Typical Mill Installation Power Point Tool List Etc.

General Ball Mill Installation Guidelines

General Pre-construction Presentation For Single Drive Mill This is to prepare the customer and their contractor information to get manpower, materials & tools to conduct the installation

METSO YORK, PA. USA Recommended that a Metso Field Service Engineer be present during the mill installation / alignments and commissioning

INSTALLATION

SCHEDULE REVIEW

The material covered today will allow for the main mill components to be installed so structural steel can be installed if required, then mill installation & alignments can be completed there after.

The Metso installation manuals have all the information required for the rod mill installation, if you have questions refer to the mill manuals or contact Metso.

Storage of Equipment There is a complete list of detailed storage information in the manuals. Key point is the main rod mill motor, it has to be stored in side and heaters terminated

General Man Hours Per Mill • Generally Mills of this size will take approx. 12,000 man-hours to install • Approx. 20 - 22 weeks • Approx. 10 people off & on, 5 - 6 people will be required most of the time; millwrights, crane operator, riggers, pipe fitters, electricians, labors & supervisors • Electrical is not included in these figures

REVIEW OF TOOLS AND MATERIALS FOR MILL INSTALLATION To be supplied by Mill Erectors / Contractor

TOOL LIST • Hydraulic torque wrenches or equal to torque flange bolts to approx. 10,000 ft. lbs. • Sockets & wrenches for all mill flange hardware • Basic / Normal tools to be supplied by mill installation contractor / erector • • • • •

Hammers Chain Hoist (Various sizes up to 10 tons) Oxygen / Acetylene Torch set up Welding machines Etc. Etc.

Tools • Different size hammer (slugging) wrenches for hold down bolts and anchor bolt nuts • Many other standard construction tools normally used on large projects to be supplied by mill contractors / erectors • Special precision tools required for installing mills to be supplied by erectors

Other Equipment & Task • Scaffolding around concrete foundations to work on baseplate installation etc. Also under mills when the liners are installed • 20’ container with shelves for mill parts • Temporary power to hydraulic jacking system; power supply information in rod mill manual • ISO 150 weight oil for the auxiliary trunnion bearing hand pumps

• PRECISION TOOLS: • Precision optical level accuracy .001” per ft. or equal…with different length precision white scale that come with level • Precision level(s) .002” per foot 12” • Feeler gauges 3” - 4” .0015” to .035” / 12” .002” - .035” • Straight edges (stainless) beveled on edges 2’ 4’ & 6 3 - 4” wide • Dial indicators and magnetic bases with .000” - 1” travel .001” resolution Total of 4 each required • Outside Micrometers 6” - 18” .001” resolution • Hole (telescope) gauges .125” to .500” • 50 ft. metal tape measure ft. • Metal files, mill or bastard cut 10 &12” long ( 2 dozen) • Flat sharpening stones (Qty. 1 dozen) • Plumb bobs 10 to 12 oz. (Qty. 1/2 dozen)

• Additional tools and equipment required • Piano wire 8 gauges (.020”thick) Qty. 1 dozen boxes 50’ LG • Stainless steel shim stock, thickness .002” - .031” Qty. of boxes pending mill size (Rolls in 6” & 12” wide x 50” LG) • Alignment (drift) pins for assembly of shells, heads, etc. These pins are used only to assist the assembly of sections • Leveling blocks (different sizes) and accessories prior to installing baseplates (See additional information on slides) • Grout for baseplates (cement-based, nonshrink, nonmetalic fluid grout such as 5 Star 100 or epoxy grout to be determined by customer)

BALL MILL COMPONENTS Lining

Gear Guard

Main Bearing

Trommel

Gear

Shell

Discharge Chute

Feed Chute Jacking Cradle Motor Inching Drive

Head

Reducer Clutch

Pinion Bearings 10

© Metso Corporation 2003

January 1, 2005

MILL TRUNNION BEARING BASEPLATES

FOUNDATION PREP WORK • Rough TOP of Concrete Before Installation Leveling Blocks • Insure Anchor Bolts Are In Correct Location Use steel wedges in sleeves to reposition anchors • Fabricate and Install Piano Wire Batter Boards • Check TOP of Concrete Elevation • Layout All Leveling Blocks or Jackscrews on TOC

Piano Wire Batter Board

JACKSCREW or LEVELING BLOCKS INSTALLATION PROCEDURES

Jack Screw Method is recommended to save material cost & man-hour cost. These can be purchased through Metso

Rough Up Top of Concrete Prior to Installing / Setting The Jackscrews & Baseplates

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Epoxy Jackscrews per instructions in the installation manual.

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Jackscrews installed on roughed up concrete.

Note: Install Jackscrews on both sides of each anchor bolt as required. 24

Baseplate installed on jackscrews. Adjust jackscrews to achieve required elevation & levelness.

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Side view of baseplate & jackscrews

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Trunnion Baseplate(s) grouted after alignments completed & signed off by Metso

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© Metso Minerals, Inc.

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© Metso Minerals, Inc.

Date/Title/Author

DO NOT GROUT DRIVE TRAIN Pinion, Reducer, Motor, Inch Drive Baseplates Until all alignments have been completed

•Clean & Prep mating Flanges •Clean with solvent or other cleaning agents •File all surfaces with metal file •Make sure there are no burs or high spots even around the holes •All mating surface must be dry, no oils or sealants to be used

CABLE (SLING) PROTECTION

4 IN. OR 6 IN. DIA. PIPE SPLIT DOWN THE MIDDLE, APPROXIMATELY 12 - 16 IN LENGTH.

DO NOT CHOKE (BASKET)

RUBBER BACKING SHOULD ALSO BE AVAILABLE

Step 1: Chain falls on both sides of mill to prevent mill from rotating, etc.

Chain Hoist (Both Sides)

Tie Down Assembly

CRANE HOOK

LIFTING LUG

Step 2: Using overhead crane, rotate shell with gear half installed to the lower position.

Step 3: Install matching gear segment.

Chain Hoist (Both Sides)

Tie Down Assembly (Typical)