Maintenance and Operation Manual For Secondary Crushing Improvement - RevC

“OPERATION AND MAINTENANCE MANUAL FOR IMPROVEMENTS IN
SECONDARY CRUSHING IN 1-MINE CRUSHING PLANT”
SHOUGANG HIERRO PERU SAA
NOVEMBER 2013
INDEX
INTRODUCTION.....................................................................................................................................4
GOALS 4
1. LOCATION..................................................................................................................................5
2. SYSTEM OVERVIEW...................................................................................................................5
2.1 GENERALITIES............................................................................................................................5
3. SAFETY CONSIDERATIONS........................................................................................................6
3.1 ELECTRICAL HAZARD.................................................................................................................7
3.2 MECHANICAL HAZARD..............................................................................................................8
3.3 PERSONAL PROTECTIVE EQUIPMENT (PPE) REQUIRED............................................................8
3.4 COLLECTIVE PROTECTION EQUIPMENT (CPE) REQUIRED.........................................................8
4. RESPONSIBILITIES......................................................................................................................8
4.1 HEAD OF DEPARTMENT............................................................................................................8
4.2 FOREMAN OR CREW LEADER....................................................................................................9
4.3 OPERATORS...............................................................................................................................9
5. OPERATION...............................................................................................................................9
5.1 DESCRIPTION OF OPERATIONS.................................................................................................9
5.1.1 TRANSPORTATION AND RECEPTION OF THE MINERAL............................................................9
5.1.2 SECONDARY CRUSHING PLANT 1 - MINE (DRY COOBING).......................................................9
5.2 OPERATION AND MAINTENANCE OF EQUIPMENT.................................................................10
5.2.1 CONVEYOR BELTS....................................................................................................................10
5.2.1.1 MAIN PARTS OF CONVEYOR BELTS.........................................................................................10
5.2.1.2 OPERATION.............................................................................................................................11
5.2.1.3 PROBLEM IDENTIFICATION.....................................................................................................13
5.2.1.4 PREVENTIVE MAINTENANCE...................................................................................................13
5.2.1.5 CORRECTIVE MAINTENANCE...................................................................................................14
5.2.2 CONICAL CRUSHER..................................................................................................................16
5.2.2.1 OPERATION.............................................................................................................................18
5.2.2.3 INSPECTION AND MAINTENANCE INTERVALS........................................................................22
5.2.2.4 CORRECTIVE MAINTENANCE...................................................................................................23
5.2.2.5 LUBRICATION SYSTEM............................................................................................................25
Manual de operación y mantenimiento de mejoras en chancado secundario

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5.2.3 CHUTES....................................................................................................................................26
5.2.4 SHARE......................................................................................................................................26
5.2.4.1 MAIN PARTS OF THE SHEETER................................................................................................27
5.2.4.2 OPERATION.............................................................................................................................27
5.2.4.3 FIXING AND ALIGNMENT OF THE VIBRATORY SHEEDER........................................................27
5.3 START UP.................................................................................................................................28
6. ROUTINE INSPECTION OF SECONDARY CRUSHING................................................................29
ANNEX A: MAINTENANCE FORMATS....................................................................................................31
ANNEX B: MAINTENANCE CHART.........................................................................................................37
ANNEX C: EQUIPMENT ARRANGEMENT SCHEME................................................................................45
ANNEX D: EQUIPMENT MANUALS........................................................................................................47

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INTRODUCTION
This Manual contemplates the procedures and recommendations for the Shougang Hierro Perú
Company (SHP) to carry out the Operation and Maintenance (O&M) work of the crushing plant
system No. 1 - Mine.
The operation and maintenance of the crushing plant system No. 1 - Mine must be based on what is
indicated in this manual, which identifies the processes that make possible the optimal, efficient and
effective operation of the system without interruptions due to failures of any of the elements,
processes or operations caused by poor operation or maintenance.
This maintenance manual must be flexible, therefore, it must be periodically reviewed to update it
according to existing needs. These reviews will include the necessary instructions for any new
procedure, equipment or installation that has been executed as a result of improvements,
expansions or modifications in the crushing plant system No. 1 - Mine.
Finally, it is necessary to establish an adequate control system that allows at any time to recognize
which operation or maintenance processes are being executed, whether they are being carried out
appropriately or which ones must be modified, deleted or added to achieve the final objective of
operation and maintenance.

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GOALS
The objective of this manual is to provide necessary instructions for the correct operation and
maintenance of the secondary crushing of the N⁰1-mine plant, which is why it is recommended to
read it before the operation and maintenance of the system components.
The specific objectives of this manual consider the following aspects:
a) Know the job clearly and do it safely.

b) Operate the plant in accordance with applicable environmental regulations, permits and
limitations, conserving the environment without spills.
c) Operate the plant efficiently according to established procedures.
d) Conceptually know the process that develops in each of the areas of the plant.
e) Understand the principle of operation of the equipment used in the process.
f) Know the control of the process in such a way that the operator is in a position to recognize and
correct failures, and to suggest improvements or modifications that allow reducing operation
and production costs.
g) Execute operating procedures correctly, securing equipment and avoiding damage to it.
1. LOCATION
The secondary crushing improvement system is located in plant No. 1 of the Shougang Hierro
Perú SAA mining complex, in the mine area, northeast of the district of San Juan de Marcona,
Province of Nazca, Ica Region, located on the coast Peruvian 530 km south of the city of Lima.
2. SYSTEM OVERVIEW
2.1 GENERALITIES

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Metallurgical unit operations consist of crushing, grinding, flotation of valuable sulphides,
removal of water from the produced concentrates, dispatch of the concentrates and disposal
of the tailings.
Crushing is the process in which the mineral is reduced in size according to specifications
according to the type of mineral, to be used in the benefit process (magnetic plant).
The primary and secondary crushing process of the mineral is carried out in the mine,
obtaining a diameter of 2 inches which is sent to the San Nicolas plant by a system of
conveyor belts (conveyor).
MINE CRUSHING.
In this process, mineral crushing is carried out; for this, two crushing plants are used:
Plant 1: Ore crushing, with a capacity of 1400TMH
Plant 2: Crushing of ore and low grade, with a capacity of 2500TMH
The crushed ore is deposited in the crude stock fields, classified by the type of mineral
CRUSHING SAN NICOLÁS.
From the crude stock fields, it is sent to the San Nicolas crushing plant, in which there are
two production lines (Line N⁰1 and Line N⁰2), in which the tertiary crushing process is carried
out.
The crushed ore goes through a screening process. The ore is deposited in nine silos,
classified by the type of mixture, according to the scheduled production. The crushing plant
facilities include:
a) crude oil stock

b) Line N°1 (works in open and/or closed circuit)
c) Line N°2 (works in open circuit)
The crushed and classified ore from the silos, where it has arrived from the crusher, enters
the magnetic plant to be subjected to the fine grinding and coarse grinding processes.
SECONDARY CRUSHING IMPROVEMENT PROJECT IN PLANT 1 - MINE
The project: Improvements in secondary crushing, consists of installing a new infrastructure,

composed of two production sub-lines with the capacity to process 1400 TMH of iron ore
from the primary crusher. Simultaneously and individually, the following will be installed:
 02 7 foot conical crushers
 02 vibrating screens with their respective feed and discharge chutes for fine material
and coarse material
 02 conveyor belts to feed the vibrating screens
 02 integrated feeder belts with magnetic pulleys to separate high-grade material from
sterile (Dry Cobbing).
 01 conveyor belt to remove sterile material

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3. SAFETY CONSIDERATIONS
Keep the work area free of traffic, for its correct operation and performance of maintenance
maneuvers when required.
Before carrying out operation and maintenance tasks, it is necessary to Identify the Dangers
and Evaluate the Risks to which the operator will be exposed, in order to prevent possible
damage to their health.
Some relevant approved standards are shown below:
a) Supreme Decree No. 014-92-EM, TUO of the General Mining Law

b) Supreme Decree No. 018-92-EM, Regulation of Mining Procedures
c) Supreme Decree No. 016-93-EM, Regulation for Environmental Protection in Mining
Metallurgical Activity
d) Supreme Decree No. 055-2010-EM, Occupational Health and Safety Regulations and
other complementary measures in mining
e) Regulations of Shougang Hierro Perú SAA
Article 301 of Supreme Decree No. 055-2010-EM:
In concessions for transporting concentrates on conveyor belts, supervision and maintenance

programs will be implemented, as well as operation monitoring control systems, topographic
monitoring, lighting, ventilation, anti-noise, dust protection, communication and drainage;
electrical installations, engines, fire protection systems and contingency plans
LOCATIVE HAZARD
Location Hazard refers to the adverse conditions of the location that may cause damage to
health, whether: deficiencies in the ground, manipulation of objects, unevenness, traffic,
entrances and exits, confined spaces, etc.
ASSOCIATED RISK CONSEQUENCE PRECAUTIONARY MEASURES

Falls at the same level Bruises, wounds, lacerations, Avoid uneven floors, mark and
Falls at different level dislocations, fractures, trauma, delimit the work area, locate tools
Falling Objects amputations, death, etc. away from the edges, secure them
Collapse to fixed places
Crash, Run over, Overturn
Some environmental management measures establish that:
- The mineral conveyor belt will be covered to prevent the generation and dispersion of dust.
- To avoid leaks, the flow of mineral in the conveyor belt should not present any load on the
edges.
3.1 ELECTRICAL HAZARD

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If the unit to be intervened has an electrical energy source and circuits, the energy flow must
be cut off by turning off the electric keys and blocking them to ensure that no one reconnects
them while the work is being carried out. . This must be done in coordination with the
department in charge of electrical supply.

Direct or indirect contact with Electrocution, burns, arrest Cut off the flow of electrical energy and
energy cardio-respiratory, death, etc. electrical locking of equipment.
3.2 MECHANICAL HAZARD

Bang Bruises, fractures, wounds, death, Fastening tools and equipment, timely
etc. inspection and maintenance of tools and
Entrapment Tears, lacerations, fractures, death,
equipment
etc.
Court Wounds, bleeding, amputations,
death, etc.
Detachment projections Wounds, invasive foreign bodies, Object projection blocking, EPPs
etc
These include possible damage that may be caused by the equipment present in the units,
and blocking them must be carried out as a preventive measure. Examples include: Poorly
secured tools and/or equipment, tools and/or equipment in poor condition, sharp tools
and/or equipment, loose particles.
3.3 PERSONAL PROTECTIVE EQUIPMENT (PPE) REQUIRED
Because it is a crushing system, the following EPPs are considered:
to) Safety helmet, chinstrap

b) Work uniform
d) Respirator, Cartridges with dust filters
F) Safety glasses
g) Leather gloves: for moving tools, equipment and discovering access
h) Rubber gloves: for work in contact with water.
Yo) Rubber boots with steel toe
k) Fall protection system
3.4 COLLECTIVE PROTECTION EQUIPMENT (CPE) REQUIRED
To secure the work area it is necessary to have the following EPCs:

to) security tapes
b) Safety signs: signs
4. RESPONSIBILITIES
4.1 HEAD OF DEPARTMENT
to) Instruct the operating personnel on this operation and maintenance manual of the
equipment in the crushing process.
b) Instruct staff on the Dangers and Risks associated with the work.
c) Deliver the inspection and maintenance forms for the Crushing System units
established in this manual.
d) Enforce the schedule of inspection and maintenance activities.

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and) Enforce existing internal work and safety regulations.
F) Coordinate with the affected areas and inform them of the intervention that will be
carried out.
4.2 FOREMAN OR CREW LEADER
to) Instruct the operating personnel on this O&M (operation and maintenance) manual.
b) Instruct staff on the Dangers and Risks associated with the work.
c) Enforce the schedule of inspection and maintenance activities.
d) Enforce existing internal work and safety regulations.
and) Coordinate existing electrical and mechanical locks.
F) Review and endorse the completion of the Safe Work Analysis (ATS) form.
g) Request and control the stock of equipment, tools, materials, PPE and EPCs necessary
to carry out the work.
4.3 OPERATORS
to) Attend the training of this O&M manual

b) Attend training on the Dangers and Risks associated with the work.
c) Comply with the schedule of inspection and maintenance activities.
d) Comply with existing internal work and safety regulations.
and) Fill out the Safe Work Analysis (ATS) form.
F) Request the equipment, tools, materials, PPE and EPCs necessary to carry out the
work from the warehouse.
g) Carry out inspection and/or maintenance work following the guidelines established
by this manual.
h) Report events that occurred during the implementation of activities.
5. OPERATION.
5.1 DESCRIPTION OF OPERATIONS.
5.1.1 TRANSPORTATION AND RECEPTION OF THE MINERAL.
The ore is transported, in trucks belonging to SHP, to the reception platform where it is
weighed with the help of a platform scale and then sent for primary crushing.
5.1.2 SECONDARY CRUSHING PLANT 1 - MINE (DRY COOBING)
The conveyor belt 011-008 with a capacity of 1400TMH transports the ore from the crude
stock and delivers the ore through the pan chute 150-CH-001 to two conveyor belts with a
capacity of 700TMH each, which are the belt 150-BC-001A ( 60”x15m) and the strip 150-BC-
002A (60”x15m)
The material transported by the belts is unloaded through the loading chutes 150-CH-001B
and 150-CH-002B to the secondary conical crushers 150-CC-001 of 7' STD and 012-010 that
are driven by a 300HP engine. -700RPM.
The load fed to the crusher is 490TMH; which after being crushed, is transported by the
feeder belt 150-BC-001B and 150-BC-002B, to the dry coobing separator chute 150-CH—
001AE

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The separator chute discharges the waste material to the conveyor belt 150-BC-001E with a
capacity of 280TMH towards a pile of waste material and to the conveyor belt 011-011 with a
capacity of 1120TMH the high-grade ore towards the stock pile to be transported by the
conveyor belt to San Nicolás
Primary crushing equipment: Birosborg Buchman 66x84 jaw crusher – 300HP- 600RPM
Secondary crushing equipment: Symons Norberg 7' STD conical crusher 300HP- 700RPM
For more details see Annex D
Figure 1: Existing equipment Plant N°1 – Mine

5.2 OPERATION AND MAINTENANCE OF EQUIPMENT
5.2.1 CONVEYOR BELTS
Conveyors are commonly used to move thick, relatively dry material. The design and
configuration of conveyor belts varies significantly.
The ore is transported in a belt usually made of layers of fabric, steel ropes and bonded or
vulcanized rubber. The top and bottom layer are made of rubber of adequate thickness to
resist abrasion. The conveyor belt moves on flat idlers or, more frequently, on idlers with
angles.
The feed belt has a zero speed switch located on the tail pulley to detect any belt slippage. It
also has emergency cords so that area personnel can make emergency arrests of the belt. It
is also equipped with belt misalignment switches. Each of the aforementioned switches,
when activated, causes an alarm and causes the belt to stop by interlocking. Misalignment
switches, however, have a pre-alarm signal to allow the condition to correct itself before
stopping the belt. At the discharge point of the belt, there is a sampler, which allows mineral
samples to be extracted to be analyzed in the laboratory.
5.2.1.1 MAIN PARTS OF CONVEYOR BELTS

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A) The Band : It is made of canvas completely covered with rubber (vulcanized). The
operation is carried out by the movement of the pulleys and idlers, their movement is
constant and endless because they are joined at their ends.
B) The pulleys : They transmit movement to the belt and with it transport the mineral. They
are placed at the ends of the belt, called head pulley or tail pulley depending on their
location. We have the following types of pulleys
Drive pulley It is coupled to the motor that transmits movement, it is made of steel,
cylindrical in shape.
Counterpulley . It is located under the belt, near the head pulley, where the belt returns.
It is also called a brake pulley.
C) The idlers : They hold the belt between the main pulleys and help it turn.
Various types of rollers are used
Curved pulleys : They are found below the face of the belt that conducts the mineral.
They are made up of three flat “V”-shaped rollers that form a channel with the belt to
prevent cargo spills.
Return idlers . They serve to prevent the sash from hanging. They are found below the
belt, where it does not carry bone mineral on its return. Some rollers are made of rubber
Impact rollers . They serve to cushion the fall of the mineral on the belt and prevent it
from breaking due to impact. They are made of rubber and are located under the belt at
the height of the chutes.
Guide rollers . They are the same as curved idlers, but sit on a single pivot pin. The end
idlers have a special counterweight system, which rotates the entire idler, in such a way
that it corrects small deviations of the conveyor belt.
Vertical rollers . They check that the belt does not come out of its place, that is, they
straighten the belt. They are located on the sides of the conveyor belt.
D) The Templars. As its name indicates, it adjusts or tempers the belt, preventing it from
slipping due to being too loose. The following types of temperers are available
Screw temperer . They temper the belt by the simple procedure of adjusting or moving
the tail pulley and also serve to center the belt when it is tilted.
Counterweight temperer . Increases the tension in the belt by regulating the
counterweight and in this way the work operation is maintained.
E) The blades
Guard guide blades . They are used to prevent load spills from the belts to the floors.
They are placed under the chutes that feed load to the conveyor belts, they serve to
avoid cutting the conveyor belt with the iron plates or due to friction.
Cleaning blades . They are used to clean the belts. They are placed below the head pulley
and above the belt on the head pulley.
F) The Transmission System: It serves to communicate movement to the belt, and is made
up of:
 The motor

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 The pulleys
 The speed reducer
 The pinion
5.2.1.2 OPERATION
PRELIMINARY CONSIDERATIONS
START
a) The 150-BC-001E belt must be started under vacuum.

b) Once the belt 150-BC-001E is in operation, gradually open the gates of the separator
chute (Dry Coobing) 150-CH-001AE until normal operating conditions are established.
c) Press the Start/Stop button on the 150-BC-001E strip; located on the control board 150-
JBC-007
d) Start the belts 150-BC-001A; 150-BC-002A and 150-BC-001B; 150-BC-002B by pressing
the Start/Stop button located on the control panel 150-JBC-005 and 150-JBC-006
respectively
e) Start the feeder belt 011-008
STOP
To stop the bands, lock the band 011-008 in the stop
Evacuate the remaining load and close the chute gates150-CH-001AE
De-energize the electric motors of the belts 150-BC-001A, 150-BC-002A, 150-BC-001B; 150-BC-002B
and 150-BC-001E (ascending order)
The terms of operation of the conveyor belts are:
inspect the work area, and eliminate unsafe conditions.
The inspection of the transport belts must be mandatory at the beginning and end of each watch,
and periodically during the watch.
Inform the supervisor about the operational conditions of the conveyor belts, or if any unsafe
conditions exist.
Before tearing off the belt, check that there are no people near the belt.
The side guards must be well aligned; to avoid spills, truncations and cuts in the strips.
Pulleys and idlers free of caked load; to prevent the belt from becoming misaligned
The discharge chutes of the belts must be free of load; to prevent the belt from getting stuck or
immobilized.

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Do not overload the belt.
If the belt is immobilized; cut the load, set lock out, unload the belt and then remove the lock out
and proceed to start
Safety considerations in the operation of belts to take into account are:
Do not clean the pulleys or idlers when the belt is in operation.
Do not cross over the belt when in operation
If you have any emergency, please pull the “Emergency” stop rope
Keep a safe distance when equipment is in motion.
Do not operate the belts with loose clothing.
5.2.1.3 PROBLEM IDENTIFICATION
A. REMOVAL OF CONVEYOR BELTS.
A conveyor belt decenters or deviates to one side for the following reasons:
a) When the head or tail pulleys are loaded

b) caked (especially too much moisture)
c) When the idlers (return) have a fine caked load
d) When the strip is poorly spliced (cut without a square)
e) When the adjustment of the belt is incorrectly done
f) About Ore loading
g) Poor centering of the idlers
The following damage can occur to an off-center belt:
a) Break the coupling, chain or engine pulley belt

b) Spill cargo (ore)
c) Block or jam the belt
d) Breaking, widening or damaging the belt
e) Burn the belt motor
f) Cause accidents to the operator
B. JAM IN THE CONVEYOR BELTS
The conveyor belts get stuck and stop for the following reasons:

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a) When they are too loose
b) When most idlers don't work
c) When the belt is decentralized
d) When the head or tail pulley is wet or greasy
e) When they are overloaded
f) When there is a load under the belts, at the height of the pulleys
g) When the pulleys and idlers have a fine caked load
5.2.1.4 PREVENTIVE MAINTENANCE
The main actions for preventive maintenance are:
a) Verify that the pulleys and idlers are clean, free of caked load, free of crusts and in full
operation.
b) Check that the tensioning mechanism is in good condition
c) Inspect the temperature of the engine lubrication pads, speed reducers, bearings and
transmissions.
d) Check that the bearings are well lubricated
e) Clean the load under the belts, pulleys and idlers
f) Do not use the belts for any purpose other than the transportation of ore.
g) Do not force the belt when planting, unload it before starting it again
h) Listen for any strange noises on the conveyor belts.
i) Check that the guide rollers work normally
5.2.1.5 CORRECTIVE MAINTENANCE
FAILURES CAUSE CORRECTION
The belt runs idle on 1) Light

the tail pulley counterweight recalculate the required weight and adjust the
counterweight or tensioner screw
Realign install limit switches for added safety

2) Rollers or pulleys
out of square with

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the center line of

the conveyor
3) Locked rollers Release the rollers and lubricate them
The feed must be in the direction of travel and

4) Improper loading,
at the speed of the belt, centered on it. Control
spillage
flow with feeders, chutes and skirts
5) Material Remove buildup, install cleaning devices,

accumulation scrapers and inverted V plates
Load in the direction of travel of the belt, to the

6) Side loading
center of the conveyor
The entire belt runs 7) When the belt is Give the new fascia time to settle. If the fascia
empty at all points of deformed on one does not fit properly or is not new, remove the
the line side deformed section and splice a new piece.
8) Improperly located
Relocate rollers or insert additional rollers
rollers
spaced to support belt
Idem 2), 4),5)
9) Inappropriately Use correct fasteners. Reset after a short time

spliced or poorly run. If the splice is inappropriate, remove the
secured belt splice and make a new one.
A section of the belt Repair the edges of the sash. Remove any
10) Worn or broken
runs empty at all points wasted or out-of-square sections and splice
edges
on the line with a new piece.
Avoid rolling up the strip or storing them in

11) Arched sash humid environments. The new sash should be
straightened when forced or replaced
The belt runs empty on 12) Worn pulley cover

Replace it. Use molded liner for wet conditions
the drive pulley Idem 2), 5),8)
The belt is moved to

one side of the curl on Idem 2), 5), 8)
specific rollers

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13) Insufficient
Increase the winding with a idler pulley. Coat
traction between
The belt slips the drive pulley. In wet conditions, use molded
belt and pulley
liner. Install proper cleaning devices for safety
Idem 1), 3), 5),12)
If the line is overextended, consider using two

14) Drive below the overhead systems with transfer points. If the
The belt slips when
belt frame is not rigid enough for the load, install
starting
Idem 1), 12), 13), the strap with adequate flexibility when out of
service.
Use vulcanized splice within recommended

15) Excessive tension
limits
16) Counterweight too Reduce tensioner tension to slip point, then

heavy tension again
17) Wrong differential

Make necessary adjustments
Excessive stress on the speed
belt
Use belts designed for specific conditions. For
18) Damage from
abrasive materials working in cuts and between
abrasives, acids,
folds, make spot repairs with cold patches or
chemicals, heat,
permanent replacement patches. Replace
mold, oil
metal o-ring fixing with stepped vulcanized
Idem 5),14)
joint
19) Pulley too small Use a larger diameter pulley

The girdle breaks at or
after the fasteners, the 20) Material between
Use skirt properly: Remove buildup. Implement
fasteners come off belt and pulley
maintenance
Idem 9),12),14)
5.2.2 CONICAL CRUSHER

Crushers are machinery where minerals are received from inside the mine, and from the
coarse hoppers to be reduced to small sizes or pieces.
In the crushing section we use three types of crushers.
a) Primary Crusher: Conical

b) Secondary crusher. Symons Nordberg

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In a conical crusher, material is crushed between a cone or conical crushing head (mantle)
and a curved bowl (concave). Both the mantle and concave are covered with replaceable
liners called cuirasses, or mantle liner and concave liner respectively. The crusher mantle is
supported in two ways: in a thrust ring, which is part of the rotating eccentric assembly; and
in a set of breaks from the quicionera.
The eccentric assembly is formed by a heavy metal sleeve whose external part is eccentric
and making a slight angle with the vertical axis of rotation; a gear ring at the bottom of the
eccentric; a circular counterweight; the thrust ring; and various oil tight seals. The external
part of the eccentric rests on a lower head bushing pressed into the crusher mantle. The
inner part of the eccentric is pressed into an inner sleeve rest which in turn rests around the
stationary main shaft.
The eccentric assembly is rotated around the main shaft by the crusher motor through a set
of pulleys and belts, the counterweight and the gear ring. The rotating eccentric acts as a
cam and moves the crusher mantle through a rotating pattern, where it moves toward the
concave, then away from it in repeated cycles. The minimum opening between the mantle
facings and the concave is called closed side setting (CSS). Experience has shown that about
80 percent of the crusher's product is finer than this setting and 20 percent is slightly coarser.
The maximum opening is called the open side setting (OSS).
Figure N°2 Conical crusher

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The frame rest assembly, containing a frame and a frame liner, is attached to the top of the
stationary main structure. A hemispherical surface that has the lower part of the crusher
mantle rests on the lining of the jaw to form a spherical ball joint. Lubricating oil reaches the
joint through grooves in the lining of the joint.
The ball joint assembly allows the head to rotate in circular motion while maintaining full rest
support throughout the crushing cycle. Figure 3 illustrates the eccentric action of the crusher
mantle. The material is fed into the crusher from the top to the feed distributor plate which
rotates with the mantle and distributes the feed around the crushing chamber. The material
falls into the cavity between the concave and the mantle and is squeezed and fractured
during the rotating action where the mantle is close to the concave lining. As the mantle
recedes, fractured (finer) material is deposited in the concave, where the opening is
narrower. The material breaks down more as the mantle recedes.
Figure N°3 Eccentric movement of the conical crusher
For further reference, consult the equipment manual, see Annex
MAIN PARTS OF THE SYMONS NORBERG CONE CRUSHER
The Symons Norberg secondary crusher performs secondary crushing of coarse ore.
The main parts that are distinguished in this crusher are the following:
a) The Bolw is the fixed part of the crusher.

b) The Mantle is the moving part of the crusher.
c) adjustment ring
d) Cup, cup cover
e) head, head cover
f) The main shaft, on this shaft the cone (Mantle) is mounted

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g) The countershaft and pinion are connected to the crusher motor through the flat belt.
h) Spring system.
i) The lubrication system, consisting of: The oil pump; pipes and connections; the little
glass; and the oil tank.
j) The movement system, which is made up of: The motor; the engine pulley and the
flywheel.
For further reference see Annex D
5.2.2.1 OPERATION
A) Startup, commissioning
The shredder is powered by an electric motor. Starting the crusher is ultimately

equivalent to starting the electric motor, in accordance with the manufacturer's
instructions. It is not recommended to place material of any kind in the crusher during
start-up.
To boot, proceed as follows:
Starting the lubrication system
a) Start the electric motor

b) If the crusher is equipped with an integral pump that only operates when the crusher
is also running, check if oil is reaching the oil tank from the drain pipe. If the pump is
operating properly, oil should begin to flow from the drain line to the tank almost
immediately upon start-up, which can be easily checked by removing the inspection
plug from the oil tank cover.
c) Check the direction of rotation of the horizontal shaft or countershaft
d) Check countershaft speed
Caution
Do not let the crusher run for more than two minutes if you see no sign of oil on the feed
sight gauge or in the drain pipe inside the oil tank, as serious damage to the crusher may
occur.
Normally, the oil flow rate flowing from the pipe is sufficient to fill half of the pipe. The
lack of this oil flow can be caused by various causes:
o Lack of oil in the lubrication system
o Oil pump failure
o Obstructions in the supply line
o Incorrect relief valve adjustment
o Dirty oil filters
Note

19
Although the crusher was tested in operation at the factory, it is advisable, after initial
start-up or after new bearings have been installed, to allow the crusher to run at no or
reduced load for several hours. This will allow you to verify that all parts are working
satisfactorily and are well lubricated. It is also advisable to observe the oil temperature
more carefully during this phase.
B) Crusher adjustment
The adjustment of the crusher depends on the size of the product required. In most
cases, the bowl will need to be adjusted so that the opening between the grinding
elements on the closed side measures a distance slightly less than the maximum size of
the desired product. In addition to readjusting the cup when changing material size, it is
also necessary to readjust the cup to compensate for wear on the grinding parts.
The crusher setting is changed by either lowering or raising the bowl on the adjustment
ring, rotating the bowl assembly clockwise to lower or counterclockwise to raise.
Lowering the cup decreases the setting and raising the cup increases the setting.
Cup Adjustment (Adjustment Pulley and Duckworth Adjustment Device)
This device consists of a cast swivel and a pulley located on either of the two shoulders
on the adjusting ring, to rotate the cup, and the Duckworth device to lift the cup to the
grinding position. To adjust the cup using the adjustment pulley and the Duckworth
device, carry out the operations described below:
a) Using a mallet, tap out the tapered cotter pins. Do not remove the cotter pins from
the cotter pins until the initial load has been removed from the cotter pins. This will
prevent the cotter pins from coming out completely. The cotter pins are then tapped
lightly and removed by hand.
b) Remove some of the washers from the locking shafts
c) Attach the swing cable to the adjusting cap ring and around the pulley, adjusting
pulley and Duckworth adjusting device. Attach the cable to the corresponding side of
the adjustment cap to obtain the correct direction of rotation
d) Move the locking levers to one side and rotate the bowl by pulling the cable with a
crane, truck or tractor, until it is in the proper position.
e) Move the locking levers back into place against the adjustment cap and insert the
cotter pin into the locking lever and into one of the adjustment cap ring fixing holes.
It may sometimes be necessary to turn the lid slightly in one direction or another to
align the holes in the locking lever and ring.
f) Remove or add the correct number of washers on each locking shaft so that when
the taper key is pushed into place, the key protrudes an equal distance from both
sides of the shaft. Always reinstall the washers so that a thick washer with a
minimum thickness of 25mm is on top to withstand the pressure of the taper key
without bending the washer.
g) Insert the taper keys into the locking shaft and use a hammer to push them in to
raise the bowl to its grinding position and prevent the bowl from rotating. Do not hit

20
the cotter pins in consecutive order, but alternately and 180 degrees apart so that
the cup assembly rises evenly. It is important that the cotter pins are perfectly
tightened to prevent even slight movement in the cup threads. A clear, resonant
sound when the cotter pins are struck is a sign that the cotter pins are securely in
place.
h) Place the cotter pins into each of your cotter pins
i) Check that the cotter pins are properly tightened after the crusher has been running
for several hours and retighten them if necessary.
Minimum crusher setting
In no case should the crusher be adjusted to a setting below the minimum recommended
for a given size of machine. Operating at a setting less than recommended produces
excessive spring action and results in an unsatisfactory product.
Furthermore, it places undue stress on the crusher, resulting in increased maintenance
costs. The table: MINIMUM RECOMMENDED SETTINGS FOR DISCHARGE, shows these
values for the different sizes of crushers. These adjustments are in harmony with
maximum production and satisfactory performance of the machine.
CRUSHER SIZE MINIMUM RECOMMENDED

CAVITY TYPE
(STANDARD) SETTING FOR DISCHARGE
Fine 6-3mm
2 feet Coarse 9-5mm
Very coarse 12-7mm
Fine 9-5mm
3 feet Medium 12-7mm
Very coarse 19-0mm
Fine 9-5mm
Medium 12-7mm
4 feet
Coarse 19-0mm
Very coarse 19-0mm
Fine 12-7mm
Medium 15-9mm
4-1/4 feet
Coarse 19-0mm
Very coarse 25-4mm
Fine 15-9mm
Medium 22-0mm
5-1/2 feet
Coarse 25-4mm
Very coarse 38-0mm
Fine 19-0mm
Medium 25-4mm
7 feet
Coarse 31-7mm
Very coarse 38-0mm
Fine 4-7mm
Medium 9-5mm
7 feet short head
Coarse 12-7mm
Very coarse 15-8mm
MINIMUM RECOMMENDED SETTINGS FOR DOWNLOAD
C) Stop

21
The order to follow to stop the Nordberg Symons crusher is as follows:
a) Cut the load

b) Wait for all the mineral load to pass
c) Stop the machine by pressing the “Stop” button
d) Clean the crusher
e) The crusher should never be stopped before the entire load has passed, because then it
will have problems starting again.
a) Check oil circulation

b) Check that there are no oil leaks from the countershaft or lubrication pipe connections.
c) There should be no strange noises or strange vibrations
d) Check the tension and correct centering of the flat belt
e) The discharge chute is clean, without obstructions and without gaps that allow mineral
to escape.
f) Check that the crusher does not have any loose or broken bolts.
g) Check the condition of the jackets
h) Check the temperature of the countershaft bearing
i) Check that the download product is the appropriate size
5.2.2.3 INSPECTION AND MAINTENANCE INTERVALS
8 HOURS 40 HOURS
Check the oil level in the tank Check the V-belts for tension, wear or damage.
Check for oil leaks in both the pipe and the
Check the oil temperature
crusher.
Check the oil flow on the visual fuel gauge Check whether the head and cup covers are
or the oil pressure if equipped. tight
Check engine power consumption Check the crusher regulation
Check the tightness of the screws and see
Check the end game
if the tapered cotter pins are tight
Clean countershaft housing and oil tank
Check for loose fasteners and connections
breathers
With the bowl in the grinding position, grease
Observe for strange noises, signs of wear
the adjusting ring and bowl threads through the
or abnormal stresses on the crusher parts.
grease nipples on the adjusting ring.
When crushing elements approach the Check the pulleys for dust buildup, cracked
wear limit, inspect them daily spokes, and check the shaft tightness.
Check the flow of oil returning to the tank
Check the tightness of the power plate bolts
from the crusher and the relief valve
Check the operation of the alarm system
Check that the crusher floats smoothly
when stopped before stopping.
Check if the feed to the crusher is

22
distributed correctly
Check if the crusher has free discharge
200 HOURS
Release the bowl assembly from its grinding position and rock it
See if the lubricating oil is dirty and contaminated. Change it if necessary
Examine the oil strainer inside the tank for metal particles. The occasional presence of metallic
particles is normal. Many particles would indicate that the pressure is excessive on the bearing
faces or that one or more of the bearings have failed.
Check head and cup covers for wear
Examine wear on plate and feed cone
2000 HOURS
Check the wear of the footplates
Check the wear of the inner and outer eccentric bearing
Inspect ring gear and pinion teeth for wear, tooth play, and root clearance
Examine the wear of the seat cover lining.

Check the snap ring seal ring and spring box for wear. Also check the effective pressure of the
seal ring springs (standard seal only)
Inspect the vertical shaft and head for wear.

Check cup wear and adjusting ring threads
Check the countershaft bearing for wear
Check gaskets, gaskets, O-rings and seals for oil leaks
Check pump and oil distributor gear teeth for wear (integral pump only)
Check the clearance between the head deflector ring and the rubber skirt surrounding the
water jacket (water seal only)
Examine main frame liner for wear
Look for wear on the arm guards and countershaft housing.
Examine for cracked welds
Change the oil in the tank
Examine the springs surrounding the outside of the crusher to see if they are the correct
installation length
5.2.2.4 CORRECTIVE MAINTENANCE

23
PROBLEM PROBABLE CAUSES CORRECTION/COMMENT
Worn pump Check oil flow (GPM) in drain line
Insufficient running Inspect the knuckle cover and head ball for
clearance between vertical wear. Use the recess in the kickstand cover as
shaft and eccentric inner a guide; the head must be ready and without
bearing visible unevenness
Check the slope of the drain line between the
crusher and the tank. (minimum 1X12) Clean
Oil does not drain properly
the breather on the side of the counter shaft
housing
Too much crushing at the bottom of the
Crusher liners inadequate
crushing cavity, causing excessive energy
for the job being done
consumption
Excessively hot or hard load,
This application requires the installation of an
causing the crusher to
oil cooler
generate more heat
Restore the free space or play between the
Insufficient clearance for oil
crankshaft and the eccentric; Oil trapped
to pass between the top of
between the inner eccentric bearing and the
the eccentric and the
vertical shaft causes a local hot spot (space
Shredding underside of the bracket
required: ¼” to 1/8” = 6 to 3 mm)
overheats
Check to see if the relief valve is
malfunctioning due to wear, foreign particles,
Insufficient oil supply
or a stuck spring causing oil to bypass the
crusher.
Too much tension on the V-
Readjust belt tension
belts
Inappropriate oil used in the Use suitable oil. Oil is recommended for
crusher extreme pressures
Readjust the outer play (1/32” to 1/16” =0.8
There is no outside game
to 1.6mm)
This is usually due to inadequate feeding
Shredding consumes
conditions. Excessive fines in the feed, or
excessive energy
crusher setting too high for the application
Do not set the crusher below the minimum
Very tight crusher
recommended discharge
Insufficient play between Oil trapped between the outer eccentric
the top of the outer bearing and the eccentric - the top of the
eccentric bearing and the bearing should be flush with the top of the
bottom of the ring gear main frame
Dirt or rust buildup between
the adjusting ring and cup
threads due to:
Input of hot material (slag) Pour antifreeze on the threads
Loosen adjusting cap screws or Duckworth
Poor thread lubrication cotters or release pressure on hydraulic
stuck cup
fasteners and run material through crusher
Worn adjusting cap or dust
Run pieces of wood through the shredder
collar seal
Put small pieces of mild steel to go through
Lack of weather protection
the crusher
Operating for too long a Heat the adjusting ring.

24
period at one time
Do not remove the adjusting ring from the
Damaged threads
main frame
Head cover: Check to see if an excessive amount of zinc or
Vertical shaft nut or nordbak material has been put on and left in
clamping nut does not contact with the vertical shaft nut seat or
tighten automatically retaining nut.
Head cover:
The cup or The automatic tightening device will not work
The crusher countershaft
head cover has if the countershaft rotates in the wrong
rotates in the wrong
come loose direction.
direction
Cup cover:
Cup cover badly worn; thin section bends
broken hooks
Cup cover: Rubber belt washers were not installed when
Loose or broken U-bolts bowl cover was replaced
Clean the breather on the side of the
countershaft housing. Use high pressure air
The crusher is not well
to clean the long molded gap in the
ventilated
countershaft housing that connects to the
Oil leak at the
breather
end of the
countershaft Kinked or clogged launcher Replace drain hose and/or remove kink or
housing pulley housing drain hose kink in drain pipe
Oil does not drain quickly
from the pitcher housing,
Install a separate return line to the oil tank
especially when the oil is
cold
Very worn parts of the feed plate or

Weight change due to worn
distributor. Add weight to distributor or
crusher parts
replace worn parts
The head and vertical shaft move with the

Excessive head rotation eccentric because the inner eccentric bushing
Excessive is stuck
vibration Incorrect engagement of the crown, or
Interference in the roots of rubbing of the bottom of the crown on the
the ring and pinion teeth pinion. Raise the eccentric assembly with
shims
Against bent axle Replace the countershaft
Crusher pulley completely Remove dirt buildup from spokes and pulley
out of balance rim
Make sure that the grinding elements seat

Wear of properly when assembled with the
Crusher works with loose
contact surface corresponding parts and that the adjustment
cover, head or bowl
on head or cup nut or vertical shaft nut is properly tightened
before operating the machine.
Crusher is operating with The thin section of the grinding elements

excessively worn head or bends, thus accelerating the wear of the
25
bowl cover contact surfaces of the head or bowl.
Note: For further reference see Annex
5.2.2.5 LUBRICATION SYSTEM
The moving parts (transmission elements) are lubricated with an oil, which is introduced to
the crusher by means of a pump; When the machine is started, the oil pump begins to work.
Oil circulation must be observed frequently. If the oil does not circulate, stop the crusher
immediately and notify the supervisor.
The crusher lubrication system pumps oil through a filter, heat exchanger, and then is pushed
up through interconnected passages in the main shaft, to the bearing surfaces of the
eccentric bushing, head bushings and finally upward through the groove and friction surface
of the groove liner. Figure 4 illustrates the various oil flows throughout the crusher. Excessive
oil flow from the crankcase liner allows oil to flow through holes in the mantle and spill onto
the gear and pinion teeth, note the oil grooves in the crankcase liner. Simultaneously, a
separate line pushes oil through the countershaft housing to the countershaft rests.
Finally the oil is collected in a sump at the bottom of the main structure and returned by
gravity through pipes to the supply tank.
Figure 4
5.2.3 CHUTES

26
The chutes serve to protect and cushion the mineral load, otherwise the feeder would suffer
from excess weight.
The care that must be taken with the shots are:
a) The chutes should not have gaps, because load spills will occur, which will dirty the
floors.
b) The discharge channel must be clean, without wood, logs, etc. so that the load comes out
freely
c) The blades must be in good condition
d) The maintainer must communicate to the supervisor about the operating conditions of
the feed screens, if any unsafe conditions exist.
5.2.4 SHARE
The Vibrating Screen is used for classification of bulk material in general. On the first deck, a
classification with a larger opening mesh will be carried out and on the second deck a finer
classification will be carried out. The Vibrating Screen is supported by springs. Vibration is
carried out by means of robustly constructed exciters mounted on the support bridge. The
drive motor may optionally be fixed on the right or left or on a drive base lower than the
shaft. The Vibrating Screen command must be done through the general installation control
panel.
Industrial sieving is defined as the classification of material into size groups, according to the
cross-sectional area of the particles; as they pass over a surface; which contains openings of
fixed dimensions
The ore that comes from the primary crusher has a large amount of fines, smaller sizes than
those discharged by the crushers. If this fine load entered the Crushers we would give it
unnecessary work, which could cause caking in the crusher jackets and less space would be
available to crush the large pieces, which are the ones that really need to be crushed. These
fines could also cause blockages in the
Crushers To solve these problems, grizzlies (single and double deck) are used, which have the
mission of separating the coarse mineral from the fine mineral that accompanies it, and are
installed before the crushers.
For further reference, consult the equipment manual, see Annex
5.2.4.1 MAIN PARTS OF THE SHEETER
The main parts of the vibrating screen are as follows
a) The mesh of the vibrating screen

b) The eccentric shaft
c) The feeding shot
d) The fines discharge chute

27
e) The unloading chute of the thick ones
f) The transmission system, consisting of:
g) The engine, engine pulley and “v” belts
h) Speeder
i) Steering wheel
j) Support on spring packages
5.2.4.2 OPERATION
a) In case of interference in the operation of the machine/equipment, immediately turn off

the machine.
b) Ensure that no one is in danger from operating the machine/equipment.
c) Do not turn off or disconnect the drainage equipment from the machine when it is
working.
d) In the case of the grizzly rail, it must be cleaned periodically by the operator.
e) For further reference see Annex
5.2.4.3 FIXING AND ALIGNMENT OF THE VIBRATORY SHEEDER
a) The springs must be installed on the supports.

b) The box must be installed on top of the springs.
c) The spring supports must be aligned and level both longitudinally and transversely to the
direction of shaking.
d) Arrange the gradation and consider the drying time of the material.
e) Maintain correct V-belt tension Test force F = 150 to 200 N
The Vibrating Screen can only be installed by specialized technicians. Carry out the
installation of the Vibrating Screen according to the electrical diagram.
MECHANICAL VERIFICATION
a) Check all fixing screws.

b) Check angle of inclination and horizontal leveling transversely to the inclination of
the screen.
c) Check if there is damage to the screen meshes.
d) Check for the presence of foreign bodies on the screen meshes and remove them if
they exist.
e) Grease the lubrication points (amount and type of lubrication indicated in the
lubrication list).
PREVENTIVE MAINTENANCE
to) The screen mesh must be in good condition, without gaps that allow thick loads to
pass through. If the mesh has gaps, the coarse load would stop, that is, the screen
would make a poor size classification, with consequent damage to the grinding
section.

28
b) Clean the fines discharge chute, especially when the mineral is wet
c) The screen screen holes must be clean, free of load, wires, etc.
d) The lubrication of the exciters is through oil.
5.3 START UP
The feeding sections to the secondary crushing and the crusher operate 24 hours a day,
seven days a week. Stoppages are mainly necessary for maintenance or when the delivery of
ore from the mine to the primary crushing is interrupted for long periods.
The secondary crusher is controlled from the control room located in the secondary crushing
area. The primary crusher control room monitors the feed circuit at all times.
The auxiliary packages come with their own control system based on the PLC (Programmable
Logic Controller) and allow local control with communication to the DCS system (Distributed
Control System) of the main plant, for remote monitoring of the process variables, of the
status of the equipment, interlocks and, in certain cases, a remote start/stop control from
the operator consoles.
Each engine in the area can be started or stopped on the ground using pushbuttons or from
the control room by the operator. There are no local/remote selector switches except those
included on local control panels and variable speed drive units. Normal operation will be
from the control room.
A pre-startup check of all main and auxiliary equipment is necessary when any part of the
plant is started up after a complete shutdown.
In addition to the start-up procedures specified in this manual, the plant can be partially
started after one or more equipment has been stopped for maintenance. In this case, carry
out the corresponding checks and reviews prior to start-up, for each piece of equipment on
which work is carried out.
The secondary crushing area requires the following components for its start-up and
operation:
 Mineral.
 Electric power.
 Water.
 plant air
6. ROUTINE INSPECTION OF SECONDARY CRUSHING
During normal operation, the operator must frequently perform routine inspections. This
area consists of equipment ranging from the feeders to the curing drum (membrane
prepared on a resin base). This includes the feed conveyors, the crusher, all conveyors and
auxiliary equipment of the secondary crusher.
The operator makes regular rounds of these areas to observe the equipment, generally every
two hours or as frequently as necessary. In particular, the operator must make a complete
inspection of this part of the plant at the beginning of each shift.

29
If the inspection reveals that some equipment needs minor adjustments or repairs, the
operator carries out the necessary work. If the problem observed is more widespread and
requires the section's immediate attention, the operator requests maintenance assistance. If
the observed problem does not require immediate attention, the operator issues a work
order so that the necessary tasks can be included in a future scheduled maintenance period.
The following procedure is an outline of the main points that should be observed and
reviewed during the routine inspection
SECURITY
Apply all field safety and health rules, regulations, guidelines and principles when performing
all job duties.
Special equipment required
 Flashlight.
 Security lock.
 Crushing report summary sheet, clipboard and pencil.
 Small tools.
PROCEDURE
1) Check the entire lighting system and notify maintenance of any damaged or burned
out bulbs.
2) Check all hallways, railings, safety gates, stairs and other passageways to make sure
they are safe. To ensure a safe workplace arrange for repairs and/or modifications, if
necessary. Eliminate all risk of falling.
3) Clean up all spills and dispose of material in approved manner.
4) To ensure a safe workplace, collect and dispose of all scrap metal, wood, paper and
other debris.
5) Verify that there is sufficient mineral. If the amount of material is inadequate,
contact the primary crusher operator to arrange for additional feed to be delivered.
6) Inspect feed belt to vibrating screen
7) Verify that the safety guards are in place.
8) Make sure all safety guards are in place.
9) Check the equipment for loose bolts.
10) Check that the pulleys do not present cracks, wear due to distension, displacement in
the axles and that the bearings are lubricated correctly.
11) Verify that the general condition of the belt is satisfactory. Check that there is no
excess wear, breaks and grooves and check the condition of the belt joints. Inspect
for signs of lateral shift.
12) Inspect belt idlers: 150-BC-001A; 150-BC-002A; 150-BC-001B; 150-BC-002B; 150-BC-
001E.Check for excessive wear or holes in the idlers.
13) Inspect the guards along both sides of the sashes for wear: 150-BC-001A; 150-BC-
002A; 150-BC-001B; 150-BC-002B; 150-BC-001E.
14) Make sure material is flowing through the chute and that the clogged chute detector
is not damaged.
15) Check the belt scrapers for damage and proper adjustment.

30
16) Check that the electric drive motor, drive coupling, reducer, as well as drive
components do not have loose or damaged parts. Check that there are no oil leaks in
the reducers.
17) Inspect the secondary crusher
18) Make sure there are no abnormal noises in the motor and drive assemblies. If
necessary, call maintenance personnel to inspect the condition of the equipment.
19) Make sure all safety guards are in place.
20) Check the oil level in the secondary crusher lubrication system. Check the oil level in
the sight glass on the side of the lubricant tank.
21) Check the oil level of the crusher hydraulic system.
22) Check for signs of leaks around the motor, bearings, countershaft and motor drive
area.
23) Check that the engine mounting bolts are not loose.
24) Check for loose bolts or parts.
25) Make sure there is no material accumulating in or spilling from the crusher. Make
sure the distributor plate distributes the material evenly.
26) Make sure material is flowing freely through the crusher discharge chute.
27) If necessary, adjust the crusher setting.
28) Record the results of your inspection in the crusher inspection report.
29) Look for obvious defects. Make sure there is no mineral buildup around the scale
idlers and between the platform and the conveyor belt frame. Following proper safe
work procedures, remove any accumulation of material. Verify that the weighbridge
assembly moves freely and that the idlers rotate freely.
30) Visually inspect the vibrating feeder
31) Make sure material is flowing and the vibratory feeder is not clogged.

31
ANNEX A: MAINTENANCE FORMATS
DAILY RECORD OF THE CRUSHER OPERATOR

OBSERVATIONS
ADJUSTMENT
OIL
CLOSED SIDE
COMMENTS
DATE
OBSERVED
TEMPERATURE
ALARMS
ENERGY
ROOM
TIME
OIL

32
CONSUM
AND Yes
YEAH
NO
ED
AND With cooling The maximum temperature difference 15°F (-9.44°C)

between the supply line and the oil return
Yes No cooling line must be 9°F (-12.77°C)
PREVENTIVE MAINTENANCE FORMAT FOR SYSTEM COMPONENTS
PREVENTIVE MAINTENANCE REPORT FORMAT OF THE MAIN COMPONENTS OF THE SYSTEM
OPERATOR:
DATE:

33
Conveyor belts
Screens
Chute load of screen
Chute load of crusher
Chute pants
Crusher
EQUIPMENT OR COMPONENT HISTORY SHEET
SHP HISTORY SHEET OF AN EQUIPMENT OR DEPARTMENT OF MECHANICAL ELECTRICAL-

COMPONENT MINE MAINTENANCE
NAME OF THE TEAM: REGISTRY NUMBER:

34
LOCATION: AREA OR DEPARTMENT:
ORDER SPARE PARTS USED

DESCRIPTION OF THE REPAIR
DATE NO. TIME USED
CARRIED OUT
AMOUNT NAME CODE
OBSERVATIONS
EQUIPMENT CONTROL SHEET
SHEET OF
SHP EQUIPMENT CONTROL MAINTENANCE DEPARTMENT
REGISTRY NUMBER:

35
NAME OF THE TEAM:
LOCATION:
AREA OR DEPARTMENT:
BRAND:
SERIES:
MODEL:
ENGINE:
POWER:
VOLTAGE:
RPM:
LUBRICANT:
LUBRICANT AMOUNT:
INSTALATION DATE:
OBSERVATIONS:
SHP WEEKLY ACTIVITIES REPORT SHEET MAINTENANCE DEPARTMENT
WEEK:
Year:
Employee's name:…………………………………………………………………. Position:…………………………………………

36
DATE No. OF WORK DONE ALLOTTED REAL TIME OBSERVATIONS
ORDER TIME
PERMISSIONS
OBSERVATIONS:
F = Missed
P = Personal
I = IGSS
E = Disease
S = Union
WEEKLY ACTIVITIES REPORT SHEET

37
ANNEX B: MAINTENANCE CHART

38
CONVEYOR BELT MAINTENANCE CHART
JANUARY FEBRUARY MARCH APRIL MAY JUNE

MONTH
ACTIVITY JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER
WEEK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Conveyor belt 150-BC-001A
Conveyor belt 150-BC-002A
Conveyor belt 150-BC-001B
Conveyor belt 150-BC-002B
Conveyor belt 150-BC-001E
Manual de operación y mantenimiento de mejoras en chancado secundario 39

BELT 150 COMPONENTS MAINTENANCE CHART –BC-001A

MONTH
WEEK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Band
Pulleys
Polines
Tempering-Blades
Transmission system

BELT 150 COMPONENTS MAINTENANCE CHART –BC-002A

MONTH
WEEK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Band
Pulleys
Polines
Tempering-Blades
Transmission system

BELT 150 COMPONENTS MAINTENANCE CHART –BC-001B

MONTH
WEEK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Band
Pulleys
Polines
Tempering-Blades
Transmission system

BELT 150 COMPONENTS MAINTENANCE CHART –BC-002B

MONTH
WEEK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Band
Pulleys
Polines
Tempering-Blades
Transmission system

BELT 150 COMPONENTS MAINTENANCE BOOKLET –BC-001E

MONTH
WEEK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Band
Pulleys
Polines
Tempering-Blades
Transmission system
MECHANICAL EQUIPMENT MAINTENANCE BOOKLET

MONTH
WEEK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Chute pants 150-CH-001
Chute loading screen 150-CH-001A
Chute loading screen 150-CH-002A
Chute loading crusher 150-CH-001B
Chute loading crusher 150-CH-002B
Fines discharge chute 150-CH-001C
Fines discharge chute 150-CH-002C
Chute unloading crusher-150-CH-001D
Chute unloading crusher-150-CH-002D
Dry Coobing separator chute

ANNEX C: EQUIPMENT ARRANGEMENT SCHEME

46
LAYOUT SCHEME OF MECHANICAL EQUIPMENT AND ITS PROJECT CODING

ANNEX D: EQUIPMENT MANUALS

48

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“OPERATION AND MAINTENANCE MANUAL FOR IMPROVEMENTS IN

SECONDARY CRUSHING IN 1-MINE CRUSHING PLANT”

SHOUGANG HIERRO PERU SAA

Manual de operación y mantenimiento de mejoras en chancado secundario

Manual de operación y mantenimiento de mejoras en chancado secundario

Manual de operación y mantenimiento de mejoras en chancado secundario

The specific objectives of this manual consider the following aspects:

a) Know the job clearly and do it safely.

Manual de operación y mantenimiento de mejoras en chancado secundario

CRUSHING SAN NICOLÁS.

a) crude oil stock

SECONDARY CRUSHING IMPROVEMENT PROJECT IN PLANT 1 - MINE

The project: Improvements in secondary crushing, consists of installing a new infrastructure,

Manual de operación y mantenimiento de mejoras en chancado secundario

Some relevant approved standards are shown below:

a) Supreme Decree No. 014-92-EM, TUO of the General Mining Law

Article 301 of Supreme Decree No. 055-2010-EM:

In concessions for transporting concentrates on conveyor belts, supervision and maintenance

ASSOCIATED RISK CONSEQUENCE PRECAUTIONARY MEASURES

Some environmental management measures establish that:

3.1 ELECTRICAL HAZARD

Manual de operación y mantenimiento de mejoras en chancado secundario

ASSOCIATED RISK CONSEQUENCE PRECAUTIONARY MEASURES

3.2 MECHANICAL HAZARD

ASSOCIATED RISK CONSEQUENCE PRECAUTIONARY MEASURES

3.3 PERSONAL PROTECTIVE EQUIPMENT (PPE) REQUIRED

Because it is a crushing system, the following EPPs are considered:

to) Safety helmet, chinstrap

3.4 COLLECTIVE PROTECTION EQUIPMENT (CPE) REQUIRED

To secure the work area it is necessary to have the following EPCs:

Manual de operación y mantenimiento de mejoras en chancado secundario

4.2 FOREMAN OR CREW LEADER

to) Attend the training of this O&M manual

5.1.2 SECONDARY CRUSHING PLANT 1 - MINE (DRY COOBING)

Manual de operación y mantenimiento de mejoras en chancado secundario

For more details see Annex D

Figure 1: Existing equipment Plant N°1 – Mine

5.2.1.1 MAIN PARTS OF CONVEYOR BELTS

Manual de operación y mantenimiento de mejoras en chancado secundario

Manual de operación y mantenimiento de mejoras en chancado secundario

a) The 150-BC-001E belt must be started under vacuum.

To stop the bands, lock the band 011-008 in the stop

Evacuate the remaining load and close the chute gates150-CH-001AE

The terms of operation of the conveyor belts are:

inspect the work area, and eliminate unsafe conditions.

Manual de operación y mantenimiento de mejoras en chancado secundario

Safety considerations in the operation of belts to take into account are:

Do not clean the pulleys or idlers when the belt is in operation.

Do not cross over the belt when in operation

Keep a safe distance when equipment is in motion.

Do not operate the belts with loose clothing.

5.2.1.3 PROBLEM IDENTIFICATION

A. REMOVAL OF CONVEYOR BELTS.

a) When the head or tail pulleys are loaded

The following damage can occur to an off-center belt:

a) Break the coupling, chain or engine pulley belt

B. JAM IN THE CONVEYOR BELTS

Manual de operación y mantenimiento de mejoras en chancado secundario

5.2.1.4 PREVENTIVE MAINTENANCE

The main actions for preventive maintenance are:

5.2.1.5 CORRECTIVE MAINTENANCE

FAILURES CAUSE CORRECTION