Download 01 Zijin CO SAG and Ball Mills V 0.1- training program

Training Program Course Outline
SAG and Ball Mill:
Maintenance with Basic Operations
SAG and Ball Mills
File Name: 01_Zijin_CO_SAG and Balls_V 0.1
Table of Contents
1.1
General Introduction ......................................................................................................... 3
1.2
Module Purpose................................................................................................................ 3
1.3
Nominal Duration .............................................................................................................. 3
1.4
General Learning Outcomes ............................................................................................. 3
1.5
Training Manual Contents ................................................................................................. 4
1.5.1
Learning Outcome One — Equipment-Specific Safety ............................................... 4
1.5.2
Learning Outcome Two— Equipment introduction ..................................................... 4
1.5.3
Learning Outcome Three — Overview of Mill Functions ............................................ 4
1.5.4
Learning Outcome Four — Basic Mill Operations ...................................................... 5
1.5.5
Learning Outcome Five — Regular Preventative Maintenance .................................. 5
Learning Outcome Six — Maintain Lubrication and Hydraulic Systems ................................... 6
1.5.6
Learning Outcome Seven — Conduct Major Maintenance......................................... 6
1.5.7
Learning Outcome Eight — Mechanical Troubleshooting........................................... 7
1.6
Resource Requirements ................................................................................................... 7
1.6.1
Human Resources ..................................................................................................... 7
1.6.2
Physical Resources ................................................................................................... 7
1.6.3
Reference Documents ............................................................................................... 7
1.7
Pre-Requisites .................................................................................................................. 7
1.8
Delivery............................................................................................................................. 8
FLS
Status: DRAFT
Date:6 July 2021
Printed copies are uncontrolled unless stamped CONTROLLED
Version: 0.1
1
SAG and Ball Mills
File Name: 01_Zijin_CO_SAG and Balls_V 0.1
Proprietary and Confidentiality Statement: This training material and all later refinements and
amendments (collectively, “Training Material”) contain intellectual property, technical know-how
and other highly confidential information that are proprietary to FLSmidth. This Training Material
and related documents may only be used for training and knowledge transfer purposes. For that
purpose, you may disclose and distribute this Material to persons in your organization and others
retained by you to evaluate its contents. However, no part of this Training Material can otherwise
be disclosed or distributed to others or quoted, copied or reproduced in any form for any purpose
without FLSmidth’s prior express written permission. Copyright © 2021 FLSmidth A/S. All rights
reserved
Revision history
Release
0.1
Release Details
Draft
Date
Approved by
06/07/21
Approval
Name:
Date:
Signature:
FLS
Status: DRAFT
Date:6 July 2021
Printed copies are uncontrolled unless stamped CONTROLLED
Version: 0.1
2
SAG and Ball Mills
File Name: 01_Zijin_CO_SAG and Balls_V 0.1
1.1
General Introduction
This course outline provides the trainer with the following information about the FLSmidth SAG and
Ball Mill Maintenance training module. The information provided in this document provides:
•
The purpose of the training module
•
The estimated delivery time
•
Learning outcomes
•
Resource requirements
•
Trainee pre-requisites
•
Delivery
•
Assessments
•
Requirements for module completion.
1.2
Module Purpose
The purpose of this training module is to provide the trainees with an understanding of the
structure and maintenance the FLSmidth SAG and Ball Mills
1.3
Nominal Duration
This module is designed to be delivered in 24 hours. However, the time taken to complete the
module will vary, as it depends on such factors as:
•
The teaching method used by the trainer
•
The pre-existing knowledge and skills of the trainees at time of entry to the training session
•
The abilities of individual trainees.
1.4
General Learning Outcomes
On completion of this training module, the trainee will be able to:
•
Explain the principles of comminution and mineral liberation
•
Explain and demonstrate the safety requirements when working on or around SAG and ball
mills
•
Identify and name the major components of SAG and ball mills
•
Conduct effective pre-start inspections on SAG and ball mills
•
Conduct basic operations on SAG and ball mills including, start up, running for maintenance
purposes, “inching” the mills and shut down
•
Conduct effective running inspections on SAG and ball mills
•
Carry out regular preventative maintenance tasks on SAG and ball mills
•
Carry out major maintenance tasks
•
Troubleshoot mechanical SAG and ball mill problems.
FLS
Status: DRAFT
Date:6 July 2021
Printed copies are uncontrolled unless stamped CONTROLLED
Version: 0.1
3
SAG and Ball Mills
File Name: 01_Zijin_CO_SAG and Balls_V 0.1
1.5
Training Manual Contents
The contents of the training manual are as follows:
•
Topic One — Equipment-Specific Safety
•
Topic Two — Equipment Introduction
•
Topic Three — Overview of Mill Functions
•
Topic Four —SAG and Ball Mill Basic Operations
•
Topic Five — Regular Preventative Maintenance
•
Topic Six — Lubrication and Hydraulic Systems
•
Topic Seven — Conduct Major Maintenance
•
Topic Eight — Mechanical Troubleshooting
The contents of each of the topics listed above are as follows:
1.5.1 Learning Outcome One — Equipment-Specific Safety
•
Identify the safety requirements when working on or around grinding mills
•
Identify hazards relating to work on or around grinding mills, especially during running
inspections
•
Describe the hazards and correct controls when working with hydraulic and pressurized
systems
•
Use appropriate safety procedures when removing/installing mill components and when
working on or around mills
•
Recognize tasks considered to be “high risk” and apply appropriate safety measures
•
Recognize situations where stored energy may be present and apply appropriate safety
measures
•
Describe the safety equipment (emergency stop switches, barriers, etc) in place around the
mills and their purpose
•
Apply appropriate housekeeping measures in the mill area.
1.5.2 Learning Outcome Two— Equipment introduction
•
Understand the process flows of the comminution circuit
•
Describe the differences between SAG and ball mills
•
Describe the purpose of grinding mills within the comminution circuit
•
Describe the effects of variation in particle size distribution on downstream processes
1.5.3 Learning Outcome Three — Overview of Mill Functions
•
Identify the major components of SAG mills
•
Identify the major components of ball mills
FLS
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Date:6 July 2021
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SAG and Ball Mills
File Name: 01_Zijin_CO_SAG and Balls_V 0.1
•
Describe the purpose of each individual major component and how they fit into the overall mill
system
•
Describe the overall operation of mills
•
Describe the hydro-lift lubrication of the trunnion bearings
•
Outline the operation of the gear drive systems
•
Describe the operations of the braking systems
•
Describe the mill liner types and their functions within the mill
•
Describe the mill feed arrangements
•
Describe the discharge trommel and it purpose
•
Explain the comminution process and the grinding processes of impact, attrition and abrasion
•
Outline the processes in the closed circuit (screening, discharge collection, pebble crushing,
pumping, cyclones, returns to mill feed)
•
Describe the grinding media used in both SAG and ball mills
•
Identify/describe upstream and downstream processes which can have an effect on mill
performance and which have the potential to cause accelerated wear or damage
•
Describe the need to optimize ore feed relative to the size and capacity of the mills and the
mechanical stress and wear that can result from oversize or undersize feeds.
1.5.4 Learning Outcome Four — Basic Mill Operations
•
Carry out pre-start inspections
•
Conduct correct mill start-up operations (including hydro-lift system and brake system)
•
Conduct inching operations
•
Conduct running inspections of the mill
•
Relate input variables such as feed rates and ore characteristics to the performance of the mill
•
Use local and remote-control systems and instruments during operations (start-up, running
conditions and shut-down) and maintenance and relate vital indications on monitoring
equipment to actual mill performance (including alarms and warnings)
•
Apply knowledge of the mill control logic during start-up, operation and shut down to monitor
warnings and alarms in the PLC
•
Monitor mill operation and Identify vital signs indicating variations in mill performance
•
Use correct mill shutdown procedures.
1.5.5 Learning Outcome Five — Regular Preventative Maintenance
•
Describe the overall maintenance schedule
•
Conduct time-based preventative maintenance tasks and inspections (each shift, weekly,
monthly, 6-monthly, annual)
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Date:6 July 2021
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Version: 0.1
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SAG and Ball Mills
File Name: 01_Zijin_CO_SAG and Balls_V 0.1
•
Demonstrate an understanding that thorough regular inspections and prompt corrective action
will greatly reduce mill downtime
•
Describe/identify indicators of actual or potential mechanical problems as revealed by walkaround inspections
•
Describe/demonstrate the checks and inspections for major components (hydraulic systems,
trunnion bearings, liners, trommel, feed arrangements, etc.)
•
Describe/demonstrate the mechanical checks and inspections for the gearless drive
•
Describe/demonstrate liner wear management including the correct use of specialized tools
•
Describe/demonstrate how to assess and rectify mill shell damage
Learning Outcome Six — Maintain Lubrication and Hydraulic Systems
•
Describe/identify the hydraulic and lubrication systems relating to the mill
•
Read and interpret hydraulic and lubrication circuit schematics identifying components, flow
directions and recommended pressures and flow rates
•
Describe/use system points to diagnose and identify faults within the hydraulic and lubrication
systems
•
Describe/demonstrate measures that can be used to minimize lubrication system
contamination
•
Describe/conduct preventative maintenance tasks on hydraulic, lubrication and cooling
systems
•
Explain the importance of correct temperature control in the lubrication system
•
Maintain lubricant condition through sampling, contamination control and maintenance
activities.
1.5.6 Learning Outcome Seven — Conduct Major Maintenance
•
Read, interpret and use the parts lists to identify and order the correct parts
•
Follow mill design specifications to establish recommended safe operating limits and ensure
mills are re-set to recommended specifications during and following major maintenance
activities
•
Describe/demonstrate the location of critical fasteners and how to determine the correct torque
settings
•
Follow step procedures during the removal and replacement of major components (liners,
bearing seals, bearings, thrust rails, brake pads, trommel lining)
•
Use specialized tools and equipment during major maintenance shut-downs
•
Inspect and measure major components to assess whether they should be replaced or can be
reinstalled for ongoing use
•
Adhere to recommended quality procedures in relation to cleanliness, correct torque settings
and equipment fitting tolerances
FLS
Status: DRAFT
Date:6 July 2021
Printed copies are uncontrolled unless stamped CONTROLLED
Version: 0.1
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SAG and Ball Mills
File Name: 01_Zijin_CO_SAG and Balls_V 0.1
•
Identify component abnormalities caused by excessive heat and wear and other mechanical
problems.
1.5.7 Learning Outcome Eight — Mechanical Troubleshooting
Describe basic fault-finding techniques — gathering information from a range of sources to assist
in determining root causes of mechanical problems
Understand common mill faults and possible means of rectification
Use mill control data to establish trends and operating history which indicate adverse mechanical
conditions
Refer to OEM manuals and other technical data to determine recommended specifications and
settings
Use diagnostic testing equipment and test points to diagnose and identify faults
Understand the need for obtaining assistance in cases where causes of problems are not readily
apparent (not leaving faults unresolved).
1.6
Resource Requirements
The following human and physical resources are required for the delivery of this module:
1.6.1 Human Resources
Trainers and assessors must have successfully completed an instructional skills course and have
relevant technical qualifications equal to, or higher than, the material that is being taught and
assessed. Trainers must have recent industry experience in the subject being taught and, ideally,
should have extensive experience in the subject matter.
1.6.2 Physical Resources
The following physical resources are required for instruction and assessment of the content of this
module:
•
•
•
•
•
•
Training venue with visual presentation capability and whiteboard
Handout notes (training manual)
PowerPoint presentation
Copy of assessment instruments and answer sheet
Access to other relevant training literature
Access to a mill system for field visits and practical assessment (if required).
1.6.3 Reference Documents
The following additional texts and/or references may be required for instruction and assessment of
the content of this module. These are listed at the end of the relevant training manual.
•
Relevant equipment information, such as OEM (Original Equipment Manufacturer) manuals
(listed at the end of the mill training manual)
•
FLSmidth equipment manuals and other relevant documentation.
1.7
Pre-Requisites
Each trainee must have completed the following requirements before commencing this training
module:
FLS
Status: DRAFT
Date:6 July 2021
Printed copies are uncontrolled unless stamped CONTROLLED
Version: 0.1
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SAG and Ball Mills
File Name: 01_Zijin_CO_SAG and Balls_V 0.1
•
Site induction (if training is conducted on site)
•
Area induction (if field visit to the mill is conducted as part of the training and assessment).
1.8
Delivery
The content of this training module requires that trainees, trainers and assessors place an
emphasis on safety as well as on the practical aspects of mill system structure and operation. It is
critical that trainees fully understand the safety requirements before they are permitted to conduct
a field visit or conduct any practical assessment on an operational mill.
Trainers and assessors should take note of the following points about training delivery:
•
The assessments have been designed to measure the trainees’ competence. All activities
conducted during the training sessions should be oriented towards assisting the trainees to
attain competence.
•
The trainer must set a high standard of work practice from the start of the training program.
Practices that are designed to ensure safe operation are important and must be adhered to at
all times during training.
•
If a field visit or assessment is conducted on an operational mill, the trainer and/or assessor
must ensure that the trainees understand and adhere to the safety requirements of working on
or around mills.
FLS
Status: DRAFT
Date:6 July 2021
Printed copies are uncontrolled unless stamped CONTROLLED
Version: 0.1
8