MANUAL1 - Copia - 3

Transportation
Mill
and Storage
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 respons ibility 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: Puolikkotie 10, PO Box 86
FI-02201 Espoo, Finland
Telephone: +358 (0) 20 529 211
Fax: +358 20 529 2200
Internet: www.outotec.com
09
08
07
06
05
04
03
02
01
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-2223-00-30-0004
Document Title:
Mina Justa Mills
Installation and Maintenance Manuals
Equipment No: Item No:

17-30-BM N/A Transportation and Storage
2223-ML-201
Original instructions Translation of the original instructions
Language code: EN
[Document Title 4]
© Outotec Oyj 2013. All rights reserved. [Document Title 5] 2 (14)

Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Outotec Document ID:
[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Transportation
Mill
and Storage
Contents
Contents ........................................................................................................... 3
1 Dimensions and mass ............................................................................ 4

1.1 Major component weights ............................................................. 4
2 Transportation ........................................................................................ 5
2.1 Packaging..................................................................................... 5
2.2 Loading and unloading.................................................................. 5
2.3 Transportation .............................................................................. 6
3 Storage.................................................................................................... 8
3.1 Extended storage.......................................................................... 9
3.1.1 Mill heads and trunnions .......................................................... 9
3.1.2 Mill shells ................................................................................. 9
3.1.3 Ring gears and pinions .......................................................... 10
3.1.4 Shell and head fasteners, foundation fasteners, anchor bolts
and T-bolts............................................................................. 10
3.1.5 Pinion bearing assemblies ..................................................... 10
3.1.6 Mill bearings .......................................................................... 10
3.1.7 Reducers & Bearings ............................................................. 11
3.1.8 Lubrication systems ............................................................... 11
3.1.9 HV Electric motor storage ...................................................... 12
© Outotec Oyj 2013. All rights reserved. 3 (14)

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Transportation
Mill
and Storage
1 Dimensions and mass
1.1 Major component weights
Refer to Description of Equipment section for estimated weights of the largest single lifts
for this grinding mill. Estimated weights exclude packaging, dunnage, and lifting
equipment (for example, hooks, slings, chains, spreader bars, and so on).
.
DANGER
Selection of lifting equipment must be made by qualified personnel. In certain

instances, local regulations may require review by a licensed Professional Engineer. It
is the responsibility of the user to determine the actual weight being lifted, establish
appropriate safety practices, and comply with all applicable regulations before
attempting any lift. Improper selection of lifting equipment can cause severe injury and
loss of life.
NOTE: The major lifts for the grinding mill are shown in specific Outotec lifting
drawings. Ensure these drawings are used in the lift planning process.
DANGER
Always use suitable equipment rated for the load and qualified personnel when handling
mill components. Severe injury and loss of life can occur if components are
mishandled.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Transportation
Mill
and Storage
2 Transportation
2.1 Packaging
Packaging protects the grinding mill’s components from damage during storage and
handling; it also aids transportation and organizes loose components. Do not open the
packaging until ready for installation.
Packaging is designed for 6 months of protection in a non-aggressive environment.

Aggressive environments include, but are not limited to:
• extremely high or low temperatures or humidity

• large fluctuations in temperature or humidity
• exposure to chemicals (for example, acids, bases, chlorides, cleaners,
solvents, and fumes), ultraviolet radiation (for example, bright sunlight
at high altitude, welding), or ozone (for example, nearby electric
motors).
Removal of, or damage to, the component packaging increases the exposure of the
components to the environment, and potentially reduces the storage life of the
components.
.
CAUTION
Inspect equipment upon receipt, and immediately report any damaged packaging to
Outotec.
2.2 Loading and unloading
Lifting lugs have been provided for the large major components of the mill. Other
components are containerized or palletized for ease of loading and offloading by means
of standard handling equipment. Care must always be taken during handling to prevent
damaging components or packaging by impact, shock, or vibration. Damaged
packaging may expose the components to the environment and reduce the storage life
of the component. Suitable equipment rated for the load must be used at all times and
handling should be performed by qualified personnel only.
.
DANGER
Always use suitable equipment rated for the load and qualified personnel when handling
mill components. Severe injury and loss of life can occur if components are
mishandled.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Transportation
Mill
and Storage
.
CAUTION
Mill components are large and heavy with precision machined surfaces, and/or sensitive
electrical instruments, and must be handled very carefully. In certain locations on the
equipment, even a small bump can cause serious damage. Contact the nearest Outotec
office immediately if mill components are bumped or damaged during handling;
seemingly minor damage could halt installation of the grinding mill.
.
CAUTION
At low temperatures, grinding mill components can exhibit brittle behavior. For steel
items (for example, mill shells) this temperature is usually -40 °C, but for certain iron
items (for example, mill heads, ring gear, gearbox housings) brittle behavior can occur
at temperatures as high as 0 °C. When working outdoors, or in extreme cold, grinding
mill components are particularly susceptible to damage by impact, shock, or vibration
during lifting and handling. Make sure to select lifting equipment and procedures
appropriate for the temperature range anticipated during loading and unloading. Always
keep personnel away from suspended crane loads.
.
CAUTION
Items such as mill shells, mill heads, gear guards, and trommels have large surface
areas that can catch gusts of wind. When working outdoors, wind loads can arise
suddenly and act in any direction, possibly causing a loss of control during the lift. It is
the user’s responsibility to determine when it is safe to perform lifting and handling
outdoors, and to select lifting equipment and procedures suitable for the anticipated
weather conditions.
2.3 Transportation
Suitable restraints rated for the load must be used during transportation of mill
components. Transportation vehicles must be sized for the load to prevent damage to
the vehicle, the mill components or injury to transportation personnel. Always be careful
to minimize impact, shock, and vibration when transporting or handling grinding mill
components. Damaged packaging may expose the components to the environment
and reduce the storage life of the component.
NOTE: Vibration during transportation can cause ring gear distortion. Ring gears
when trucked should preferably loaded onto trailers with air suspension.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Transportation
Mill
and Storage
.
WARNING
Abrupt changes of direction or speed can impose very large forces on the mill
components. Properly sized restraints are required to secure the components during
transportation. Properly sized transportation vehicles are required to absorb those
forces. Damage to major mill components and possible injury and even death may
occur if transportation equipment is not properly sized, maintained and operated.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Transportation
Mill
and Storage
3 Storage
This section outlines Outotec’s general storage and handling requirements for grinding
mills, as well as the recommended extended storage and preventive maintenance
procedures for grinding mill components awaiting installation. The information
presented here is intended as general storage instructions; where manufacturers of
purchased equipment have provided instruction manuals (for example, motors, and so
on) their specific storage requirements take precedence.
Store mill components in an area that is dry, well ventilated and protected from the
elements (for example, direct sunlight, wind, rain, dust, extreme temperatures, falling
debris). The best storage location is indoors; where indoor storage is not practical,
components can be stored outdoors on solid, vegetation-free, well-draining ground with
weather and sun protection (for example, tarpaulins).
The following general requirements apply:
• To prevent moisture ingress, always store components above ground

level. The storage location must be adequately drained to prevent
standing water above, below, or around the mill components.
• Orient components to prevent condensation build-up and permit
natural drainage.
• Remove drain plugs (or open drain valves) from tanks, pumps, and
other natural condensation collection areas.
• Store pipe work vertically or at an angle to permit natural drainage.
• Use plastic sheeting to prevent moisture wicking from wooden blocks
onto steel items. Periodically lift these items to check for rust where
metal surfaces contact wooden blocks.
• Electrical equipment or components containing wiring, circuit boards,
electrical contacts, or instrumentation must always be stored indoors,
especially in regions subject to extreme temperatures.
• Mechanical components left in their original packaging may be stored
outdoors in non-aggressive environments, for a maximum of 6 months.
• Periodically inspect components for corrosion or damage due to
storage conditions. If damage occurs during storage, first improve the
storage conditions to prevent further damage, and then repair the
damage promptly.
• Large machined pieces must be stored in a level position up off the
ground and supported evenly to minimize stresses due to self weight.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Transportation
Mill
and Storage
.
CAUTION
Storing mill components in aggressive environments may cause damage by degrading

precision mechanical equipment. Additionally, storing electrical components in
aggressive environments may damage sensitive electronics. Consult the nearest
Outotec office immediately if components or packaging appear damaged during storage.
3.1 Extended storage
Mill components may be packaged for extended storage if requested by the client prior
to project delivery. In some instances, the need for extended storage may not be
known until after the mill is delivered. This section contains general recommendations
for extended storage; however, site-specific storage instructions should be reviewed
with the nearest Outotec office.
During extended storage, a layer of copper-impregnated shrink film, such as Intercept

Shrink Film [trade name], can be applied over the existing packaging for an additional
measure of protection. Consult the manufacturer for specific instructions on the use
and application of shrink film.
In addition to the general storage requirements listed earlier, the following extended
storage recommendations apply to the specific mill components listed below. Inspect
stored components monthly for any signs of corrosion or damage.
3.1.1 Mill heads and trunnions
• Coat all machined and unpainted surfaces with Tectyl 506 [trade name]
or equivalent.
• Use Denso [trade name] petrolatum tape to fully coat machined journal
bearing surfaces.
• All liner bolt holes and tapped holes to be plugged or grease filled.
• Place on rigid parallel supports for storage.
3.1.2 Mill shells
• For shell-supported mills, coat the journals in Denso [trade name]

petrolatum tape.
• Coat all machined and unpainted surfaces with Tectyl 506 [trade name]
or equivalent.
• All liner bolt holes and tapped holes to be plugged or grease filled.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Transportation
Mill
and Storage
3.1.3 Ring gears and pinions
• Coat all machined and unpainted surfaces with Tectyl 506 [trade
name], or Denso [trade name] petrolatum tape, or equivalent.
• All tapped holes to be plugged or grease filled.
• Full sling/chain protection around teeth and other machined surfaces to
prevent damage.
3.1.4 Shell and head fasteners, foundation fasteners, anchor bolts and T-
bolts
• Indoor storage is recommended for storage longer than 4 weeks or in

poor weather conditions.
• Coat all fasteners with Tectyl 506 [trade name] or equivalent.
• Each assembled bolt shall be fully covered with Netlon [trade name]
protective netting or equivalent product prior to packaging.
• Seal package of fasteners in Intercept Shrink Film [trade name] or
equivalent with suitable moisture absorbing desiccant granule packs.
• Check fastener condition every three months, reapply Tectyl 506 [trade
name] where necessary and re-wrap with fresh moisture absorbing
desiccant.
3.1.5 Pinion bearing assemblies
• Keep pinion bearing housings, bearings and spacers in packing boxes.

• Ensure that pinion bearing housings and bearings are fully wrapped
and sealed to prevent the ingress of water and dust.
• Ensure that the packing boxes have suitable long-term storage
provision for draining.
3.1.6 Mill bearings
• Keep bearing housings in packing boxes.

• Ensure that trunnion bearing housings and bearings are fully wrapped
and sealed, or boxes are plastic lined to prevent the ingress of water
and dust.
name], or Denso [trade name] petrolatum tape, or equivalent.
• All tapped holes to be plugged or grease filled.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Transportation
Mill
and Storage
3.1.7 Reducers & Bearings
• If storing for more than 3 months:

o Oil-lubricated bearings shall be drained and filled with new
operating oil and Shell VSI 8235 at 2% lubricant system to
operating level and then run for a short while to ensure
complete coverage, after which all openings are closed.
Grease-lubricated bearings shall be cleaned and re-greased
with the appropriate grease, turned and closed thoroughly. The
internal parts shall be sprayed with Shell VSI 8235.
o Reducers shall if possible be drained while hot, then filled to
operating level with new operating oil and Shell VSI 8235 at
2% lubricant system operating volume and finally circulated for
a short period of time. Where circulation is impracticable, the
oil shall be applied by flushing, spraying or brushing.
Irrespective of any treatment, all openings shall be closed
thoroughly afterwards.
3.1.8 Lubrication systems
• Store lubrication systems indoors, at a temperature of +15 °C to +30

°C, in their original packing boxes (if supplied in packing boxes).
name], or Denso [trade name] petrolatum tape, or equivalent. Check
the condition of these surfaces every 6 months.
• All tapped holes to be plugged or grease filled. Check these holes for
damage every 6 months.
• Remove all drain plugs and open all drip tray drain valves.
• Rotate all pump and motor shafts by hand for a few revolutions during
each monthly inspection.
• Pre-charge the accumulators to approximately 5 bar, per the
manufacturer’s manual. Check this pressure every 6 months.
• If storing for more than 3 months:
o Fill flow dividers with oil.
o Fill tank to operating level with new operating oil and Shell VSI
8235 at 2% lubricant system operating volume. Wet all tank
surfaces with the oil by flushing, spraying or brushing.
Irrespective of any treatment, all openings shall be closed
thoroughly afterwards.
• Every 6 months, check hoses for damage, such as cracks, dissolved
elastomer, or visible reinforcing cords.
• Every 12 months, replace the reservoir air breather.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Transportation
Mill
and Storage
• See manufacturer’s equipment manual for specific storage

recommendations.
3.1.9 HV Electric motor storage
• Store motors in a clean, dry area that is free of vibration, and located
away from any sources of extreme heat or cold. Indoor storage is
recommended for storage longer than 4 weeks or in poor weather
conditions.
• If the motor has a shaft locking mechanism, leave it in place to prevent
vibration damage during storage.
• Connect the motor’s anti-condensation (space) heaters, and run them
continuously during storage.
• Use care to ensure that parts such as the fitting surface, key, shaft
extension and axial center hole remain free of any foreign matter.
• Check insulation resistance at the stator during each inspection, and
make sure the resistance stays above 50 Mohms (as measured with
1000 VDC megger).
• Where low insulation resistance indicates that the motor has absorbed
moisture it must be dried with external heat until thoroughly dry and
insulation resistance meets minimum requirements.
• Motors with spherical roller bearings: Rotate shaft by hand for a few
revolutions during each monthly inspection.
• Motors with white metal bearings: A temporary lube system is required
to rotate the shaft during monthly inspections.
• Where practical, perform a run-test every three months.
• See manufacturer’s equipment manual for specific insulation
resistance testing and storage recommendations.
• Electric motors must not have packaging opened or damaged to
prevent water ingress.
.
WARNING
Insulation resistance testing poses an electric shock hazard. Use only trained
personnel, suitable testing equipment, and appropriate safety procedures when testing
the insulation resistance of electric motors. The motor manufacturer’s
recommendations for insulation resistance testing take precedence over this section.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Transportation
Mill
and Storage
.
CAUTION
Rotating dry bearings will damage their precision-machined surfaces. Verify that the
motor’s shaft bearings have been lubricated per the manufacturer’s directions before
rotating the shaft or performing a run test.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
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 Installation

Mill Installation
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 respons ibility 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: Puolikkotie 10, P.O Box 86
FI-02201 Espoo, Finland
Telephone: +358 (0) 20 529 211
Fax: +358 20 529 2200
Internet: www.outotec.com
09
08
07
06
05
04
03
02
01
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]
Project Phase: Site No.: Site No.:
Execution 10194601 – 0001A 10194601 – 0001A
Project Name: Customer Document ID:
Mina Justa Mills JU-001-06-0001A-2223-00-30-0005
Document Title:
Mina Justa Mills
Installation and Maintenance Manuals
Equipment No: Item No:

17-30-BM N/A Installation
2223-ML-201
Original instructions Translation of the original instructions
Language code: EN
[Document Title 4]
© Outotec Oyj 2013. All rights reserved. [Document Title 5] 2 (87)

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
Contents
Contents ........................................................................................................... 3
1 Safety ...................................................................................................... 6
1.1 Installation check sheets ............................................................... 6
2 Installation tools ..................................................................................... 7

2.1 Recommended installation tools.................................................... 7
2.1.1 Cleaning material ..................................................................... 7
2.1.2 Lifting equipment ..................................................................... 7
2.1.3 Measuring tools ....................................................................... 7
2.1.4 Hand tools ................................ Error! Bookmark not defined.
2.1.5 Other tools ............................................................................... 7
2.2 Erection cradle.............................................................................. 8
2.3 Installation jacks ........................................................................... 8
2.3.1 Installing installation jacks ........................................................ 9
3 Preparations ......................................................................................... 10
3.1.1 Protective coatings................................................................. 10
3.1.2 Contamination ....................................................................... 10
3.1.3 Machined surfaces................................................................. 10
4 General assembly procedures ............................................................. 11

4.1 Installing hydrostatic bearing supported mills (HSB) ................... 11
4.2 Installing spherical roller bearing supported mills (SRB) .............. 11
4.3 Installing fasteners ...................................................................... 12
4.3.1 Tightening fasteners .............................................................. 12
4.3.2 Controlling fastener preload ................................................... 13
4.3.3 Using elongation method to control fastener preload .............. 14
4.3.4 Using torque to control fastener preload ................................. 14
4.4 Mill installations in cold ambient conditions.................................. 16
5 Foundation and general assembly ...................................................... 18

5.1 Design concerns ......................................................................... 18
5.2 Foundation tolerances ................................................................ 18
6 Foundation preparation & sub-soleplate installation ......................... 20

6.1 Preparing foundation (scabbling)................................................. 20
6.2 Preparing sub-soleplates and soleplates ..................................... 20
6.3 Installing sub-soleplates .............................................................. 20
7 HSB2 Bearings and Mill Body Installation........................................... 22

7.1 Mill bearing housing base ........................................................... 22
7.1.1 Preparing bearing housing before installing ............................ 22
7.1.2 Bearing housing particulars .................................................... 23

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
7.1.3 Installing bearing housing base .............................................. 23

7.2 Mill shell & heads ........................................................................ 24
7.3 Mill bearing installation & housing completion.............................. 27
7.3.1 Preparing bearings before installing ....................................... 27
7.3.2 Installing axial thrust bearing .................................................. 27
7.3.3 Installing radial bearing pads .................................................. 28
7.3.4 Installing bearing housing seal ............................................... 29
7.3.5 Installing upper bearing housing............................................. 31
8 HSB4 Bearings and Mill Body Installation........................................... 32

8.1 Mill bearing housing base ........................................................... 32
8.1.1 Preparing bearing housing before installing ............................ 32
8.1.2 Bearing housing particulars .................................................... 33
8.1.3 Installing bearing housing base .............................................. 33
8.2 Mill shell & heads ........................................................................ 34
8.3 Mill bearing installation & housing completion.............................. 37
8.3.1 Preparing bearings before installing ....................................... 37
8.3.2 Installing the pad bearings ..................................................... 37
8.3.3 Installing bearing housing seal ............................................... 38
8.3.4 Installing upper bearing housing............................................. 40
9 Mill assembly (SRB) ............................................................................. 42

9.1 Installing main bearing soleplates ............................................... 44
9.2 Mill bearing installation (SRB) ..................................................... 45
9.2.1 Typical bearing installation procedure .................................... 46
9.2.2 Installing held bearing housing ............................................... 48
9.2.3 Installing free bearing housing................................................ 48
10 Drive train ............................................................................................. 50

10.1 Installing variable speed drive ..................................................... 50
10.2 Installing ring gear ...................................................................... 50
10.2.1 Preparing ............................................................................... 50
10.2.2 Mounting, fastening and alignment of gear ............................. 52
10.3 Installing pinion bearings/pillow blocks ........................................ 53
10.3.1 Installing pinion bearing soleplates ......................................... 54
10.3.2 Gear contact set up and blue contact test............................... 57
10.4 Installing main and inch drives .................................................... 57
10.5 Installing main drive motor .......................................................... 58
10.5.1 Installing motor base (Singular base) ..................................... 58
10.5.2 Installing motor bases (Multiple base) .................................... 59
11 Gear guard ............................................................................................ 60

11.1 Installing guard ........................................................................... 60
11.2 Installing gear seal ...................................................................... 61
11.2.1 Installing felt seals.................................................................. 61

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
11.2.2 Installing Barricade seals ....................................................... 61

11.3 Installing pinion seals .................................................................. 62
11.4 Installing infrared sensor ............................................................. 62
11.5 Grouting ..................................................................................... 63
11.5.1 Foundation grout.................................................................... 63
11.5.2 Grouting installation method A: cementitious grout ................. 63
11.5.3 Grouting installation method B: epoxy grout ........................... 64
12 Mill lining............................................................................................... 65
12.1 Installing mill lining ...................................................................... 66
12.1.1 Preparing ............................................................................... 66
12.1.2 Inching the mill (no interlocks) ................................................ 66
12.1.3 Installing head lining .............................................................. 69
12.1.4 Installing shell lining ............................................................... 70
12.1.5 Installing grate discharge mills (additional activities, if
applicable) ............................................................................. 71
13 Mill feed................................................................................................. 73
14 Mill discharge ....................................................................................... 75
15 Trommel ................................................................................................ 75
16 Mill lubrication system (HSB)............................................................... 76

16.1 Installing bearing housing seal lubrication ................................... 78
17 Mill lubrication system (SRB)............................................................... 79

17.1 Installing bearing lubrication system ............................................ 79
18 Gearbox oil lubrication system ............................................................ 80
19 Pinion lubrication system (oil based) .................................................. 82
20 Gear spray lubrication system ............................................................. 85
21 Mill automation and control ................................................................. 86

21.1 Installing control panel ................................................................ 86
21.1.1 Installing mill bearing monitoring equipment ........................... 86

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
1 Safety
WARNING
The assembly of any grinding mill poses potentially serious hazards to personnel and
equipment. To reduce these risks, Outotec recommends using trained crews
experienced in installing grinding mills. An Outotec field service representative/site
advisor must be present to provide advisory services during mill installation and
commissioning to maintain the Outotec mill warranty.
The role of the site advisor is to provide assistance in developing installation procedures
and guide the installation crew with the best practices for equipment installation. The
site advisor knows the equipment and is equipped with customized Installation
Inspection and Test Plans for the mill installation.
To validate Outotec’s Equipment Warranty, an Outotec representative must be present

to provide advisory services during the mill installation and commissioning, and critical
installation and commissioning settings must be recorded and accepted by Outotec’s
Engineering Department.
Note that the procedures and step by step details provided in this manual are for
reference only, and do not include all of the steps necessary for proper installation nor
do they provide an intricate level of detail. It is expected that along with an Outotec site
advisor, the client contracts an experienced and competent installation crew. The crew
would work together with the site advisor in developing exact procedures for installation
based on site conditions, equipment availability, and other specific variables.
Assemble the grinding mill according to the assembly drawings, parts list provided and
the following instructions. It is not the intent of these instructions to cover all possible
installation methods and practices, nor do these instructions comprise a specification for
the installation work. Instead, this manual calls attention to the difficulties commonly
encountered with the installation of this type of equipment. It is assumed that an
experienced mill installation contractor and qualified tradesmen who will follow the
normal precautions and good practices associated with their trades will perform the
installation work.
At all stages of installation, the installer must perform inspections to ensure an

extremely high level of construction quality. These inspections shall be witnessed by
the site advisor, contractor foreman, and client personnel as required. All inspections
shall be documented and signed-off by the witnesses.
1.1 Installation check sheets
The Outotec installation technician commissioned to control the quality of the mill
installation uses proprietary Installation Checksheets to record the important aspects of
the installation. A hardcopy of the Inspection & Test Plan associated with these
Checksheets will be provided to the mill owner at the end of the installation.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
2 Installation tools
2.1 Recommended installation tools
It is the responsibility of the installation contractor to study the equipment and ensure
that the necessary tools and equipment are available for the mill installation.
Tool requirements may vary depending on mill size and extent of shop assembly. As a
minimum, Outotec recommends the following tools for the erection, alignment, and
start-up of your Outotec grinding mill. Field service representatives generally travel by
air and therefore carry few tools, if any.
Outotec offers standard shipping containers packed with a full set of installation tools
and lifting equipment that can be used at site during installation and commissioning,
under the supervision of our field service representative. The tool containers and special
tools can be purchased or rented at competitive rates, depending on availability.
NOTE: The tools and rigging list have to be adjusted according to the given mill size.
This document lists the required typical tools for reference.
2.1.1 Consumables and cleaning material
See attached Basic Consumables List for Mill Installation.
2.1.2 Rigging equipment
See attached Basic Rigging Equipment List for Mill Installation.
2.1.3 Basic tools
See attached Basic Tool List for Mill Installation.
2.1.4 Specialist tools
See attached Specialist Tool List for Mill Installation

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
2.2 Erection cradle
Figure 1. Erection cradle
The erection cradle assembly consists of a shell support frame and cradle.
The shell support frame and cradle are used to support the shell during mill installation
and jacking operations.
DANGER
The erection cradle of a HSB mill is not designed to lift a fully loaded mill. Attempts to
lift a fully loaded HSB mill using the erection cradles could result in catastrophic
damage and personnel injury or death.
2.3 Installation jacks
Four hydraulic jacks are supplied to be located on jacking bases that are embedded on
concrete piers. The hydraulic jacks are used to lower the shell assembly onto the
bearings during installation or in the case of SRB mills for removal and installation of
new bearings.
Hydraulic power for the jacks is supplied from either hand pumps or an electrically-
driven unit..

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
2.3.1 Installing installation jacks
Refer to the assembly drawings and vendor brochures for positioning the jacks and
assembling the hydraulics.
.
WARNING
Follow the hydraulic vendor instructions. These brochures provide specific assembly
instructions and additional safety notices.
Examine the jacks and maintenance cradle before and after each use. Do not use the
jacks if they are damaged.
.
WARNING
Contact the nearest Outotec sales office promptly if the jacks appear to be damaged.
Never attempt to repair or modify jacking assemblies. Damage or unauthorized
modifications may weaken the jacks or maintenance cradles and may result in the loss
of life or property.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
3 Preparations
3.1.1 Protective coatings
Remove rust-preventive compounds from machined surfaces and bolt holes.
3.1.2 Contamination
Clean dirt and grit from machined surfaces, oil passages, water passages and piping.
3.1.3 Machined surfaces
Check machined surfaces and screw threads for nicks and burrs and remove if
necessary.
• Remove rust preventative coatings and oils.

- Consult the equipment manuals for the correct procedures for removing the
coatings.
- Do not leave the surfaces unprotected for an extended period of time,
unprotected surfaces will rust.
• Check the surfaces for flatness and burrs; stone if necessary.
CAUTION
Consult Outotec if any of the following machined areas are damaged:
• Gear or pinion
• Mill shell
• Mill head
• Bearing surfaces.
Attempting to repair any of these areas may cause additional damage.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
4 General assembly procedures
The following procedure is a typical assembly sequence. Refer to the remaining

sections of this manual for more detailed assembly instructions.
4.1 Installing hydrostatic bearing supported mills (HSB)
1. Set the soleplates for the bearings.

2. Install and align bearing housing bases.
3. Install bearings into housings and align.
4. Assemble mill shell pieces when on erection cradles set to have the shell centerline
coincide with the intended finished mill centerline and then install heads onto the
assembled shell.
5. Install and connect trunnion bearing lubrication unit and panels. Raise mill body
using the service jacks, remove installation cradles and lower back on to trunnion
bearing pads.
6. Flush trunnion bearing lubrication unit. Check mill lift and record readings.
7. Install drive train, working from the mill to the motor. Start with the ring gear, install
and align the pinion, clutch (if applicable), reducer (if applicable), and motor.
8. Install gear guard and gear spray lubrication system.
9. Install clutch air group (if applicable).
10. Double-check pinion and drive component alignment and record readings.
11. Grout out mill, taking care to avoid air pockets.
12. Install and test all lubrication systems.
13. Install rubber liner backing, mill liners, and filler material (if applicable).
14. Install and align mill feeder and mill discharge components.
15. Complete all electrical connections for mill drive, accessory equipment, and
interlocks.
16. Initiate the Starting Up and Running In Procedure, refer to the Commissioning and
Startup section of this manual.
17. Perform final mill drive inspection and alignment.
4.2 Installing spherical roller bearing supported mills (SRB)
1. Set the soleplates for the bearings.

2. Install and align bearing housing bases.
3. Assemble mill shell and heads above final mill centerline.
4. Mount trunnion bearings to mill trunnion journal.
5. Lower mill assembly onto housing bases.
6. Finish installation of bearing housings and pack bearing with grease.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
7. Install drive train, working from the mill to the motor. Start with the ring gear, install
and align the pinion, clutch (if applicable), reducer (if applicable), and motor.
8. Install gear guard and gear spray lubrication system.
9. Install clutch air group (if applicable).
10. Double-check pinion and drive component alignment and record readings.
11. Grout out mill, taking care to avoid air pockets.
12. Install and test all lubrication systems.
13. Install rubber liner backing, mill liners, and filler material (if applicable).
14. Install and align mill feeder and mill discharge components.
15. Complete all electrical connections for mill drive, accessory equipment, and
interlocks.
16. Initiate the Starting Up and Running In procedure, refer to the Commissioning and
Startup section of this manual..
17. Perform final mill drive inspection and alignment.
4.3 Installing fasteners
NOTE: The following sections use the terms bolts and fasteners interchangeably. To
avoid any doubt consider studs, bolts and fasteners as each being applicable when
only one is mentioned in the text.
4.3.1 Tightening fasteners
When tightening fasteners, refer to Figure 2 for the recommended tightening sequence.
In general, locate the fasteners that are furthest apart and tighten them first. Alternate
diagonally to fix the corners of the joint. After the corners are secured, tighten the
fasteners that lie on the unclamped portion of the joint. Alternate diagonally to split the
unclamped regions until all the fasteners are tightened. If the joint contains any fitted
fasteners, install them first, but only fully tighten last as fully tightening them will
compromise the fit.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
Figure 2. Tightening pattern
.
WARNING
Paint under fasteners or in fastenered joints will result in the fasteners becoming loose
during operation, with possible breakage, personal injury and/or equipment damage.
4.3.2 Controlling fastener preload
When assembling the mill refer to the drawings or the following sections for fastener
preloads and tightening torques. Table 1 lists the preload force for tightening fasteners
with a hydraulic tensioner. Table 2 lists the tightening torque required to generate the
desired preload on the fastener. The torque values in the following tables apply to
lubricated, standard threads (i.e. no Gripco, Nylok, or deformed locking threads).
Proper joint preload is imperative for the successful operation of the mill. Improperly
installed fasteners may lead to breakage and / or flange leakage. Fastener torque may
not accurately represent fasteners preload. Outotec requires the use of fastener
elongation measurements to confirm fastener preload. Final fastener preload must be
verified by trained personnel using an ultrasonic fastener measuring micrometer.
Outotec must review and accept the qualifications and procedures of the preload
measurement personnel.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
4.3.3 Using elongation method to control fastener preload
The elongation method has three phases, detailed as follows:
• Preparation
- Prior to assembly, measure and record the reference (i.e. no load) lengths of
all fasteners.
• Assembly
- Using the reference length, tighten each fastener such that the total
elongation is within the specified range for that joint. Record the final
elongation.
• Run-In
- Fastener tightness must be checked at various stages after restart, refer to
the Commissioning and Start Up section of this manual, chapter Fastener
Maintenance.
.
WARNING
Improperly tightened fasteners pose a potential hazard to personnel and may damage
the mill during operation. Verify that you are installing fasteners of the correct diameter,
length, and material grade. Do not use fasteners without any grade markings. Avoid
using fasteners of uncertain or unknown origin. Whenever possible use calibrated
equipment for tightening these fasteners.
.
WARNING
Any values listed on an assembly drawing or in a vendor bulletin take precedence over
those found in the following tables.
.
WARNING
When tightening the foundation fasteners do not exceed the recommended maximum
allowable grout strength. Consult grout specification.
4.3.4 Using torque to control fastener preload
WARNING
The use of torque to tension critical fasteners is inappropriate. Critical fasteners are any
fasteners that rotate during operation of the mill.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
The use of torque methods is typically applied to the tightening of foundation bolts and
static components. Table 2 lists the appropriate torque to apply for various fastener
sizes and types.
Table 1. Minimum tension force in fasteners (kN) at 80% preload
THREAD TENSION GROUTED 320 MPA 640 MPA

DIAMETER AREA FOUNDATION OR OR
(MM) (MM2) FASTENERS CLASS 4.6 CLASS 8.8
24 338 65.7 86.5 173.1
30 540 88.3 138.2 276.5
36 788 133.4 201.7 403.5
42 1083 186.4 277.2 554.5
48 1424 221.7 364.5 729.1
56 1967 253.1 503.6 1007.1
Table 2. Tightening torque in Nm for untreated, lubricated bolts
THREAD GROUTED CLASS 4.6 CLASS 8.8

DIAMETER FOUNDATION
(MM) BOLTS
10 47
12 81
16 197
20 169 192 385
24 269 332 665
30 453 656 1310
36 817 1140 2280
42 1374 1813 3640
48 1804 2720 5450
56 2392 4360 8710

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
4.4 Mill installations in cold ambient conditions
Outotec does not recommend mill installation work to be performed under +5oC
temperatures for the following reasons:
• Cast iron parts are at risk of damage if handled at low temperatures. The ductile-to-
brittle transition temperature for SG Iron is around 0°C.
1. Charpy impact value, J 2. °F 3. ft - lbf 4. Temperature, °C
Figure 3. Charpy impact value against temperature of SG Iron
• The dramatic drop in impact toughness below the transition temperature makes the
risk of ductile iron damage during handling very high and gives the potential for
serious injury or death should the cast on lifting lugs fail during component lifts.
• Aligning grinding mill parts is precision work, which should not be performed at
extreme temperatures.
• Fasteners tightening across different materials will be subject to stress changes
with temperature changes. For example, soleplate fasteners tied down to concrete
foundations will loosen when temperature rises due to higher affect of temperature
on volume. Fastener tightening should not be done at extreme temperatures.
• Proper lubrication for bearings is dependent on lubrication oil temperature. Proper
oil temperature is difficult to achieve if the surrounding parts are very cold.
• Mill installations can be high risk work places. Health and Safety considerations
need to take into account affects of low temperature at work site.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
Outotec highly recommend mill installation work to be postponed until such time that all
ambient and component temperatures will be above +5 oC.
If the installation proceeds against this recommendation and Outotec's installation

representative deems aspects of the installation are being compromised by continuing
against Outotec's recommendation we reserve the right to:
• Formally state the future rework needed to remedy the compromising situation in
situations where this is possible or
• Formally state the Outotec warranty is withdrawn where future rework cannot be
practically employed to remedy the compromising situation.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
5 Foundation and general assembly
For more information on the foundation, refer to the Foundation Specification (FS001).
5.1 Design concerns
The foundation must be designed to meet the requirements imposed by local

conditions. The foundation shall be heavily reinforced to eliminate all possibility of
settlement or shifting. In areas with high salinity the surface of foundation concrete
should be protected from salt solution entering the foundation and corroding the
reinforcement bars.
Mills are always exposed to shocks caused by the grinding charge and shocks
stemming from the gearing. These shocks can cause undesirable vibrations so
arrangements should be made to minimize their propagation through the building. The
foundations for the mill, the gearing and the motor should thus form an integral unit that
is isolated from the building.
Outotec recommends consulting with a civil engineering firm on the foundation loading
diagrams. The foundation designer must consider the combined load sets for
determining the minimum, maximum, and alternating foundation loads shown on the
foundation drawing.
The dimensions shown on the foundation drawing and installation drawing must be fully
and accurately complied with. The tops of the foundations should be poured so that they
are lower than the bottoms of the soleplates by an amount indicated on the drawing.
5.2 Foundation tolerances
Table 3 lists the normal foundation tolerances.
Table 3. Recommended foundation tolerances
HEADING HEADING
Height tolerance for coarse grouting +/- 10 mm (0.39 in)
Placing of embedment parts foundation 12 mm (0.47 in) radius

pipes (if applicable)
True position of fastener groups 5 mm (0.20 in) radius
Position exactness within fastener groups 1.5 mm (0.06 in) radius
Height tolerance on embedded soleplates +/- 0.5 mm (0.02 in)

(if applicable)
Max. inclination on embedded soleplates +/- 0.3 mm/m (0.0036 in/ft)

(if applicable)

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
HEADING HEADING
Max. deflection from plumb line for 1/50

embedment parts (if applicable)
.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
6 Foundation preparation & sub-soleplate installation
6.1 Preparing foundation (scabbling)
1. Remove latent “top skin” of the concrete to expose the hard concrete underneath by
use of a chipping hammer or other suitable scabbling device. The concrete should
only be scabbled directly under the mill’s soleplates and an area of 50 mm around
the soleplates. All other concrete surfaces should be left in the “as placed”
condition.
2. Several mill foundation benchmarks should be installed and measured to ensure
there is always a clear view of at least one of them during survey works.
3. Locate mill foundation benchmarks and establish all mill and mill drive train
operating centerlines using wires or other suitable means. These centerlines
should be established off of the surveyor’s certified markers.
6.2 Preparing sub-soleplates and soleplates
1. Remove all paint, rust and other contaminants from the bottom and side surfaces of
all sub-soleplates and soleplates to obtain a clean surface that grout will adhere to.
2. Remove all rust preventatives from all machined surfaces.
3. Inspect mounting surfaces for burrs; remove to obtain a flat and smooth mounting
surface.
6.3 Installing sub-soleplates
1. Insert jacking screws into shim set bottom plates.

2. Position shim set bottom plates on the required positions on the foundation pads.
3. On average, the thickness of shim set is 50 mm, but the required thickness may
vary, depending on the finished concrete levels. Elevation of the topside of the shim
set bottom plate should be slightly lower than the finished underside of the
bedplate.
4. Level each shim set bottom plate using the three setscrews provided. Top of plate
elevation should allow:
a. 10 mm of shim between the sub-soleplate and the underside of soleplate for
main bearing soleplates.
b. 13 mm of shim between the sub-soleplate and the underside of soleplate for
drive component soleplates.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
NOTE: Ideally there should be 10mm of shim between the topside of the sub-
soleplate and the underside of the soleplate to allow for elevation adjustment during
placement of the soleplate. Drive component soleplates are set 3mm lower than
main bearing housing soleplates to allow 3mm of shim to be installed between the
drive component and its soleplate.
5. Prepare a simple mould and secure the shim set bottom plate in place using a non
shrink epoxy grout and let harden.
6. Remove any jacking screw projections above the sub-soleplate mounting surfaces
by grinding.
7. Oil the mounting surfaces of the soleplates and cover with suitable materials to
protect from damage and the elements until associated components are placed on
them.
8. When ready to set soleplates remove oil and ensure sub-soleplates are clean.
9. Roughly level sub-soleplates to their final position using the shims provided.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
7 HSB2 Bearings and Mill Body Installation
7.1 Mill bearing housing base
7.1.1 Preparing bearing housing before installing
• Unfasten the large hatches in both ends of the bearing base. Refer to Figure 4.
• Remove axial and radial bearings & stools.
• Clean the inside and bottom of the bearing bases.
.
CAUTION
Use extreme care when handling the mill bearing pads and support swivel components
to avoid damaging the mating surfaces.
Figure 4. Typical trunnion supported bearing
1. Radial bearing
2. Service jack
3. Axial bearing
4. Trunnion
5. Bearing housing

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
7.1.2 Bearing housing particulars
NOTE: Installation of the bearing housing bases with bearing pad units must precede
installation of the mill shell.
There is one free bearing housing and one fixed (held) bearing housing. The bearing
housings are typically symmetrical so they may be installed on the concrete foundations
with either side towards the mill, however this must be verified on a project by project
basis. The axial pads inside the housing may not be symmetrical, so refer to the bearing
assembly drawings for correct position of the axial pads inside the fixed bearing
housing. Also note for the inspection door opening side as they should not swing in
toward the mill heads.
The trunnion bearing housing base and cap, complete with seal faces, are
manufactured as a set and must be installed as a set. Follow match marks on the base
and caps.
Both bearing housings and pad bearing brackets are equipped with lifting lugs to ease
the handling during both installation and maintenance. The lifting lugs in the cap are
only for lifting the cap itself. For lifting complete housings the lugs in the base have to be
used.
The bearing housings have “built-in” service jacks for installation and bearing
maintenance. Traditional mill cradles with separate hydraulic jacks are not necessary
(or delivered) to mills with these types of mill bearings.
Trunnion bearings, depending on weights and destinations, are normally shipped fully
assembled with all accessory equipment except for the radial and axial bearing
assemblies. The seal rings and cap have to be disassembled before installation can
proceed.
Check for any damage from rough handling, water ingress or rust after transportation
and storing. Report any signs of damage, and if necessary take pictures. The
installation supervisor must check against the certified issued drawings relevant for the
bearing assembly to check that all components are correct and nothing is missing.
7.1.3 Installing bearing housing base
1. Level the threaded bases of the shim set assemblies using the screws provided.
The finished elevation should be slightly lower than the finished underside of the
bearing housing base.
2. Prepare a simple mould and secure the assembly in place using non-shrinkable
epoxy grout, used to prevent the packers from floating after grout has been poured
and let harden.
3. Insert the anchor fasteners into the embedded sleeves.
4. Clean the underside of the bearing housing bases.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
NOTE: Position the bearing housing bases as shown on the Foundation Assembly
drawing, resting on shims. Ensure there are sufficient shims under the main bearing
housings (located directly under the jacking area, the radial bearings and also the
holding down fastener holes).
5. Lower the bearing housing bases on top of the shim set assemblies and over the
anchors. Use shims to adjust the height and inclination of the bearing housing
bases.
6. Level and align the two housings. For instructions, refer to chapter Foundation
preparation & sub-soleplate.
7. The housings must be perfectly on mill centerline, perfectly parallel with each other,
perfectly square, at the right elevation and level prior to proceeding. Thermal growth
of the mill has to be considered when setting the free bearing housing in position,
calculation should be made and the bearing offset from the centerline the
appropriate amount.
8. Tighten the foundation fasteners to prevent movement during lowering of shell and
under-grouting.
9. Recheck all measurements.
10. Install mill shell and heads.
11. Grout the bearing housing bases in place after installation and alignment of all
equipment.
12. Fully tighten the foundation fasteners.
WARNING
When tightening the foundation fasteners, do not exceed the maximum allowable
bearing stress recommended for the grout. Consult foundation designer for grout
specification.
7.2 Mill shell & heads
Before installing the mill shell, install the bearing housing bases.
CAUTION
. The mill shell comes with bracing located at each end near the flanges. When possible,
do not remove these braces until after the head and shell have been fastened together.
1. Erect the installation cradles on the foundations.

2. Adjust the cradles to the theoretical height and position, taking into consideration
the maximum stroke of the hydraulic jacks inside the bearing housings.
3. Install and align the bottom bearing housings with correct center distance.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
4. Install bearings. Refer to chapter 7 HSB2 Bearings and Mill Body Installation
5. Mill bearing housing base.
.
CAUTION
Mill shell flange faces must be free of paint, clean and dry at assembly.
.
WARNING
Do not weld lifting lugs onto the mill shell. Improperly welded lifting lugs may pose
potentially serious hazards to personnel. Welding, burning, and grinding may damage or
weaken the shell and will void component warranty.
.
CAUTION
Use extreme care while lifting and lowering the mill shell components to avoid damaging
the bearing or bearing housing.
CAUTION
. Do not force the mill heads into the shell if the flanges fail to seat. Try to determine
where pinching occurs and jack the heads or shell until the flanges seat freely.
6. Identify the 0, 90 and 270 positions on each section to ensure correct relative
positions during assembly.
7. Install shell on cradles and fit the mill heads.
8. Make sure the male/female spigot between the shell and mill heads fit correctly.
Install and tighten the flange fasteners to the required elongation using an ultrasonic
bolt micrometer. Refer to Structural Fastener Assembly drawing for required
fastener elongation. Where the trunnion is separate to the head install the trunnion
in a similar manner to that used for the head.
9. Clean the support surface of the service cylinder in the free bearing base and jack
up the piston so the service cylinder unloads the free end installation cradle. Lift the
trunnion just enough to be able to dismantle this installation cradle.
10. Clean the surfaces of the radial pads. Make sure the pad oil pockets are clean and
totally free from any impurities. Apply some of the lubricating oil that will be used
during operation on the pads.
11. Lower the jacking cylinder until the trunnion journal rests on the radial bearing pads.
12. Repeat these operations for the held bearing end. The mill body is now resting on
the radial pads. Take away the installation cradles.
13. Verify mill shell center line level in reference to level datum point. If difference of

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
levels between the ends exceeds 0.25 mm, adjust level using the following
procedure.
Figure 5. Distance (height) between trunnion and pedestal

1. Seal diameter
2. Check mill height
3. Bearing stool
a. Check the mill height by measuring from the bottom dead center of the journal
to the bottom of the jacking base. This can be done by placing a straight edge
across the bases, so that an accurate measurement can be obtained. Refer to
Figure 5. Distance (height) between trunnion and pedestal. If there is a height
difference between the feed and discharge end then the bearing stools must be
moved either in or out within their ample clearance holes to correct the height.
In order that this measurement can be used for accurate reference, the bearing
housing bases have to be correctly leveled in all directions.
14. Double check that the mill is horizontal by using a machinist’s level on top of the
trunnions.
15. Install bearing housing top halves, tighten and finish bearing assembly according to
specification.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
7.3 Mill bearing installation & housing completion
7.3.1 Preparing bearings before installing
• Thoroughly check bearings for any damage or burrs and machine cuttings from the
factory.
CAUTION
Lube lines must be clean and free of contaminants before connecting. Make sure all
connections are tight to prevent leakage.
CAUTION
7.3.2 Installing axial thrust bearing
1. Coat the thrust pad swivel with a light coat of molybdenum disulphide grease.
2. Fit the axial bearings to the pedestal and add shims to get the bearing pads equally
spaced on both sides of the axial bearing stool, and overall between 0.5 mm
and 1 mm less than the width of the journal.
3. Fit the assembled bearing stool and axial bearing and key into the bearing housing.
Use the wedge system to adjust the axial bearing base position so that the
clearance between the axial bearings and journal is approximately equal on
both sides
Figure 6. Axial bearing adjusting wedge system
4. Fit hoses between the bearing housings and bearings. Ensure that the hoses have
been flushed with clean oil before fitting. Consider the routing of the hoses to give
maintenance access.
5. Tighten the holding down bolts.
6. If position is correct torque fasteners to the recommended value.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
.
CAUTION
To avoid damaging the thrust pad lining do not fully install the thrust bearing pads until
the mill is installed on the pad bearings.
7.3.3 Installing radial bearing pads
1. Unpack the HSB bearing assemblies and do a visual inspection. Contact Outotec if
any damage is found.
2. Remove all restrictors, ports and plugs and blow out with clean dry compressed air.
3. Reinstall all restrictors, ports and plugs.
4. Ensure lifting lugs and brackets are in position.
5. Lift the bearing assembly, taking extreme care not to damage any bearing surface.
6. Install the radial bearing bases onto the machined stools. Align according to
drawing and torque the fasteners to the recommended value.
Figure 7. Typical radial hydrostatic multi pad bearing
1. HSB upper part

2. Restrictor tube
3. Bracket
4. HSB lower part

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
1. Carefully clean the pad surfaces and coat with oil. (Use the same oil used for the
circulating lube system)
2. Install the hydrostatic bearing assembly complete with stool into the bearing
housing. Align according to drawing and torque the fasteners to the recommended
value.
3. Insert the hydraulic fittings into the lubrication ports.
4. Connect the hydraulic hoses supplied with the bearing housing as shown on the
assembly drawing..
5. Mount the temperature and displacement sensor support bracket and the
temperature and displacement sensors onto the outboard side of the up running
bearing pad.
6. Route cables through the weld couplings in the bearing housing base as shown on
the assembly drawing.
7. Ensure that the temperature sensor tips rest gently against the bearing journal
surface and have ample spring travel.
7.3.4 Installing bearing housing seal
1. Install the seals on the journal shaft sides prior to placing the shaft into the bearing
housing.
2. Mark the seal on quarter sections by stretching and marking in one direction and
then by stretching in the opposite direction by pulling from the first marks.
3. Wrap the complete one-piece seals around the shaft and stretch the seal evenly
around the seal mounting surface by matching the quarter marks on the seal with
the station marks on the trunnion.
4. Lift a section of the seal at a time inserted a continuous bead of a suitable sealant,
such as Permatex Ultrablue, between the shaft and the seal.
CAUTION
RTV Silicon based sealants are recommended for placing under the seal (i.e. Permatex
Ultrablue or Loctite Blue Maxx)
5. Position the seal according to the drawing set, ensuring dimension “X” of Figure 5 is
at least 5mm, this dimension being the gap between the start of the seal and the
axial shoulder, and the position of the free end seal is correct when thermal
expansion of the mill is taken into account.
6. Install the clamping bands on the inboard and outboard groove.
7. Install o-ring cords in both the inboard and outboard lip grooves to increase tension
on the lips of the seal, with the cord diameter being adjusted so the outboard lip
tension is greater than the inboard and the minimum cord diameter is 7mm.
8. After the head has been installed in the bearing housing and the bearing housing
cap has been fastened in place.
9. For details regarding the seals see figures below and also refer to the Seal
Assembly drawing.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
Figure 8. Typical bearing seal assembly
Figure 9. Bearing seal assembly in lower portion of housing
10. Apply a suitable sealant such a Permatex Ultrablue between the seal plates and the
sides of the bearing housings.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
CAUTION
RTV Silicon based sealants are recommended for sealing the seal plates (i.e. Permatex
Ultrablue or Loctite Blue Maxx).
11. Center the seal plates around the mill trunnion and tighten fasteners. Make sure
the seal plate segments are correctly located and aligned. Refer to Figure 9, noting
orientation of lubricant relief grooves.
12. Tighten the housing flange fasteners.
7.3.5 Installing upper bearing housing
Upper bearing housing installation can only be completed after the head is lowered onto
the bearings.
1. Install the upper bearing housings taking note of the factory match marks.
2. Apply a light coat of a suitable sealant such a Permatex Ultrablue between the
flanges.
3. Tighten the flange fasteners.
4. Mount the bearing housing weather shields.
.
CAUTION
Check that lubricant supply lines are correctly connected and flushed before starting the
trunnion bearing lube system. Before rotating the mill shell assembly in the trunnion
bearings, make sure that the trunnion bearing lubrication system is running, and
delivers oil to the trunnion bearings. Look for oil flow between the hydrostatic bearing
shoes and the trunnions. Use a dial indicator to verify that the oil pressure lifts the
trunnions off from the hydrostatic shoe bearings.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
8 HSB4 Bearings and Mill Body Installation
8.1 Mill bearing housing base
8.1.1 Preparing bearing housing before installing
• Unfasten the large hatches in both ends of the bearing base. Refer to Figure 4.
• Remove axial and radial bearings & stools.
• Clean the inside and bottom of the bearing bases.
.
CAUTION
Figure 10. Typical trunnion supported bearing

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
8.1.2 Bearing housing particulars
NOTE: Installation of the bearing housing bases with bearing pad units must precede
installation of the mill shell.
There is one free bearing housing and one fixed (held) bearing housing. The bearing
housings are not symmetrical so must be installed in the correct orientation. Ensure the
hinge side of the inspection door is not on the mill side of the bearing housing as this
can allow a door to impact with the adjacent mill head.
The trunnion bearing housing base and cap, complete with seal faces, are
manufactured as a set and must be installed as a set. Follow match marks on the base
and caps.
Both bearing housings and pad bearing brackets are equipped with lifting lugs to ease
the handling during both installation and maintenance. The lifting lugs in the cap are
only for lifting the cap itself. For lifting complete housings the lugs in the base have to be
used.
The bearing housings have “built-in” service jacks for installation and bearing
maintenance in the form of slave bearings. Traditional mill cradles with separate
hydraulic jacks are not necessary (or delivered) to mills with these types of mill
bearings.
Trunnion bearings, depending on weights and destinations, are normally shipped fully
assembled with all accessory equipment except for the radial and axial bearing
assemblies. The seal rings and cap have to be disassembled before installation can
proceed.
Check for any damage from rough handling, water ingress or rust after transportation
and storing. Report any signs of damage, and if necessary take pictures. The
installation supervisor must check against the certified issued drawings relevant for the
bearing assembly to check that all components are correct and nothing is missing.
8.1.3 Installing bearing housing base
1. Level the threaded bases of the shim set assemblies using the screws provided.
The finished elevation should be slightly lower than the finished underside of the
bearing housing base.
2. Prepare a simple mould and secure the assembly in place using non-shrinkable
epoxy grout, used to prevent the packers from floating after grout has been poured
and let harden.
3. Insert the anchor fasteners into the embedded sleeves.
4. Clean the underside of the bearing housing bases.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
NOTE: Position the bearing housing bases as shown on the Foundation Assembly
drawing, resting on shims. Ensure there are sufficient shims under the main bearing
housings (located directly under the jacking area), the radial bearings and also the
holding down fastener holes. .
5. Lower the bearing housing bases on top of the shim set assemblies and over the
anchors. Use shims to adjust the height and inclination of the bearing housing
bases.
6. Level and align the two housings. For instructions, refer to chapter Foundation
preparation & sub-soleplate.
7. The housings must be perfectly on mill centerline, perfectly parallel with each other,
perfectly square, at the right elevation and level prior to proceeding. Thermal growth
of the mill has to be considered when setting the free bearing housing in position,
calculation should be made and the bearing offset from the centerline the
appropriate amount.
8. Tighten the foundation fasteners to prevent movement during lowering of shell and
under-grouting.
9. Recheck all measurements.
10. Install mill shell and heads.
11. Grout the bearing housing bases in place after installation and alignment of all
equipment.
12. Fully tighten the foundation fasteners.
WARNING
When tightening the foundation fasteners, do not exceed the maximum allowable
bearing stress recommended for the grout. Consult foundation designer for grout
specification.
8.2 Mill shell & heads
Before installing the mill shell, install the bearing housing bases.
CAUTION
. The mill shell comes with bracing located at each end near the flanges. When possible,
do not remove these braces until after the head and shell have been fastened together.
1. Erect the installation cradles on the foundations.

2. Adjust the cradles to the theoretical height and position, taking into consideration
the maximum stroke of the hydraulic jacks inside the bearing housings.
3. Install and align the bottom bearing housings with correct center distance.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
4. Install bearings. Refer to chapter 7 HSB2 Bearings and Mill Body Installation
5. Mill bearing housing base.
.
CAUTION
Mill shell flange faces must be free of paint, clean and dry at assembly.
.
WARNING
Do not weld lifting lugs onto the mill shell. Improperly welded lifting lugs may pose
potentially serious hazards to personnel. Welding, burning, and grinding may damage or
weaken the shell and will void component warranty.
.
CAUTION
Use extreme care while lifting and lowering the mill shell components to avoid damaging
the bearing or bearing housing.
CAUTION
. Do not force the mill heads into the shell if the flanges fail to seat. Try to determine
where pinching occurs and jack the heads or shell until the flanges seat freely.
6. Identify the 0, 90 and 270 positions on each section to ensure correct relative
positions during assembly.
7. Install shell on cradles and fit the mill heads.
8. Make sure the male/female spigot between the shell and mill heads fit correctly.
Install and tighten the flange fasteners to the required elongation using a ultrasonic
bolt micrometer. Refer to Structural Fastener Assembly drawing for required
fastener elongation. Where the trunnion is separate to the head install the trunnion
in a similar manner to that used for the head.
9. Ensure the surfaces of the pad bearings in the free bearing base are clean and
greased.
10. Connect the hydraulic power units to the jacking cylinder in the base of the lower
radial bearing stools (slave pads) and slowly pump the hydraulic fluid into the
cylinder until the free end installation cradle is just lifted enoughto allow removal.
Note the jack has a design lift of 15mm only. When the cylinder is at full lift, slide
the locking rings under the bearing assembly to lock the jacks into position.
11. Repeat these operations for the held bearing end. The mill body is now resting on
the radial pads. Take away the installation cradles.
12. Lower the jacking cylinder until the trunnion journal rests on the radial bearing
master pads.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
13. Verify mill shell center line level in reference to level datum point. If difference of
levels between the ends exceeds 0.25 mm, adjust level using the following
procedure.
Figure 11. Distance (height) between trunnion and pedestal

a. Check the mill height by measuring from the bottom dead center of the journal
to the base of the jacking base. This can be done by placing a straight edge
across the bases, so that an accurate measurement can be obtained. Refer to
Figure 11. If there is a height difference between the feed and discharge end
then the bearing stools must be moved either in or out within their ample
clearance holes to correct the height. In order that this measurement can be
used for accurate reference, the bearing housing bases have to be correctly
leveled in all directions.
14. Measure the total axial clearance between the axial bearing pads and the journal
face. The clearance should be 0.8mm per side. At no time should this clearance
exceed 1.5mm. Ensure that the axial bearings are aligned with the journal correctly,
by checking the clearance between the axial pad and bearing faces is even along
the length of the axial bearing.
15. Mount the temperature and displacement sensor support bracket and the
temperature and displacement sensors onto the outboard side of the up running
bearing pad.
16. Route cables through the weld couplings in the bearing housing base as shown on
the assembly drawing.
17. Ensure that the temperature sensor tips rest gently against the bearing journal
surface and have ample spring travel.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]
Mill Installation
8.3 Mill bearing installation & housing completion
8.3.1 Preparing bearings before installing
• Thoroughly check bearings for any damage or burrs and machine cuttings from the
factory.
CAUTION
Lube lines must be clean and free of contaminants before connecting. Make sure all
connections are tight to prevent leakage.
CAUTION
CAUTION
To avoid damaging the thrust pad lining do not fully install the thrust bearing pads until
the mill is installed on the pad bearings.
8.3.2 Installing the pad bearings
1. Remove the inspection hatches.

2. If not already fitted, install the pad bearings into the housing according to the
assembly drawings removing any protective covers, bung etc in the process.
Ensure fasteners are correctly torqued and the correct amount of shims are
installed between the key and the master bearing bases. The axial pads need to be
bolted to the master radial bearing base prior to master bearing assembly being
reinstalled. Clean the surfaces of the radial pads. Make sure the pad oil pockets
are clean and totally free from any impurities.
3. Grease the surfaces of the pads in preparation for lifting the mill body from the
installation cradles.

[123456] [ENH01] [DA01] [PFB02] [00001] 9009 [OU300100100_01]

MANUAL1 - Copia - 3

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MANUAL1 - Copia - 3

Uploaded by

Copyright:

Available Formats

Transportation

Outotec logo is a registered trademark of Outotec Oyj.

Copyright © Outotec Oyj 2018. All rights reserved.

Address: Puolikkotie 10, PO Box 86

FI-02201 Espoo, Finland

Telephone: +358 (0) 20 529 211

Fax: +358 20 529 2200

Mina Justa Mills

Installation and Maintenance Manuals

Equipment No: Item No:

Original instructions Translation of the original instructions

© Outotec Oyj 2013. All rights reserved. [Document Title 5] 2 (14)

1 Dimensions and mass ............................................................................ 4

© Outotec Oyj 2013. All rights reserved. 3 (14)

1 Dimensions and mass

1.1 Major component weights

Selection of lifting equipment must be made by qualified personnel. In certain

© Outotec Oyj 2013. All rights reserved. 4 (14)

Packaging is designed for 6 months of protection in a non-aggressive environment.

• extremely high or low temperatures or humidity

2.2 Loading and unloading

© Outotec Oyj 2013. All rights reserved. 5 (14)

© Outotec Oyj 2013. All rights reserved. 6 (14)

© Outotec Oyj 2013. All rights reserved. 7 (14)

The following general requirements apply:

• To prevent moisture ingress, always store components above ground

© Outotec Oyj 2013. All rights reserved. 8 (14)

Storing mill components in aggressive environments may cause damage by degrading

3.1 Extended storage

During extended storage, a layer of copper-impregnated shrink film, such as Intercept

3.1.1 Mill heads and trunnions

3.1.2 Mill shells

• For shell-supported mills, coat the journals in Denso [trade name]

© Outotec Oyj 2013. All rights reserved. 9 (14)

3.1.3 Ring gears and pinions

• Indoor storage is recommended for storage longer than 4 weeks or in

3.1.5 Pinion bearing assemblies

• Keep pinion bearing housings, bearings and spacers in packing boxes.

3.1.6 Mill bearings

• Keep bearing housings in packing boxes.

© Outotec Oyj 2013. All rights reserved. 10 (14)

3.1.7 Reducers & Bearings

• If storing for more than 3 months:

3.1.8 Lubrication systems

• Store lubrication systems indoors, at a temperature of +15 °C to +30

© Outotec Oyj 2013. All rights reserved. 11 (14)

• See manufacturer’s equipment manual for specific storage

3.1.9 HV Electric motor storage

© Outotec Oyj 2013. All rights reserved. 12 (14)

© Outotec Oyj 2013. All rights reserved. 13 (14)

Outotec Oyj Tel +358 (0) 20 529 211

English 2018 Installation

Outotec logo is a registered trademark of Outotec Oyj.

Copyright © Outotec Oyj 2018. All rights reserved.

Address: Puolikkotie 10, P.O Box 86

FI-02201 Espoo, Finland

Telephone: +358 (0) 20 529 211

Fax: +358 20 529 2200

Mina Justa Mills

Installation and Maintenance Manuals

Equipment No: Item No:

Original instructions Translation of the original instructions

© Outotec Oyj 2013. All rights reserved. [Document Title 5] 2 (87)