chute to form a riding ring for the double rubber lipped feed seal.

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Description of
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Equipment
2.9.3 Feed trolley
Figure 25. Feed trolley
The feed trolley is a fabricated steel structure that supports the feed spout and rock box.
The trolley has four wheels and rides on a pair of customer supplied rails. The feed
trolley must be locked in place with a lock pin so that the feed spout can be properly
aligned with the feed seals.
2.9.4 Rock box (if supplied)
The rock box is supplied with replaceable wear plates that protect the box from the
impact and abrasion of ore falling from the feed conveyor. The top of the rock box has a
labyrinth seal which is designed to interface with the customer supplied feed chute.

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Description of
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2.9.5 Feed seal and slurry slinger
Figure 26. Feed seal and slurry slinger
The feed seal consists of a water-purged double lip rubber seal. The seal runs on the
wear ring which is clamped to the feed spout.
A slurry slinger tapers out from the feed opening and directs seal water and any slurry
that happens to leak past the feed seal away from the mill trunnion bearing.
2.10 Mill discharge assembly
The mill discharge assembly consists of a discharge trunnion liner and, where needed,
a ball retaining ring.

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Description of
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Equipment
2.10.1 Discharge trunnion liner
Figure 27. Discharge trunnion liner
The discharge trunnion liner is a fabricated steel sleeve with several flanges. It protects
the inside of the discharge trunnion and provides a mounting flange for the attachment
of the trommel, if provided. The interior of the trunnion liner is lined with 15 mm of black
rubber over 6 mm of contrasting rubber or may be fitted with snap in rubber liners where
the product size demands greater wear resistance. The trunnion liner structure itself is
not considered a wear item and with proper maintenance it should last the entire life of
the mill, however, routine repairs to the wear lining within the trunnion lining must be
performed regularly to maintain effectiveness.
WARNING
The integrity of the trunnion liner is critically important to prevent slurry racing between
the trunnion liner and the trunnion. Slurry racing is very destructive and can lead to
catastrophic failure of the mill structure.
Foam fillers are often used to fill the void between trunnion liner and trunnion to reduce
the risk of slurry ingress which can result in catastrophic damage.

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Description of
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Equipment
2.10.2 Ball retaining ring
The ball retaining ring (if supplied) is a hardox plate which has slots to allow slurry to
pass through. The ring is located at the inboard end of the discharge trunnion liner. It is
fixed in place with compression bolts.
NOTE: The ball retainer slots are directional. If the larger aperture side of the slot is
not oriented toward the discharge end of the mill, major problems with pegging of the
retainer may occur.
2.11 Trommel assembly
Figure 28. Trommel assembly
The mill trommel, where supplied, is a fabricated steel frame with a mounting flange.
The outside surfaces of the frame are covered with rubber or polyurethane and the
inside is lined with replaceable molded polyurethane panels with slotted openings.
Spirals are fitted inside the trommel to promote discharge of ball fragments that work
their way past the ball retaining ring.

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Description of
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Equipment
2.12 Lubrication systems
2.12.1 Lubrication systems for HSB mill
The HSB mill needs an operational lubrication system. Refer to Operation section of this
manual for operational description and interlocking.
Different systems take care of the mill lubrication:
• The mill support bearings and pinion bearings have a hydrostatic oil circulating
system.
• The bearing housing seals are lubricated by an automatic intermittent oiling system.
• The gear set is lubricated by an automatic intermittent grease spray system.
• The main reducer(s) are lubricated with a continuously circulating oil system. Refer
to the manufacturer’s manual for more information.
• The inch drive reducer uses a bath type lubrication system. Refer to the
manufacturer’s manual for more information.
• The main drive motor bearings are lubricated with a continuously circulating oil
system. Refer to the manufacturer’s manual for more information.
Refer to the manufacturer’s manual for a complete description of the bearing lubrication
system.
2.12.2 Lubrication systems for SRB mill
The SRB mill needs and operational lubrication system. Refer to Operation section of
this manual for operational description and interlocking.
Different systems take care of the mill lubrication:
• The mill support bearings and seals have an intermittent grease system.
• The gear set is lubricated by an automatic intermittent grease spray system.
• The mill main speed reducer and the pinion bearings have a circulating oil system.
Refer to the manufacturer’s manual for a complete description of the bearing lubrication
system.

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Description of
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3 Process description
3.1 Tender sizing datasheet

Insert sizing calcuations from proposal documents here.
3.2 Initial charge of grinding media
As grinding media wear down, they reduce in size so additional top-size media are
added to the mill, thus an equilibrium of media size distribution is created. This size
distribution is advantageous to the grinding process and increases grinding efficiency.
In order to create an equivalent charge distribution as soon as possible, the mill must be
initially charged with media of different sizes, this sometimes being called a seasoned
charge fill.
3.3 Suggested initial charge
Table 1. Suggested initial charge
MEDIA TYPE: ENTER MEDIA TYPE MEDIA TOP SIZE: ENTER TOPSIZE
Media diameter Percent change Weight in

metric ton
3.4 Media wear rate

Grinding media wears away with the processed ore during grinding and is removed from
the slurry in a downstream process. The rate at which grinding media wears is based
on several factors including; media material, ore body type, throughput, and power. We
have provided ranges of anticipated wear rates and charging rates.
Table 2. Media wear and charging rates
Media Type Media Diameter
Rod Length Mass per Media

(for rod mills) Unit (ball or rod)
Dry feed rate Estimated Media

Consumption

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Description of
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Estimated Wear Estimated Charging

Rate Rate
3.5 Power draw

Main motor current is directly related to mill load. During commissioning a motor current
baseline should be established for duty load on the mill. During normal startup this
current can be expected to spike 1.5 to 1.6 times the baseline duty current. However,
spikes higher than this at startup can indicate the presence of a locked charge.
Additionally, if the power draw increases or decreases during mill operation, it is a sign
that the load in the mill may be increasing or decreasing and not always in a related
manner. If the increase or decrease of power draw is unexpected, significant and
sustained (or increasing) a normal mill shut down may be used in order to discover the
cause of the change in load.
Motors equipped with fixed brushes should be de-brushed according to the motor
manufacturer recommendation when continuously running with power lower than
nominal.
WARNING
Wound rotor induction motors are fitted with carbon brushes that wear over time.
Incorrect maintenance practices that allow the build-up of carbon dust within the brush
housing can result in arcing. Arcing within the brush housing will result in severe
damage to the motor.
3.6 Locked charge

A locked charge occurs when the mill is stopped and the charge settles in the voids
between the media. This settlement prevents proper rolling of the charge in the mill at
startup. Locked charges have been known to release from the shell at angles beyond
vertical and cause severe damage to the mill.
Care should be taken to prevent a mill from starting with a locked charge. Power draw
can be a very course indicator of locked charge; however, this indicator must be
programmed in to the control logic after a normal starting trend has been developed.
All Outotec ball mills are provided with locked charge protection which consists of
logical interlocks requiring the mill to be inched prior to start up if the mill has sat for an
extended period of time. Refer to the Operation section of this manual for more
information.

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Description of
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Equipment
WARNING
A locked charge start can result in catastrophic damage to the mill structure. Great care
must be taken to operate in such a way as to minimize the risk of locked charge events;
refer to the Operation section of this manual.
WARNING
Locked charge events and the damage that may occur through any occurrence are not
covered by the Outotec warranty for this mill. At the instruction of the mill owner
Outotec may allow adjustment to locked charge risk minimization protocols installed
with the mill but the mill owner takes full responsibility for the consequences.

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Description of
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Equipment
4 Technical data
Table 3. Customer information
CUSTOMER INFORMATION
Company issuing award
Customer order number
Delivery date
Company name - end user
Site location
Project name
Table 4. Proposal information
PROPOSAL INFORMATION
Outotec proposal number
Proposal entered by
Quotation date
Sales manager
Table 5. Project information
PROJECT INFORMATION
Outotec equipment number
Project manager
Installation date
Commissioning date
Table 6. Site data
SITE DATA
Site comments

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Description of
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Equipment
SITE DATA
Site advisor
Seismic zone
Site H20 temperature (°C)
Site H20 pressure (kPa)
Site air pressure (psi)
Table 7. Equipment description
EQUIPMENT DESCRIPTION
Mill type
Mill shell ID (m)
Mill length FF (m)
Mill effective grinding length (m)
Motor power (hp)
Motor power (kW)
Mill support type
Mill drive type
Motor type
Process type
Discharge type
Equipment comments
Quantity
Drive train location (viewed from

feed end)
Mill control
Commissioning

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Table 8. General mill technical data
GENERAL MILL TECHNICAL DATA
General assembly dwg
Technical comments
Design mill speed (rpm)
Max mill speed (rpm)
Min mill speed (rpm)
Shell direction of rotation
Mill liner material
Mill liner thickness (mm)
Media material type
Media topsize (mm)
Normal Operating Level* (media /

total charge): XX% / XX%
Maximum Operating Level*

(media / total charge): XX% /
XX%
Structural Design Level* (media /

total charge): XX% / XX%
Power Draw at Normal Operating

Level: xxxxkW
Power Draw at Maximum

Operating Level: xxxxkW
Motor power is calculated using
95% Efficiency of Drive
Number of hard copy instruction

manuals
Number of electronic instruction

manuals
Table 9. Major mill component weights
MAJOR MILL COMPONENT ESTIMATED WEIGHT (KG)
Shell

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Description of
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Equipment
MAJOR MILL COMPONENT ESTIMATED WEIGHT (KG)
Main motor assembly
Head (with integral trunnion)
VFD (transformer cabinet)
Ring gear (each half)
Main gearbox
VFD (power cell cabinet)
Main bearing housing (excluding

bearing)
Trunnion bearing baseplate
Pinion (excluding bearings)
Gearbox lubrication system

(excluding oil)
Gearbox baseplate
Table 10. Process data
PROCESS DATA
Feed material
Material characteristic
Material specific density
Ball BWI (kWh/mt)
Max feed size - F100 (µm)
Feed size - F80 (µm)
Product size - P80 (µm)
Process type
Process comments
Dry feed rate (mtph)
Feed moisture (%)

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PROCESS DATA
Duty charge level (%) To be removed?
Circuit type
% Circulating load
% Solids
Slurry pH
Slurry temperature (°C)

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Description of
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5 Product modifications
Information about modifications to the product: how modifications affect the warranty
and how they change the manufacturers responsibility in dealing with accidents.

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Description of
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Glossary
Autogenous grinding (AG) A grinding process where the grinding media is comprised of larger pieces
of the ore body.
Ball mill (BM) A grinding mill which uses balls as the grinding media. Typically the balls
are steel and comprise 30-40% of the total charge.
Can A piece of the mill shell. The shell may be comprised of one or more cans
depending on size and other constraints.
Charge The grinding media and ore body being ground.
Charge, fluidized The condition where the components of the charge are homogeneously
dispersed, allowing for smooth flow of the charge within the mill during
rotation.
Charge, locked The condition where a mill charge settles in an “at rest” state creating a
pseudo-solid. This condition posses a severe risk to damaging the mill if
the mill is not “inched” to fluidize the charge.
Coupling A device used to attach two rotating shafts. Couplings can be rigid, flexible,
or fluid based, depending on the application requirements.
DCS Distributed Control System.
Discharge The charge which has exited the mill, which consists of ground ore body,
media fragments and, during wet grinding processes, lubricant, usually
water.
Discharge end The end of the mill where the discharge is ejected.
Drive end The end of the drive train where the main motor is located.
Effective grinding length (EGL) The length dimension of a mill where grinding work is performed.
Feed The ore body which enters the mill to be ground. In wet grinding the feed
also includes a lubricant, usually water.
Feed end (FE) The end of the mill where the feed enters.
Gearbox/ Reducer A mechanical speed reduction device where input shaft speed is reduced
several times over to an appropriate output shaft speed through the use of
gears.
Grinding A communition process where abrasion, impact, and attrition are the
primary forces creating the size reduction. Typically this is done in a
horizontal rotating mill.
Grinding, wet Where a lubricant is added to the grinding process to increase flow and
reduce heat buildup. Typically water is used as the grinding lubricant.
Head The piece of a mill which provides radial support for the shell. Additionally,
in trunnion supported mills, the head attaches the trunnion to the shell and
transfers the loads from the shell to the trunnions.
HSB Hydrostatic shoe bearing.
HSB2 Hydrostatic shoe bearing, furnished with 2 hydrostatic pads per main
bearing housing.
HSB4 Hydrostatic shoe bearing, furnished with 4 hydrostatic pads per main
bearing housing.
Inching Unit For slow rotation of the mill (used in maintenance)

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Description of
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Lifting lugs Attachment points for lifting equipment pre installed. Additional lifting lugs
should not be added in the field unless prior approval from Outotec has
been received.
LRS Liquid resistance starter.
Media An additive to the grinding mill which aids in the grinding process. This can
be steel balls or rods, ceramic “pebbles”, or larger pieces of ore.
Mill A rotating machine used to perform grinding work.
Motor, auxiliary Any of a number of smaller motors used to power auxiliary equipment such
as generators or pumps.
Motor, main The large driving motor(s) used to rotate the mill.
Non-drive end The end of the drive train which is opposite from the main motor.
O-ring A circular shaped solid core seal part. O-Rings typically come joined as a
full circle, however, can also be provided as a string.
Pillow blocks Bearings housings for support bearings of the drive shaft.
Pinion The driving gear in a gear and pinion set. This gear transmits the rotational
force from the main motor to the ring gear to rotate the mill.
PLC Programmable Logic Controller.
Pulp racing Damage which is caused by slurry running in a lateral groove against a non-
wear part. Pulp racing can cause significant damage to the mill shell,
heads, and trunnions. A common symptom of pulp racing is leakage at joint
flanges.
RTD Resistance type device (temperature probe).
Semi-autogenous grinding A grinding process where a modest percentage, 15% by volume, of the
(SAG) charge is comprised of grinding balls. The remainder of the media is
comprised of various sizes of ore body.
Shell The piece of the mill which forms the diameter and length. The shell
provides the structural support for the mill liners.
SRB Spherical roller bearing.
Trunnion The piece of the mill which extends from the head for attachment of
feed/discharge assemblies and, in trunnion supported mills, for bearing
assemblies.
Trunnion liner A cast or fabricated piece which is designed to reduce the internal diameter
of the mill trunnion.
Trunnion lining A wear lining designed to protect the Trunnion Liner from abrasion and
impact.
WRIM Wound rotor induction motor.
V-ring Seal profile consisting of a seal lip and a clamping block. The name comes
from the shape made where the seal lip meets the clamping block.

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Copyright © 2018 Outotec Oyj. All rights reserved.
Outotec Oyj Tel +358 (0) 20 529 211

P.O. Box 86 www.outotec.com
FI-02201 Espoo E-Mail info@outotec.com
DQ-070049
SAG Mill
English 2018 Safety

SAG Mill Safety
This document (”Manual”) is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This Manual is intended for the use of Outotec's customers only for the purposes of
the agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the Manual shall be used, reproduced, translated, converted,
adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including withou t limitation, sale, resale, licence, rental or lease,
without the prior express written consent of Outotec.
Customer understands and accepts that the information in this Manual is subject to any change without notice. It is the customer's responsibility to determine whether there have
been any such updates or amendments.
The Manual has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every
effort has been made to ensure that the information in this Manual is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the
accuracy or completeness of the Manual. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort or
in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, includin g without limitation incidental, special, direct or
consequential damages arising out of or in connection with the use of the Manual. Outotec's liability for any errors in the Manual is limited to the docume ntary correction of errors.
Outotec logo is a registered trademark of Outotec Oyj.
Other product names mentioned in this Manual may be trademarks of their respective companies, and they are mentioned for identification purposes only.
Copyright © Outotec Oyj 2018. All rights reserved.
Outotec Oyj
Address: Riihitontuntie 7 D, PO Box 86
FI-02200 Espoo, Finland
Telephone: +358 (0) 20 529 211
Fax: +358 20 529 2200
Internet: www.outotec.com
09
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00 sanrau 30.11.2018 sanrau 30.11.2018 sanrau 30.11.2018 Preliminary
Rev Name Date Name Date Name Date Revision Text
Prepared Checked Released
Status: Original Size:
JUPreliminary [Orig. Size]
Customer: Project Phase: Site No.:
Marcobre Execution 10194601 – 0001A
Project Name: Customer Document ID:
Mina Justa Mills JU-001-06-0001A-2223-00-30-0003
Document Title:
Mina Justa Mills
Installation and Maintenance Manuals
Equipment No: Item No:

17-30-BM N/A Safety
2223-ML-201
Original instructions Translation of the original instructions
Language code:

1
SAG Mill Safety
Contents
Contents ........................................................................................................... 3
1 Essential safety principles ..................................................................... 4

1.1 Purpose of this manual ................................................................. 4
1.2 Purchased components ................................................................ 4
1.3 Principles for safe use of SAG Mill ................................................ 4
2 Limits of use ........................................................................................... 6

2.1 Environmental............................................................................... 6
2.2 Mechanical ................................................................................... 6
3 Personnel qualifications and training.................................................... 8
4 Personal protective equipment .............................................................. 9
5 Hazards and risks ................................................................................. 12

5.1 Mechanical hazards .................................................................... 12
5.2 Hazards related to maintenance.................................................. 12
5.3 Electrical hazards ....................................................................... 14
5.4 Hazards related to working environment ..................................... 14
5.5 Noise hazards............................................................................. 14
5.6 Ergonomic hazards ..................................................................... 14
5.7 Hazards related to materials and substances .............................. 15
5.8 Hazards related to control system ............................................... 15
5.9 Residual risks ............................................................................. 15
6 Emergency stops and safety switches ................................................ 16

6.1 Emergency stops ........................................................................ 16
6.2 Mill motor safety switch ............................................................... 16
7 Safety guards........................................................................................ 17
8 Safety fences ........................................................................................ 19
9 Chemical substances ........................................................................... 20
10 Environmental aspects......................................................................... 21

1
SAG Mill Safety
1 Essential safety principles
WARNING
Read the instruction manual.

.
Failure to observe the limitations, requirements, cautions, and warnings in these
instructions could result in death or severe injury.
1.1 Purpose of this manual
The Outotec grinding mill was designed and manufactured to meet strict quality and
safety standards. This manual is intended to provide instructions to skilled operators
and service personnel so they can safely install, operate, and maintain the mill.
WARNING
This manual does not purport to address all the safety concerns associated with
grinding mill installation, operation or maintenance practices. It is the responsibility of
the user to establish appropriate safety and health practices and determine the
applicability of regulatory limitations before construction.
1.2 Purchased components
Some components provided with the mill have been purchased from other original
equipment manufacturers (OEM). The customer is responsible of complying with all
OEM product guidelines.
WARNING
Failure to comply with all original equipment manufacturer guidelines constitutes

negligence on the part of the customer.
1.3 Principles for safe use of SAG Mill
• Keep the site clear of any useless material so that work is not disturbed or made
more difficult or dangerous.
• Do not operate the mill while persons are inside the mill or safety guards are
removed.

1
SAG Mill Safety
• Perform scheduled maintenance tasks regularly (see document Maintenance).

• If you notice a fault or any other thing that can create a hazard, always inform all
persons and act to remove the danger.
• Make sure that the fastenings of the gratings and handrails are correctly fastened.
• Inspect the parts you step on, such as bridges and platforms, for corrosion and
erosion effects.
• Do not use welding equipment near the shell, since they are rubber lined.
• Before starting the machine:
- Check that all safety guards are in position.
- Check that the surroundings of the moving parts are clear of
obstacles.
- Make sure that all persons are informed and clear of danger
zones.
• Before going inside the mill:
- Turn off the main circuit breaker of the MAIN electric motor and
lock it with a padlock.
- Turn off the safety switch of the inching unit motor and lock it
with a padlock.
- Make sure that the feed of material is prevented.
- Ensure brake is engaged.
• Do not go inside the mill alone. A safety controller is always needed.
- Safety controller means a person who is present outside the
mill and who can raise an alarm in the event of emergency.
• Isolate the machine from the surroundings during the maintenance work.
• Do not bypass alarms in order to operate the machine when alarms are active.
• Do not touch the electrical assemblies once commissioning has been completed.
• Use strong, inspected, and approved scaffolding.

1
SAG Mill Safety
2 Limits of use
SAG Mill is intended for the grinding process. Grinding (tumbling) mills are used to
reduce the particle size through attrition, abrasion, or impact.
SAG Mill is designed according to the regulations and recognized safety rules. It is
intended only for correct use. In addition, the machine is to be used only when in perfect
condition regarding technical safety.
If used incorrectly, hazards to life or damage to the machine can occur. Remove
immediately all faults that may impair safety.
WARNING
Do not use SAG Mill or its equipment for any other purpose than intended. If the
machine is used in some other way than intended, Outotec is not responsible for any
consequences.
2.1 Environmental
• Locate the mill so that the drive unit is not exposed to direct sunlight.
• Recommended temperature for the safe use of the machine is listed in Description
of Equipment.
• The mill can be located either outdoors or indoors.
• Required space for safe installation and operation is expressed in the main
drawings.
2.2 Mechanical
• Only trained personnel should access the rock box hatch.

• Do not access the hatch when the mill is operational.
• Lock out the feed supply prior to accessing the rock box hatch.
• Do not access the discharge trunnion liners if the trunnion rotates. A fixed guarding
around the trunnion prevents the personnel from accessing the rotating equipment.
• Do not enter the mill if the load is unbalanced.
• Main bearings: exposure to electrical connections to electric oil heaters
• Use a mechanical winch inside a mill, not an electrical one. Using an electrical
winch is dangerous.

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SAG Mill Safety
Velocity severity Medium

(RMS) Small Machines Machines Large Machines
mm/s in/s Class I Class II Class III Class IV
0.28 0.01
0.45 0.02 Good
Good
0.71 0.03 Good
Good
1.12 0.04
Satisfactory
1.80 0.07
Satisfactory
2.80 0.11
Unsatisfactory Satisfactory
4.50 0.18
Unsatisfactory Satisfactory
7.10 0.28
Unsatisfactory
11.20 0.44
Unsatisfactory
18.00 0.70 Unacceptable
Unacceptable
28.00 1.10 Unacceptable
Unacceptable
45.00 1.77
Excerpt from ISO 10816-1, Vibration Severity Class
• All Grinding Mills are considered Class III equipment. When vibration enters the
orange areas steps should be taken to investigate the source of the problem.

1
SAG Mill Safety
3 Personnel qualifications and training
Only the personnel who have the required skills, experience, and specific training may
install, operate, service or decommission the equipment. If you are unsure about the
requirements, contact Outotec.

1
SAG Mill Safety
4 Personal protective equipment
Personal protective equipment is clothing and equipment providing personnel with a

last-line of defense against hazards in the workplace. The following personal protective
equipment symbols are used in SAG Mill manuals.
Wear ear protection
Wear eye protection
Wear head protection
Wear protective gloves
Wear a safety harness
Wear safety footwear
Wear respiratory protection
During installation, wear:
• ear protection
• head protection
• protective gloves
• safety harness (outside the safety fences, and when working on the mill)
• safety foot wear.

1
SAG Mill Safety
NOTE: Make sure that you have adequate training for using a safety harness.
During operation, wear:
• ear protection
• eye protection
• head protection
• safety footwear.
During maintenance, wear:
• ear protection
• eye protection
• head protection
• safety harness
• safety foot wear
• respiratory protection (when going inside the mill).
Follow also the site-specific instructions on what personal protective equipment is

required.
NOTE: You are responsible for providing the personnel with the necessary personal
protective equipment. Outotec does not supply the personal protective equipment.
WARNING
. Wear personal protective equipment such as a safety harness, protective clothing, eye
and face protection, hearing protection, respiratory protection and so on.
WARNING
Skin contact with hydrocarbons and hydrocarbon ingestion are hazardous. Beware of
hydrocarbon spills or leaks around the lubrication systems. Always obtain an MSDS for
the hydrocarbons in use.

1
SAG Mill Safety
CAUTION
The noise levels around the mill are excessive. Wear hearing protection.
CAUTION
Before starting maintenance work inside the mill, remove balls and ore from overhead.
CAUTION
Beware of falling objects, such as rocks and slurry when working inside or around the
mill or water leaks. Do not stand directly under the feed hopper.
CAUTION
Slurry and scat can eject from the discharge cone. Beware of the splashing slurry and
exiting scat.

1
SAG Mill Safety
5 Hazards and risks
The Outotec® SAG Mill machines are CE-marked according to the Machinery Directive
2006/42/EC.
Even if you take care of all necessary safety precautions, there are still residual risks
that you need to be aware of when using the machine. They are also presented as
warnings in the appropriate installation, operation, and maintenance manuals.
Follow the instructions in this chapter to prevent any remaining hazards or dangerous
situations.
5.1 Mechanical hazards
CAUTION
. Do not start the mill if the inching drive coupling is engaged.
• Without an operational inching drive and brake and appropriate lock-out procedures
it is not safe:
- to install the mill.
- to install the mill liner.
- to perform any other work.
• Beware hazardous rotating parts such as gears, pinion, shafts and the mill body.
• Follow the plant’s instructions when lifting the equipment.
- Lift and transfer the equipment carefully. Lift the parts from the
lifting eyes or marked points.
- Make sure that the lifting equipment is strong and safe enough
and approved for lifting.
- Plan the lifting process. Note also the hazards caused by the
possible interruption of the lifting process.
- Do not stand under a lifted load.
5.2 Hazards related to maintenance
CAUTION
Use appropriate lock-out procedures during pinion, gear ring and inching drive
commissioning and maintenance.

1
SAG Mill Safety
CAUTION
Make sure that the motors are uncoupled when conducting motor bump test.
CAUTION
An unbalanced load can cause mill rotation.
• Wear protective gloves when you handle hydraulic oils or change oils.
• Pressurized lubrication oil can cause death or serious injury.
• Ensure the lubrication system is not pressurized before maintenance, repairs or
disassembly.
• Beware hazardous parts such as lubrication systems, bearings and hoses.
WARNING
In case of an inching drive malfunction or failure, shrapnel may injure personnel. Do not
bypass the safety system.
CAUTION
Mill components are heavy. Use caution when lifting and handling them.
Changing mill body liners requires manual effort and lifting of loads in excess of
normally recommended amounts. Use job rotations and mechanical assistance when
working. Remember sufficient fluid intake especially if the climate is hot. Take frequent
breaks, if necessary.
CAUTION
Restricted access to the axial bearings lead to working outside standard work level. Use
job rotations and mechanical assistance when working. Remember sufficient fluid intake
especially if the climate is hot. Take frequent breaks, if necessary.

1
SAG Mill Safety
5.3 Electrical hazards
• Follow the plant’s instructions on when and how to disconnect electricity.

• Connect the grounding points on the frame of the machine to the ground before
connecting the machine to a power supply.
• Cut the power supply to the machine before maintenance, repairs or disassembly
and use the appropriate lockout-tagout procedure.
• Beware hazardous parts such as motors and devices for measurement.
5.4 Hazards related to working environment
• Wear a safety harness during installation and maintenance to prevent falling from
platforms or gratings.
• Clean all oil or grease spills immediately to avoid falls and slips.
• Do not leave any loose tools in the area.
• Take care of adequate ventilation when working inside the mill.
CAUTION
Mill interior is a confined, hot and humid space. Use job rotations and mechanical
assistance when working. Remember sufficient fluid intake especially if the climate is
hot. Take frequent breaks, if necessary.
CAUTION
Background vibration can cause discomfort.
5.5 Noise hazards
• Wear ear protection due to high noise level.
5.6 Ergonomic hazards
• Provide adequate illumination on the site and surrounding areas.

1
SAG Mill Safety
5.7 Hazards related to materials and substances
• Use appropriate protective equipment, e.g. protective gloves, against exposure to

splashes, process steams or chemicals added to the slurry. See chapter 3 Personal
protective equipment. Follow the plant’s instructions.
5.8 Hazards related to control system
• Make sure that the control system is working properly. If you notice any fault, report
them immediately.
5.9 Residual risks
• Beware the risk of injury from handling high hydraulic pressure in the plant. Periodic
preventive maintenance work must be carried out.
• The risk area containing rotating mill must be protected with a safety fence (Client).
• Safety guards must be fitted to rotating shafts/couplings.
• Beware that inspection hatches and ring gear flange guards can be opened during
operation.
• Wear ear protection due to high noise level in the vicinity of the mill in operation.
The Client is responsible for the total noise level.
• Use protective equipment when handling hydraulic oil and ring gear grease to
prevent allergic reaction.
• The operator has to make sure that no one is in the risk area before the mill start-up
after service or repair.
• It is mandatory to wear a safety harness while working at the top of the mill to
prevent the risk of falling.
• Special care must be taken when adjusting the mill.
• Beware the risk of crushing and squeezing while performing service and
maintenance work. Follow the plant’s safety instructions.
• Beware the risk of crushing and squeezing while working inside of the mill. All
media have to be switched off, disconnected and secured. Follow the plant’s safety
instructions.

1
SAG Mill Safety
6 Emergency stops and safety switches
6.1 Emergency stops
The emergency stop button allows you to immediately stop the operating machine in a
hazardous situation. Make sure that all persons know the location of the emergency
stop button and know how to use it.
The emergency stop button is situated on the door of the control panel. The colors of
the emergency stop button are yellow and red. Additional emergency stop buttons
should be located around the mill operating areas within easy reach of various locations
where it is anticipated that work will be performed during operation. These additional
emergency stop buttons are the clients scope of supply and must be wired into the
Emergency Stop Relay of the Mill Control System.
Use the emergency stop button only in emergency situations, when there is a possibility
of injury to the personnel or serious damage to the machine.
Figure 1. Emergency stop button
6.2 Mill motor safety switch
Turn off the main switch in the primary starter and release the mechanical interlock key
for use of the inching coupling.

1
SAG Mill Safety
7 Safety guards
The mill is equipped with the following safety guards:
• High speed coupling
Figure 2. Typical safety guard for high speed coupling
• Low speed coupling
Figure 3. Typical safety guard for low speed coupling

1
SAG Mill Safety
• Inching coupling
Figure 4. Typical safety guard for inching coupling
WARNING
Do not remove any safety guards before or during operation.

1
SAG Mill Safety
8 Safety fences, labels and signs
Mount safety fences around the mill to meet the requirement of ISO 13857 (by Client).
Depending on the installation the mill will have the following safety labels and signals:
• Fixed in the form of signage or control panel indicators
• Variable in the form of indication by way of operator interface unit.
It is the responsibility of mill operators to ensure compliance with these safety labels
and signals.
WARNING
Failure to comply with safety warnings or labels can result in serious injury,
death and / or equipment damage.

1
SAG Mill Safety
9 Chemical substances
WARNING
Skin contact with hydrocarbons and hydrocarbon ingestion are hazardous. Beware of
hydrocarbon spills/leaks around the feed chute. Always obtain an MSDS for the
hydrocarbons in use.

1
SAG Mill Safety
10 Environmental aspects
• Mills are heavy equipment that operate in dirty environments. This combination
means by nature there are certain considerations worth noting:
• Power Usage: Mills are one of the largest power users in any plant. Mill operators
should strive to ensure the mill operates as efficiently as possible in order to reduce
unnecessary emissions caused by generating unnecessary power.
• Slurry discharge: Large flows pass through the mills so small leakage paths can
result in large amounts of slurry being discharged to the environment. Liner bolt
breakage and feed seal failure are two major causes of uncontrolled slurry leakage.
Mill operators should strive to avoid uncontrolled, unplanned slurry discharges as
these are potentially harmful for the environment and cause result in accelerated
deterioration of the mill components.
• Lubrication oil leakage: Large volumes of oil circulate through the mill lubrication
systems, therefore small leakage paths can result in very significant leakage of oil.
Mill operators must strive to keep lubrication systems oil tight in order to limit oil
leakage.
• Seal lubricant leakage: The mill uses oil or grease lubricated seals in various duties
such as the main mill bearing housings and reducer shaft seals. These seals are
designed to weep lubricant in order to keep contaminants out of the bearings that
rely on a very clean environment if to have a long life. Efforts are made in the mill
design to limit this discharge and provide catchment solutions for leaked lubricant
however it is the responsibility of the mill operator to ensure the catchment devices
used are emptied when needed and lubricant not captured in catchment devices is
cleaned up correctly and promptly.
• Feed seal water leakage: the feed seal of the mill is designed to discharge process
water out of the mill. This process water lubricates the seal and keeps solids away
from the running surfaces of the seal thus extending the life of the seal. The mill
operator is responsible for:
- Appropriately processing the leaked process water captured in the trough
supplied with the mill.
- Ensuring the trough drain piping remains open so no leaked feed seal process
water is inappropriately discharged to the environment.
• Lubricant change and disposal: Arrange disposal of any waste lubricant in
accordance with local regulations. When you change oil, collect the used oil in
suitable containers and recycle all oil wastes. Remove the collected oil with an oil-
binding agent. Destroy the used oil, preservative agents, oil binding agents, and oil
soaked cloths in accordance with environmental legislation.

1
Copyright © 2018 Outotec Oyj. All rights reserved.
Outotec Oyj Tel +358 (0) 20 529 211

P.O. Box 86 www.outotec.com
FI-02201 Espoo E-Mail info@outotec.com
Document ID number
Mill
English 2018 Transportation

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Description of

2.7.2 Ring gear seal

Figure 15. Ring gear seal

2.7.3 Pinion seal

© Outotec Oyj 2013. All rights reserved. 24 (50)

2.7.4 Pinion shaft end cover

Figure 16. Pinion shaft end cover

© Outotec Oyj 2013. All rights reserved. 25 (50)

2.7.5 Infrared sensor assembly

Figure 17. Infrared sensor

© Outotec Oyj 2013. All rights reserved. 26 (50)

2.8 Mill lining assembly

Figure 18. Mill lining assembly

© Outotec Oyj 2013. All rights reserved. 27 (50)

2.8.1 Rubber backing

Figure 19. Rubber backing

The rubber backing is made of non-reinforced vulcanized rubber which is cemented to

© Outotec Oyj 2013. All rights reserved. 28 (50)

2.8.2 Shell liners

Figure 20. Shell liners

© Outotec Oyj 2013. All rights reserved. 29 (50)

2.8.3 Feed end and discharge end head liners

Figure 21. Feed end and discharge end head liners

2.8.4 Discharge grate (if provided)

© Outotec Oyj 2013. All rights reserved. 30 (50)

2.9 Mill feed assembly

Figure 22. Mill feed assembly

© Outotec Oyj 2013. All rights reserved. 31 (50)

2.9.1 Feed trunnion liner

Figure 23. Feed trunnion liner

© Outotec Oyj 2013. All rights reserved. 32 (50)

2.9.2 Feed assembly

2.9.2.1 Feed spout or feed chute

Figure 24. Feed spout

© Outotec Oyj 2013. All rights reserved. 33 (50)

2.9.3 Feed trolley

Figure 25. Feed trolley

2.9.4 Rock box (if supplied)

© Outotec Oyj 2013. All rights reserved. 34 (50)

2.9.5 Feed seal and slurry slinger

Figure 26. Feed seal and slurry slinger

2.10 Mill discharge assembly

© Outotec Oyj 2013. All rights reserved. 35 (50)

2.10.1 Discharge trunnion liner

Figure 27. Discharge trunnion liner

© Outotec Oyj 2013. All rights reserved. 36 (50)

2.10.2 Ball retaining ring

2.11 Trommel assembly

Figure 28. Trommel assembly

© Outotec Oyj 2013. All rights reserved. 37 (50)

2.12 Lubrication systems

2.12.1 Lubrication systems for HSB mill

Different systems take care of the mill lubrication:

2.12.2 Lubrication systems for SRB mill

Different systems take care of the mill lubrication:

© Outotec Oyj 2013. All rights reserved. 38 (50)

3.1 Tender sizing datasheet

3.2 Initial charge of grinding media

3.3 Suggested initial charge

Table 1. Suggested initial charge

Media diameter Percent change Weight in

3.4 Media wear rate

Table 2. Media wear and charging rates