HPGR’s Maintenance

Sociedad Minera Cerro Verde S.A.A.

Stephen Crosby
Sep 2010

PROVEN PERFORMANCE
SHINING FUTURE

www.fcx.com
1. Introduction
2. Key Performance indicators
3. Maintenance practices by major components
(Redesign & CBM)
a) Rollers
b) Bearings
c) Wear components
d) Hydraulic System
e) Reducers
f) Major downtime reasons

2
Introduction
Cerro Verde
Cerro Verde is an open-pit copper and
molybdenum mining complex.
Location: 20 miles southwest of Arequipa,
Peru, the country’s second largest city.
Ores: The predominant oxide copper
minerals are brochanite, chrysocolla,
malachite and copper “pitch.” Chalcocite
and covellite are the most important
secondary copper sulfide minerals.
Chalcopyrite and molybdenite are the
dominant primary sulfides.
Processes and facilities:
Crusher/conveyor, agglomerating facility,
stacker/conveyor and SX/EW facility.
Expansion: Cerro Verde completed a mill
expansion project to process sulfide ore
reserves through a new concentrator.
Completed in 2006, the mill has a design
capacity of 108,000 metric tons of ore per
day. Processing of sulfide ore began in the
fourth quarter of 2006.

3
 Introduction
Concentrator Plant
• Original design 108,000 tpd (2006)
• Debottlenecking project, to expand until 120,000 tpd (2010-2011)
• Four HPGR’s in tertiary crushing circuit

4
 Introduction
R o lle rs d u ra t io n ( H rs )
History of HPGR performance

B2
5
8,000

7,000

6,000

5,000

4,000

3,000

2,000

1,000

0
May-08 Dec-08 Jul-09 Aug-09 Current

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 Introduction
HPGR General View
3. Wear Liners - Feed Hopper

Motor

Cardan Shaft

4. Hydraulic System

Gear cooling system

1. Roller Unit
5. Gearbox 2. Bearings

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 Introduction
Tertiary Crushing Availability

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 Introduction
Major downtime reasons - 2010
DOWNTIM
ITEM DOWNTIME DETAILS E
• Rollers (tyres) wear out 1 Shutdown (HR)
392.4 ##
2 Downstream/Upstream Delay 184.5 ##
• Variable Speed Frequency 3 Others 58.4 ##
• Bearings – electrical arc, 4 Rollers (tyres) wear out 52.2 ##
5 Variable speed frecuency 10.0 ##
contamination, premature fails 6 Bearings 9.1 ##
• Transformers 7 PM E&I Maintenance 5.6
712.2
##

• Motors
99% 100%
97% 98%
450 100%

89%
400 392.4 90%
81%
80%
350

70%
300
AVERAGE DOWNTIME (h)

60%
55%

% PARETO
250
50%
200 184.5
40%

150
t
30%

100
20%
58.4 52.2
50 10%
10.0 9.1 5.6
0 0%
1 2 3 4 5 6 7

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 Rollers
Wear out profile Vs. Studs material
Arrangement #1

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 Rollers
Wear out profile Vs. Studs material
Arrangement #2

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 Rollers
Wear out profile Vs. Studs material
Arrangement #3

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 Rollers
Wear out profile Vs. Studs material
Arrangement #4

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 Rollers
Wear out profile Vs. Studs material
Arrangement #5

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 Rollers

Rollers Duration Vs. Studs material

Duration (Hrs)

14
 Rollers

Schedule to replace rollers (36 hours)

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 Rollers

Best Practices
Traverse to lift roller unit, considering space restriction

16
Rollers

Best Practices

Hopper can be removed with

Double T-Beam suspension

17
 Rollers

Condition Monitoring - TYRE WEAR OPTIMIZATION

Stud & Roller wear measure

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 Bearings
Skews
Bearings and seals can tolerate skews. The constraint is the GAP between rollers

Maximum angle allowed 1.5 ºC

~ 85 mm of skew
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 Bearings
Best Practices

Chemical clean of cooling system

Blending
reservoir

Pump

Inlet Cleaning agent: SQPR100 (HCl)

Return
20
 Bearings
Best Practices

Independent bearings cooling lines

New and greater diameter pipes were installed to have a paralell cooling lines

Before After

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 Bearings
Best Practices
One additional grease point

Before After

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 Bearings
Best Practices

New grease test for bearings

Equipment HPGR 32 HPGR 33 HPGR 34

Instalation date 19-May-10 14-Jul-10 09-Sep-10
Grease specification SKF LGEV 2/180 Kluberlub BE 41-1501 FAG Arcanol 1000
Viscocidad ISO VG 1020 Viscocidad ISO VG 1500 Viscocidad ISO VG 1000
Main properties Consistencia NLGI 2 Consistencia NLGI 1 Consistencia NLGI 2
Temp (°C ) – before
(155-165)bar,[70-80]% feeder speed 72 73 -
Temp (°C ) – after
(155-165)bar,[70-80] % feeder speed 67 62 -

- Grease pulses were increades since 6 to 11 pulses/minute

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 Bearings
Best Practices

Original
grease direction

NONE DRIVE
DRIVE SIDE
Bearing seal SIDE

arrangement Current
grease direction

GREASE DIRECTION GREASE DIRECTION

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 Bearings
Condition Monitoring
1.) Bearing clearance control 2.) Visual inspections

3.) Grease sample and test 4.) Vibration analysis and ultrasonic (SDT)

25
 Bearings
Bearings – electrical arc
Current through
bearings
Ground clamp
placements during
installation passed
current through bearings

Welding Welding
ground ground
 CV’s written
welding procedures
address this
potential

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 Wear Components
Feed Hopper

FEED HOPPER WEAR PROTECTION

2 1 Ceramic Liner  >3 months

2 Inflatable Liners >12 months
3 Steel plate BHN 500 >3 months

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Wear Components
Inflatable Liners

Inflatable Liner

Ceramic Liner

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 Wear Components
Cheek Plates - Inserts
DURATION TIME TO COMMENT
(MONTHS) REPLACE
(HOURS)
Tungsten Carbide 3 3
(HEART)

Brinell 500 (HEART) 1 1 8 TIMES

CHEAPER

HEART

BRINELL 500 (CURRENT) Tungsten Carbide

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 Hydraulic System
Best Practices

 Oil cleaness level controlled using ISO code (16/13).

 Relief valve orifice changed from 4.5 mm a 5.5 mm, to obtain more oil flow.

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 Reducers
Best Practices

 A stand-by cooling system installed (pump, heat exchanger and filters).

 Grease seal redesigned for hiag and low speed shafts.
 Oil cleaness level contolled using ISO code (18/16)

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 Reducers

Best Practices

New types of desecant breathers installed

Before After

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 Reducers

Best Practices

New oil drain conections

Before After

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 Reducers

Best Practices

New quick conectors to oil sample

Before After

34
 Reducers

On-line oil filtration machine Portable grease analysis Kit

Grease consistency

Oil bleeding characteristics

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END

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