Results: Higher availability and less service stoppages
In May of 2016, Metso was awarded the contract to manufacture the replacement head, this time with an integral trunnion to replace the bolted joint. The service contract was then later won by Metso’s Surabaya, Indonesia Field Services department. When it came time to install the new Mill Head, Metso Surabaya sent two service engineers and lead mechanical fitters to the site to work in conjunction with Masbate’s own mechanical fitters. They were responsible for carrying out the installation and commissioning.
The Metso team provided specialized skills and worked alongside the Masbate maintenance team to complete the head change out project on schedule, within budget and without safety incidents. The combined effort minimized lost production. Since the installation, the mine has not had any issues with the newly installed head, allowing them to improve the mill’s availability by reducing unplanned service stoppages. As a result, Metso has been awarded a second identical mill head order at the mine site.
Grinding mill expertise
As an OEM supplier for grinding mills with over 3000 global installations worldwide, Metso has access to a vast amount of knowledge through its engineered services groups. With the existing head coming from a third party supplier, Metso engineers worked in conjunction with the third party’s engineering group using general arrangement drawings to reference some key information such as weights and general head characteristics for the 5.3 m x 7.8 m ball mill. Designing the head with an integral trunnion required considerable reverse engineering of the existing parts while adhering to the strict tolerances needed to replace the existing head.
“I believe the dedication and attention to detail that we’ve shown and given has really helped cement our good working relationship” added Matt Wesson, Regional Product Manager – ETO Sales and Services for Asia Pacific. “This is reflected in one way by us being trusted to further expand on our supply of Wears and Spares on site as well as ongoing Field Services work and audit opportunities that we never had previously.”
Another key factor in ensuring that the installation went smoothly was the provision of a complete installation crew flown in from Surabaya who worked alongside the mine’s own crews throughout the installation process.
Jason Ives, Senior Maintenance Advisor summed up the experience of working with Metso on the project “The Engineering support and prompt responses Masbate Gold Project received from Metso during the entire process from assessment through to delivery was excellent. The utilization of Metso’s Field Services team from Surabaya was also an excellent choice for the installation of the new head, the team is extremely professional with a good attitude to job completion and safety.”
*Metso Outotec was formed July 1, 2020 when Metso and Outotec merged into one company. This case study has been written prior to the merger under the old company name.