10 MP Maintenance

MINERAL PROCESSING COURSE
Plant Maintenance
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> Mineral Processing > Engineering Design > Specialist Services > Simulation & Optimisation > Construction Management > Risk Management > Training
Maintenance
> Plant maintenance consists of:
― Planning
― Emergency maintenance
― Service maintenance
― Preventive maintenance
― Record history
― Inspections
Maintenance (cont.)
Planned maintenance is based on:

> Forethought
> Control
> Careful timing
> Preparation with the use of past plant
records
Planned maintenance will not compensate:

> Poor workmanship
> Poor design
> Abuse of equipment
> Neglect
Maintenance (cont.)
Planed Maintenance Benefits:
> Greater plant availability
> Improvement in critical parts inventory
> Greater effective utilisation of maintenance labour
> Crisis management reduction
Maintenance (cont.)
Preventative Maintenance benefits:-
> Provide maintenance complimentary to
operation requirements
> Minimise maintenance and operational costs
> Minimised reliance on outside contractors
> Reduction in equipment downtime
> Minimise level of spare parts inventory
> Minimise emergency or breakdown
maintenance
Maintenance (cont.)
> Minimise overtime requirements
> Reduced exposure of personnel to

unplanned events and
consequential improvement in safety
> Optimise man power utilisation
> To train personnel
>>
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SERVICES
Maintenance (cont.)
MAINTENANCE
CYCLE
Start Emergency
Work ?
13 1
12 Perform
2
Report Planned
s
Completion Lubrication Conduct
Ye
Inspect 6% 5%
Of Work Service PM 3
6%
Results of
MNT
6%
Inspections
Report
N
Deficiencies Convert
o
Work
INSP 4
5% 7%
Results
into MNT
Needs
Respond to
Emergency
11 Confer 5
Maintenance
Needs 6%
with OPNS
on Needs
6% OPNS accept
5%
Results or Defers
Recommendations 6
Conduct Conduct
Running Planned and Plan, Coordinate
Repairs as the Scheduled and Schedule MNT
10 Need Arises Major Repair
Work
8%
Needs as Approved
by Operations
17%8 Conduct
7
Periodic
Change out of
5%
Equipment
Components
By-Pass Detailed
Planning when
9 Doing Emergency
Work
Concept of
Maintenance
Availability
> Time that the plant is actually available for production

> Expressed as a percentage
T  p  up  100
A
T
where,
p = hours down for planned maintenance
up = mechanical and electrical downtime unplanned
T = total hours
A = availability
Availability (cont.)
> Mill Availability
Mill Availabilities
120
100
Availability (%)
80
60
40
20
0
Jan Feb Mar Apr May Jun Jul Aug Sep Ocr Nov
Months
Southern Cross Marvel Loch
Utilisation
> Is the amount of operation of available equipment
> Equipment utilisation needs to be at least 95%
Table 1. Utilisation of Availability
97 – 98 very good
93 – 96 good
90 – 92 needs improvement
< 90 a serious problem exists
>>
SERVICES
Utilisation (cont.)
T  o  100
U
T
o = downtime due to
operational, problems
T = total hours
U = utilisation
Linked Relationships
Work Order System
> Maintenance management basis
> Raised by any tradesman
> Work Order should include:
― Equipment and its location
― Equipment number
― Description of work requirements
― Priority on the work
― Cost code
― Description of work done and parts used
― Man hours involved
Work Order
CC. TYPE UNIT COMP. CAT. WEEK DUE
EQUIPMENT DESCRIPTION
DESCRIPTION OF WORK
ESTIMATED
OCC.
TIME
JOB INSTRUCTIONS/ACTIONS TAKEN MATERIAL NOTES
REQUESTED BY: COMPLETED BY:
DATE WORK SAFELY DATE
MAINTENANCE WORK REQUEST

C
Work Order (cont.)
> The Works Order stages:
― Can be raised by any person
― Must be vetted by a Supervisor
― Passed onto Maintenance
Department after supervisors vetting
― Passed onto Maintenance planner
― Ends up in hands of a tradesman
Work Order Stages
Originator Completed File
File Copy Trades Copy
Supervisor Vetting
Maintenance Planner
Resources Manpower Materials
Order Parts Warehouse

Parts Clark Remove from Area
Area Listings
Recorded
History
Area Outstanding Planning
Work Lists
Scheduling Work Complete

Work Order Completed
Tradesman
Work Order (cont.)
Work Order Planning:
> Assess the resources, manpower and materials required and
available
> Order parts if required or ensure parts are in the warehouse
> Plan the work into an organised shutdown if necessary
> Schedule the work according to priority
Work Order (cont.)
> Work order

Plant Superintendent
― Is returned to the
Maintenance
Maintenance department
Supervisor
after work completion

Service Contractors Maintenance Planner
― Is stored in records file

Electrical
Mechanical
Others
Maintenance Leading
Head
Diesel Fitter
Fitter/Operator
Boilermaker
Crane Driver
Shutdown Planning
Prime reasons for the shutdown:-
> Multiple tasks possible
> Resource utilisation
> Cost effectiveness
> Time effectiveness
Shutdown Planning (cont.)
Common shutdown criteria:-
> Why? -prime purpose for doing work
> When? -the start and finish time
> How? -the method
> What? -requirements of labour, equipment and materials
> What if? -contingency factors
People involved in shutdown planning:-
> Plant Superintendent
> Maintenance Supervisor
> Stores Supervisor
> Administration Superintendent
> Production Supervisor
> Loss Control Co-Coordinator
> Superintendent
> Administration
Reports Plant Complaints Union

Manager Information Representative
Engineering
Orders Regulations
Staff
Questions Policy
Services
Information
Complaints
Directives
Reports Maintenance Policy
Suppervisor
Information
Policies Time Tables Maintenance

Questions Regulations Planner
Priorities Orders
Reports Directions
Information
Work Sampling Schedules
Standards Standards
Maintenance Complaints
Forman
Assistance Service
Correction of Information
Complaints
Material Outages Late
Instruction, Help, Disciplin
Other Production
Foreman
Arrivals
Supervisor
Information
Information
Complaints
Information
Complaints
Personnel Complaints
Labor Use Maintenance Shop
Accounting
Stores Material Use Workers Steward
Operators Check-sheet
> E.g. Jaw Crusher Checksheet

OPERATOR DAILY CHECKS CRUSHER
OPERATOR: DATE: TIME:
Completed
Remarks
Jaw Crusher CR-01
1. Jaw holder bushings – 10
strokes of manually operated
grease pump assembly
2. Pitman assembly - 20 strokes
of hand held grease gun to
each nipple times 4
3. With jaw crusher running
empty visually check
linings are secure
>>
SERVICES
Programmed Preventative Maintenance
PPM necessities:
> Plant register of all items of equipment (MAJOR) with priority
attached
> Job Control
> Inventory management or critical spares review including

normal consumable spares
> Condition monitoring
> Shutdown planning
Bowl & Mantle Changeout
PPM (cont.)
Organizing Operating
List all equipment to be Prepare and issue PM

inspected schedules
Develop routes for fixed Conduct inspections

equipment
Prepare program for mobile Report results

equipment (prepare work orders)
Monitor repairs from PM

Prepare detailed checklist program
Establish standard times for Monitor actual Vs planned

inspections inspection times
Establish inspection intervals Adjust inspection intervals
Check method of inspection by

Determine manpower
industrial engineering
requirements
Add/delete items on checklist
Balance manpower needs
Maintenance Priorities
> Level of importance
> By-pass existence
> Duty and standby duty
existence
> E.g. Mill gearbox
Job Control
> This is the dynamic action of maintenance planning
― Job forecasting
― Planning the work
― Checking materials requirements
― Issuing the work
― Recording work completed/update
files
Inventory Management
> Requires checking of the store stock
> Checking the critical items
― Pump liners Discharge

Joint
Volute Seal Volute Seal

― Cyclone parts
― Oils and lubricants

Intake Joint
Frame Plate
Linear Insert
Impeller
Throatbush
Condition Monitoring
> Involves monitoring around the key items:
― Jaw crusher bearing
― Cone crusher
― Mill drive
― Gearbox train, etc. Mill Pinion
> Monitoring provides the facility to predict

maintenance:
― Monitoring points installed
― Trend analysis/monitoring
― Oil analysis
Gear Drive
Critical Spares
Critical spares review
> What is the likelihood of failure?
> How long to obtain spares?
> What will it cost in downtime?
> Are there alternatives?
> Recommendations
No Parts In Stock
Contingency Planning
A failure analysis plan should involve:-

> Do we have drawings
> Who can cast shells
> Who can cast white metal
> Who can cast machine
> Does anyone else have spares
> What is the overall lead time
> What is involved in change out
> Is the proposed plan satisfactory
Contingency Planning (cont.)
Following parts failure will shut down the plant:-
> Mill motors
> Mill bearings
> Mill gearbox
> Pinion and ring gear
> Pinion bearings
Item Of Equipment
1. Ball Mill
> continuous operation for gold production
2. Primary Crusher
> stops the mill , conveyors and feeders
― CV 3 highest priority
― CV 2 next priority
― CV 1 lower priority
Item Of Equipment (cont.)
3. Leach Tanks
> can be by-passed through adsorption tanks
4. Elution Column
> batch production can postpone a strip
5. Carbon Regeneration
> can be by-passed
6. Mill Water Supply
> essential continuous operation
7. Power Supply
> essential continuous operation
Reporting, Requests And Review
Weekly Maintenance Meetings
> Proposed shutdowns
> Timing work to be done
> Special tools
> Manpower
Reporting, Requests And Review (cont.)
The system needs to be continually reviewed to include:
> Problem areas
> Improvements to the system
> Retention of experience
THANK YOU
www.mets.net.au
> Mineral Processing > Engineering Design > Specialist Services > Simulation & Optimisation > Construction Management > Risk Management > Training

10 MP Maintenance

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MINERAL PROCESSING COURSE

Click to edit Master subtitle style

> Plant maintenance consists of:

Planned maintenance is based on:

Planned maintenance will not compensate:

Planed Maintenance Benefits:

> Greater plant availability

> Improvement in critical parts inventory

> Greater effective utilisation of maintenance labour

> Crisis management reduction

Preventative Maintenance benefits:-

> Provide maintenance complimentary to

> Minimise maintenance and operational costs

> Minimised reliance on outside contractors

> Reduction in equipment downtime

> Minimise level of spare parts inventory

> Minimise emergency or breakdown

> Minimise overtime requirements

> Reduced exposure of personnel to

> Optimise man power utilisation

> To train personnel

> Time that the plant is actually available for production

> Mill Availability

Southern Cross Marvel Loch

> Is the amount of operation of available equipment

> Equipment utilisation needs to be at least 95%

Table 1. Utilisation of Availability

< 90 a serious problem exists

> Maintenance management basis

> Raised by any tradesman

> Work Order should include:

― Equipment and its location

― Description of work requirements

― Priority on the work

― Description of work done and parts used

― Man hours involved

CC. TYPE UNIT COMP. CAT. WEEK DUE

REQUESTED BY: COMPLETED BY:

DATE WORK SAFELY DATE

MAINTENANCE WORK REQUEST

> The Works Order stages:

― Can be raised by any person

― Must be vetted by a Supervisor

― Passed onto Maintenance

Department after supervisors vetting

― Passed onto Maintenance planner

― Ends up in hands of a tradesman

File Copy Trades Copy

Resources Manpower Materials

Order Parts Warehouse

Scheduling Work Complete

Work Order Planning:

> Assess the resources, manpower and materials required and

> Order parts if required or ensure parts are in the warehouse

> Plan the work into an organised shutdown if necessary

> Schedule the work according to priority

> Work order

after work completion

― Is stored in records file

Prime reasons for the shutdown:-

> Multiple tasks possible

> Resource utilisation

> Cost effectiveness

> Time effectiveness