Maintenance & Mechanical

Maintenance Policy & Procedure

Maintenance Policy AreaLevel 1 (basic)Level 2 (controlling)Level 3 (improving)Level 4 (best)
2.1 MAINTENANCE MANAGEMENT LEADERSHIP                                        
2.1.1 Maintenance MissionNo missionMission developed and understood by managementMission developed and understood by management & supervisionMission developed, understood and articulated by management, supervision, maintenance team personnel & support personnel
2.1.2 Maintenance VisionNo visionVision developed and understood by managementVision developed and understood by management & supervisionVision developed, understood and articulated by management, supervision, maintenance team personnel & support personnel
2.1.3 Maintenance Process ModelDo functions coveredPlan and Do functions coveredPlan, Do and Check functions coveredAll Plan, Do, Check, Adjust functions fully covered for the site maintenance needs
2.1.4 Responsibility and AccountabilityInformal definition of roles & responsibilitiesFormal definition of roles & responsibilities covering plan & do functions. Understood by managementFormal definition of roles & responsibilities covering plan, do & check functions. Understood by management & supervisionFormal definition of roles & responsibilities covering plan, do, check and adjust functions.  Understood by management, supervision & all site personnel
2.1.5 Site Maintenance Strategy….Read more

Ball Mill Maintenance & Installation Procedure

Am sure your Ball Mill is considered the finest possible grinding mill available. As such you will find it is designed and constructed according to heavy duty specifications. It is designed along sound engineering principles with quality workmanship and materials used in the construction of the component parts. Your Ball Mill reflects years of advancement in grinding principles, materials, and manufacturing techniques. It has been designed with both the operators and the erectors viewpoints in mind. Long uninterrupted performance can be expected from it if the instructions covering installation and maintenance of the mill are carried out. You may be familiar with installing mills of other designs and manufacture – much lighter in construction. Your Ball is heavy and rugged. It should, therefore, be treated accordingly with due respect for its heavier construction.

Ball Mill Maintenance Manual

The purpose of this manual is to assist you in the proper installation and to acquaint you a bit further with the assembly and care of this equipment. We suggest that these instructions be read carefully and reviewed by everyone whenever involved in the actual installation and operation of the mill. In reading these general instructions, you may at times feel that they cover items which are elementary ….Read more

Diesel Engines

The information below is provided as representative of medium HP Diesel engines of four, six, and eight cylinders. Many other sizes and types are available and variations on four, six, and eight cylinder engines, such as in stroke, bore, and displacement—giving higher or lower HP ranges, may be obtained.

Performance Curves are for maximum, rated, and continuous performance of power units with full equipment, including radiator fan. Full equipment, as utilized in determining data as shown, include air cleaner, lubricating oil pump, fuel transfer pump, fuel injection pumps, jacket-water pump, and a suitable governor.

Fuel Consumption Curves are the fuel consumption of power units with full equipment, including radiator fan, and at various governed speeds. Fuel consumptions shown were obtained with fuel oils having 45-50 Cetane value, 30-34 A.P.I.

The Brake Mean Effective Pressure for a given load and speed can be computed for four stroke cycle engines by use of the following:

B.M.E.P = 792,000 X B.H.P Load/Cu. In. Displacement X R.P.M
Output in Metric B.H.P. (Cheval Vapeur) = Values from Curves X 1.0139
Fuel Consumption per Metric B.H.P. (Cheval Vapeur) = Values from Curves X .9862

gravity (at 60° F.), 33-42 viscosity (S.U. at 100° F.), and a total (gross) heat value of 19,000 B.T.U. per ….Read more

Determining Power Factor

Where power is purchased, and is billed on a power factor basis, the installed power company meters will provide a means of determining overall plant power factor. This may be the average power factor for the billing period, usually a month, or the power factor at time of maximum kilowatt demand, or other values depending on the kind of power factor clause and the metering method used. When power company meters are not available, or for purposes of surveys and checks on power factor on distribution lines or individual loads within the plant, the following power-factor and load-measuring methods can be used.

Power Factor

Power Factor Meter Method

An indicating or recording power factor meter will give (1) the power factor of the circuit to which connected, and (2) whether power factor is lagging or leading. Methods listed below are, however, generally more useful, because at the same time they measure power factor they show also the power data necessary in making power factor calculations.


Voltmeter, Ammeter, Wattmeter Method

On reasonably steady loads simultaneous reading of volts, amperes and kilowatts can be made from indicating or recording meters, connected ….Read more

Types of Speed Reducers

The Speed Reducer eliminates unnecessary transmission equipment, thus providing compact drives, and assures positive performance. It is made with speed reduction ratios up to 4,000 to 1 and with right angle (vertical or horizontal), or parallel shafts for either light or heavy duty. The information which follows gives applications and other pertinent data on the various general types.

Right Angle Drive Type “T” Speed Reducers are manufactured with reduction ratios ranging from 10 to 1 up to 100 to 1. These units are equipped with hardened steel, ground thread worms and phosphor-bronze gears, producing the smoothest possible transmission contact. The worm is located on the bottom or underneath the worm gear. Timken bearings are standard equipment on all these units. Five sizes are available. Special shaft extensions can be furnished.

Right Angle Drive

Parallel Drive Type “H” Speed Reducers (for single reduction with wide faced helical gears) are designed for continuous duty and long life. Reduction ratios of from 3 to 1 up to 12 to 1 are available with these units, and double reduction with this type, i.e., type “HK,” gives ratios from 10 to 1 up to 84 to 1. No dirt can interfere ….Read more

Thickener Drive Speed Reducer

The Integral Lift Vertical Worm Gear-Box Speed Reducer is used on Center and Side Air-lift Agitators, Hydroclassifiers, and on thickeners in many mills and industrial plants where it is necessary to have a simple, compact, totally – enclosed, self-lubricated reduction unit. This unit is widely used to step down speeds of high-speed motors to the slow speed required by many ore dressing and industrial machines. It has particular application on mechanisms where a positive lifting device is necessary to prevent the stirring arm, or rakes, from sticking due to rapid settling of solids during power interruptions or overloads. Other uses are for metal skimming, mixing, blending, dissolving, emulsifying, saponifying, sulphonating, causticising, washing, scrubbing, and many other uses.

Several Sizes

A high-grade bronze is used in the machined, cut-tooth, worm gear and the worm and worm shaft are machined from an alloy steel shaft—hardened, ground, and polished. The worm ring gear is bolted to the quill which transmits the torque to a splined vertical output shaft. The output shaft may be raised or lowered by means of a handwheel located on the top of the gear case. Oversize tapered roller bearings assume vertical loads, while ball bearings ….Read more

Diesel and Gasoline Engines

Engine, Diesel, Caterpillar

Caterpillar Diesel Engine brings to the users of small power units all of the advantages of the larger diesel engines.
The units are available in sizes from 52 horsepower to 190 horsepower and are all of rugged design with compactness and accessibility of parts built into all units. These engines are available in 6 and 8 cylinder sizes and with a speed range from 550 to 1650 R.P.M. The units are complete with totally enclosed clutches or open clutches, or without any clutch.

Included with these engines is an independent starting engine, air cleaner, and governor with 10% regulation (closer regulation governors are also available). Additional data gladly furnished upon request.

Caterpillar Diesel Engine

Direct Connected Units

Engine, Diesel-Sheppard

The Sheppard Diesel Engine is a relatively new development in the diesel engine field. Built in five sizes, in the low horsepower range, it fills a real need for a quick, economical and dependable power source. This engine is available in 4, 8, 16, 25 and 50 H.P. sizes and can be furnished as a complete power unit equipped with a generator of suitable current characteristics to meet requirements.

All units are equipped with electric ….Read more

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