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Project overview

Client

Philippine Gold Processing & Refining Corp.

Site

Masbate, Philippines

Year

2018

Challenge

Remote location with limited tooling.
Major structural components being fabricated in a different country.
International shipping schedules and regulations.
Structural modification of machine to suit the new dimensions of the ball mill and weights of the new pieces to be Installed.

Solution

A specialist engineering container was built and shipped to site full of tooling to perform the full scope of works.
A site visit was conducted by specialist IMR personnel to confirm critical dimensions for the project, and to ensure the IMR design and manufacture team had all necessary information available to complete the design and fabrication in full.
IMR worked closely with site to ensure that shipping schedules and deadlines were met.
A 3D model of the liner handler was created. This enabled the design to be checked and certified using fine element analysis.

Result

Refurbishment completed ahead of schedule.
Completed within budgetary limits.
Zero downtime with crew and zero harm occurring throughout entire project schedule

Case Study: Modification and refurbishment of 4 axis liner handler

Author: Sam Leonardi

Successful modifications to length, height, mounting locations and rated capacity of machine. Completed within strict deadlines in harsh conditions with zero downtime or harm.

Located on the Northern tip of Masbate Island (Philippines), this remote mine site has a process plant that is a conventional carbon-in-leach (CIL) facility consisting of primary crushing, SAG/Ball Mill grinding circuit with pebble crushing, leaching, absorption, elution, electrowinning and smelting gold recovery stages; and a cyanide detoxification stage for treating process plant tails before disposal in a new tailings storage facility (TSF)

Philippine Gold Processing & Refining Corp. contracted the expert services of IMR’s engineering team to assess the feasibility of taking the liner handler that was currently servicing the SAG mill and modifying it to suit the under construction Ball mill No3. Two of the IMR engineering team were sent to site to take key measurements and perform an initial assessment of the project’s viability.

It was deemed that modification of the existing liner handler was not only possible but a genuinely viable and cost-effective option.

Full design drawings were completed by the in-house engineering team. The 3D model was checked and certified using FEA software.

Once the design was certified the fabrication of the major components began. The fabrication of these components was completed in the IMR workshop in QLD.

All fabricated parts were shipped to site along with specialist tooling to complete the scope of works.

The machine was disassembled on site and refurbished over a period of 2 weeks before being handed back to site for use in the new Mill.

Feasibility

Preliminary assessment and feasibility report developed

Design

Design FEA (Finite Elements Analysis) tested and certification of all new structural sections for the machine.

Fabrication

IMR workshop based fabrication of all major structural compnents for modification of the machine.

On site works

On site works included the following. Disassembly of machine, replacement of hydraulic hose where necessary, replacement of e-stops, lighting replacements, electrical component replacements, wiring replacements, painting.

Commissioning

Lift machine onto mill deck, fit into mill and secure with new hold down hardware in new locations, run machine test to ensure machine works in mill and is fit for purpose.

There were many factors that contributed to the impressive results delivered by IMR. Specialist personnel that have worked collectively over decades brought together knowledge from multiple disciplines and areas of expertise to complete the project successfully and in full.

The project saw managers, coordinators and supervisors work closely with the client, construction crews, external consulting firms and quality assurance personnel to manage and maintain the schedule. Though the project was not without its challenges, expertise, precise planning approach, monitoring and evaluation of the requirements ensured the completion of the refurbishment would be ahead of schedule.

The team have worked across a complete range of mills and almost every different reline machine on the globe, which contributes to knowledge of all things Liner handler related, that creates an environment where anything is possible when IMR are contracted. This level of service minimises any challenge restraints that were involved, although, no project is challenge proof. While the refurbishment was being carried out, the mill deck was being constructed and was subjected to high foot traffic and equipment congestion. The area being used on site to refurbish the machine was also very busy and IMR had to work in conjunction with multiple work fronts. Further challenges involved the inclusion of utilising local personnel, working alongside outside foreign contractors, strict deadlines and budgetary constraints. All factors contributed to a high risk environment, as such, it was critical to ensure that strict safety standards, legal obligations and performance standards were adhered to with all involved. Health and safety are the first and foremost objectives of any project IMR undertakes. The IMR team ensured these standards were maintained and exceeded at all times with safety inspections conducted before and after each shift, in-depth discussion of safety performances, and closely monitoring the shutdown stages and all contractors. The successful completion that was well under the scheduled time with zero incidents or injuries is a testament to the IMR team, the service they deliver and their primary focus on safety.

Results

With a strong result driven approach, the IMR team in conjunction with external contractors and the client, were able to complete the refurbishment of the Liner handler successfully. This outcome was able to attribute to maintaining and completing contracted works well under budgetary requirements and assisting in additional processing times on mill start-up. Ensuring projected processing targets would be achieved by the client, if not surpassed. The zero injury and incident project saw IMR complete another project with no lost time, injury, incident or service implications, which ensures the client meets their own safety, health standards and legal obligations.

The overall response from site and corporate representatives was very positive. This outcome has been one of which IMR are proud, and a milestone that has seen the company excel in exampling the technical skill, experience, knowledge and high-quality services clients receive when employing IMR to complete their engineering projects.

Philippine Gold Processing & Refining Corp. has predominately utilized the professional services of IMR for our mill relines. The technical expertise, work standard and professionalism always shown was replicated in the design and modification works on our existing Mill Reline Machine. Refurbishing and modifying our existing Mill Reline Machine was a very efficient and cost effective alternative which was made achievable through working with the IMR Engineering team. Their commitment to achieving results and the ability to work in conjunction with site personnel during high intensity work environments safely is always commendable. I would highly recommend the IMR team for any Mill reline and engineering works.

Jason Ives
Senior Maintenance Advisor
Philippine Gold Processing & Refining Corp.

This outcome has been one of which IMR are proud, and a milestone that has seen the company excel in exampling the technical skill, experience, knowledge and high-quality services clients receive when employing IMR to complete their engineering projects.

Masbate Gold, Philippines

Located on the Northern tip of Masbate Island (Philippines) this remote mine site has a process plant that is a conventional carbon-in-leach (CIL) facility consisting of primary crushing, SAG/Ball Mill grinding circuit with pebble crushing, leaching, absorption, elution, electrowinning and smelting gold recovery stages; and a cyanide detoxification stage for treating process plant tails before disposal in a new tailings storage facility (TSF).

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Phone: +617 4053 3004
Fax: +617 3054 7240
Email: info@imrelines.com

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