Methodology for Sag Mill Installation

1. PRE-INSTALLATION PREPARATIONS.

1. Conduct inventory to all items and verify all supplied parts according to OEM part list and packing
list.
2. All parts shall be thoroughly cleaned, and all rust, dirt, grit, and foreign matter shall be removed.
Grease or protective coatings as protection of the equipment for shipment and or storage, except
prime coating, shall be removed by using suitable solvents or cleaners which will not damage the
surface finish of the equipment.

2. VERIFICATION OF FOUNDATION AND CIVIL STRUCTURES

1. Check all the levels top of concrete using Total Station and record the actual data.
2. After Checking against civil drawings record any discrepancies in the mechanical check list.
3. Check bolt locations to drawings. Foundation elevations and anchor bolt locations shall be verified
in accordance to drawing, checked, and accepted by QC Inspector prior to the start of installation of
equipment. Bending of bolts to fit equipment baseplate holes shall NOT be permitted.

3. PREPARATION OF BASEPLATES AND SOLE PLATES

1. Baseplates and equipment shall be erected on prepared foundations and aligned to the prescribed
center lines and elevations as specified on erection drawings.
2. Baseplates and equipment shall be properly levelled, aligned, set, and adjusted on packers and
shims. Use dumpy level to obtain accurate levelness. Packers shall be of adequate size to provide an
effective load bearing area. They shall be of one-piece thickness.
3. Shims shall be of the same size as the packer. It is recommended that maximum thickness of shim
shall be used to reduce the number of shims required at any one point to a minimum.
4. Levelling and alignment of all equipment shall be within the tolerance specified on the drawing or
as specified in the OEM instructions. Where equipment is received as a shop assembly unit,
alignment shall be checked and adjusted where necessary.
5. Set up secondary soles using grub screw jacks with pinpoints to hold position in concrete. Check
level in all directions and record and sign off the required OEM check sheet. This shall be done using
machine level and piano wire to ensure all points equal and properly aligned.
6. Install formworks around sole plates and pour self-leveling, non-shrink impact resistant Epoxy grout
to sub soles and allow 24-hour curing or as recommended by manufacturer prior to apply any load
to the soles.
7. Remove formworks and install hold down bolts in holes in concrete casting. secure plate with the
bolts but do not tension. Recheck for level and center lines.
8. Using mechanical level and piano/spring wire, check level and center lines measurements to ensure
squareness and alignment.

4. MILL ASSEMBLY
 1. Prepare all materials in assembly area near the structure to allow a single lift into position. Fabricate
temporary support structures and jacks strong enough to accommodate weight of Mill, size
including component parts.
2. Prepare Lifting Plan. Special lifting lugs will be required for the installation of the shell depending on
the size and weight of the assembled unit.
3. Setup the temporary support frames to the structure in according to shell dimensions. Place
support cradle for shell in position correctly to center line and level, ensure that sufficient packing is
allowed to lower the shell to final height after all components are fitted.
4. Assemble and aligned the shell, heads in sequence according to OEM manuals and erection
drawing. Ensure that all mating surfaces are clean and debris free. Clean and lubricate all bolts and
nuts prior to use with a thread lubricant to ensure uniform tensioning of the bolt.
5. Apply torque as specified in OEM manual.

6. All OEM protocols shall be prepared and signed off.

5. GIRTH GEAR ASSEMBLY AND INSTALLATION.

1. Assemble and install the girth gear as per OEM sequence and erection drawing, gear will come in
sections to be bolted to the Shell during installation.
2. Fastened the gear and ensure properly secured to the shell.
3. Girth gear alignment is to be done after the inching drive is installed and operational.
6. BEARINGS INSTALLATION

1. Fit the Bearing Cradle/pedestal with the same procedure stated above for Sole plates.
2. Bearing must be installed in accordance with the recommendation or instruction in OEM manual.
3. All bearings, motor and driven equipment bearings shall be inspected before equipment is
lubricated or placed in operations. Maintain cleanliness in all Bearings and shafts.
4. Clean all flanges and bolt holes on bottom and top halves of shell and heads.
5. After thoroughly cleaning the inlet (feed) end head. Bolt the head and fit to the shell using carrot
tapered drifts and specified bolts.
6. Torque up shell to head plate bolts as per instruction OEM manuals.
7. Repeat the same procedure for the discharge end.
8. Clean and install feed end and discharge trunnion as per OEM manual.
9. Final dimensional inspection shall be conducted and recorded to ensure shell concentricity and
center. If all reading is correct as per OEM requirements, install or placed on bearing pads.
10. Remove the temporary inner shell support structure except for the two horizontal pieces and fit
external restraints on shell at four points.
11. Clean and fit both bearing housings ensuring alignment and level.
12. Lower the shell assembly in to position once cradles/ Pedestal is set up to the assembled bearing.
13. Once bearings have been installed into housing apply mechanic blue.
14. Rotate mill using winch turfers then jack the mill up to view pattern of mechanic blue. Identify and
mark all the high spots and use oil stones tool trim down all high spots. Continue this process until
OEM specification is met.
 15. Clean the bearing shells and fill OEM recommended oil to the bearings.
16. Lower the mill to rest to the bearing.

7. PINION INSTALLATION

1. Install, level, and align sole plates.

2. Fix the sole plates and install the pinion.
3. Check to ensure a root gap using Feeler gauges ensure a root gap meets the OEM requirement on
both ends move pinion into position as close as possible.

8. GEAR BOX INSTALLATION

1. Setup the Sole plates for the gear box in the same procedure for mill and Bearing pedestal.
2. Install gearbox and verify Centerline ensure all levels and alignments are correct as per OEM and
drawing requirements.
3. Shim back and front of Gearbox to bring pinion to within tolerance recommended in OEM
Instruction Manual
4. Fill Gearbox lubricating system as per OEM recommendations.

9. INSTALL INCHING DRIVE / BARRING GEAR

1. Install Inching Drive in accordance with OEM Instruction Manual.

10. COUPLINGS

1. Couplings shall be installed and aligned in accordance with manufacturer’s recommendations.

11. ALIGNMENT OF GIRTH GEAR, PINION, AND GEAR BOX.

1. Set up a dial gauges on point specified in OEM Instruction Manual on the mill girth gear. Rotate the
mill using the inching drive to check for displacement in the gear. Record gauge reading, adjust the
Girth Gear when necessary until to OEM specifications are met.
2. Align the pinion against the Girth Gear. Check Root gap and backlash. Adjust the pinion to meet the
requirement in OEM Instruction Manual.
3. Apply Mechanic blue to the pinion and rotate the mill using the inching drive. The high spots and
adjust the pinion. Clean, reapply mechanic blue and repeat the process until the pinion and girth
gear aligned in accordance with OEM specification.
4. Aligned the gearbox and pinion as per OEM requirements.

12. MOTOR INSTALLATION

1. Install sole plates in the manner for bearing and mill pedestal.
2. Install motor Base. Align and level as per drawing and OEM instruction manual.
3. Place motor on the base and fix.
4. Install the coupling as per manufacturers recommendations.
 5. Align the drive shafts in accordance with OEM requirements. Bolt the coupling after rotational test is
done.

13. INSTALLATION OF LUBRICATION SYSTEM

1. Install the mill piping systems, hydraulic pumps, oil reservoirs, heat exchangers and filters, motors
and align and couple the motors to the pumps as per OEM Instruction Manual.
2. Flush and pressure test the systems in accordance with OEM Instruction Manual.

14. FASTENING AND FIXING

1. Clean and lubricate all bolts.

2. Install all specified bolts and apply required torque as per OEM specifications.

15. GROUTING

1. Conduct QC final inspection prior to apply grout. Grouting shall be done once all requirements are
met and all QC Documents and OEM Protocols are signed off by the clients representative.
2. Install formworks.
3. Apply Grout as per manufacturer’s recommendation. Only use approved grout as per project
specification.
16. SAFETY GUARDS

1. Safety guards shall be installed for all exposed moving and rotating parts such as chain drives and
exposed couplings.

17. Liners

1. As the system is now live Tag out the equipment and disconnect the main drive coupling at the
Motor, set-up turfers to rotate and hold the mill in position.
2. Place extraction fans in the mill discharge end to ventilate air through the unit while work is
underway.
3. Put enclosed work space procedures into place, with a sign in board and permanent trained
monitor.
4. Set-up for installation of the mill liners according to the requirements of the type being used.
5. Establish a method of moving the liners into the mill by way of a cable feed structure or mono rail,
allowing each liner or lifter to be hooked onto the system and fed into the men working inside the
mill.
6. For rubber mill liners generally two men inside the mill fit each components and one man outside
the mill fits washers nuts and rattles the bolts.
7. In most instances the liners can be installed by turning the mill in 30 to 45 0 rotations as sections are
completed.
564 Man-hours 7 men 84 hours

Commissioning, Inspection and testing

 1. After the equipment has been installed, the following shall be performed and recorded
2. Check installation for conformance with the design and specifications
3. Checking alignment of all couplings, drives, gears etc.
4. Checking freedom of shaft rotation.
5. Checking tightness of seals.
6. Make and record tests such as pressure.
7. Check that lubricating equipment is working correctly
8. Check that all moving parts are properly protected
9. Check cleanliness of equipment and systems
10. The above shall be performed without energising the plant or equipment.
114 Man-hours 3 men 3.2 days

1. When construction is completed, tests which require energising of all plant and equipment shall be
carried out. These shall be the initial operational tests of the equipment under minimum load
conditions and then at full load conditions.
2. All run-in tests shall consist of continuous operation until all bearing temperatures and equipment
vibration reach a steady state condition, within tolerances.
3. Check direction of rotation of all equipment, initially with the equipment uncoupled and then
ensure speeds are in compliance with design. Ensure that equipment operates with minimum
vibration
4. Check operation of hydraulic and lubrication systems. Oil supply to gears and bearings shall be
confirmed to be of proper volume. Gear spray systems shall provide full coverage of the face of the
gears.
180 Man-hours 3 men 5 days

1. Checks shall be made between all moving parts to be sure there is no interference and that
clearances are to required tolerances.
2. Ensure that all instrument devices (zero speed switches, alignment switches, emergency stop
switches etc) are operating properly.
3. Simulate plant or equipment operation ( No Load ) and make other adjustments as required.
4. Supervise the first fill of mill charge.