GLENCORE TECHNOLOGY  

EMPLOYEE ASSESSMENT
AND
OBSERVATION LOG BOOK
Employee Name Site

Employee No Date Issued

Competent Yes No Date Completed

Reason not
completed

Completed on Revision Date

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TABLE OF CONTENTS

NO DESCRIPTION PAGE
CP Cover page 1
ToC Table of Contents 2
AQ Assessment Questionnaire 3 - 11
1 Grinding Disc Markings & Rotation 12 - 13
2 Hydraulic Power Pack Inspection 14
3 Mill Disassembly 15 - 16
4 Removal of Discs from the Shaft 17 - 18
5 Installation of Discs onto the Shaft 19 - 20
6 Disc/Hub Rebuild Procedures 21 - 22
7 Disassemble 23
8 Gland Inspection 24
9 Gland Assembly 25
10 Gland Packing Adjustment 26
11 Gland Housing Installation 27
12 Gland Housing Removal 28
13 Gland Disassembly 29
14 Drive end flange inner liner replacement 30 - 31
15 Dismantle and Rebuild the Rotor 32
16 Shell Liner Measuring 33
17 Remove or Rotate a Used Shell Liner 34
18 Install a New Shell Liner 35
19 Low Speed Coupling Check 36
20 High Speed Coupling Check 37
21 Mill Shaft Bearing Check 38
22 Main Shaft Removal 39 - 40
23 Main Shaft Installation 41 - 42
IOH Inspection/Observation History 43
PTO 1–2-3 43
PTO 4–5–6–7-8 44
PTO 9 – 10 – 11 – 12 - 13 45
PTO 14 – 15 – 16 – 17 – 18 - 19 46
PTO 20 – 21 – 22 - 23 47

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Maintenance Questionnaire Assessment

Employee Section Date

Empl. No. ID Number

Assessor Competent Not Yet Competent

Name
Acc. No
Plant Outlay (Place correct number next to correct component)

No Question Answer C NYC

1 Isa charger water tank
Motor
Isamill
Motor lubricating system
Isamill bearing lubricating system
Sieve bend (Mill Feed)
Gearbox lubricating gearbox
Isa charger screen(Media)
Liquid resistance starter
Gland water tank
2 Write down the required P.P.E you 1) __________________________
must wear before plant
maintenance in the answer column. 2) __________________________

Required P.P.E (8) 3) __________________________

4)___________________________

5)___________________________

6)___________________________

7)___________________________

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8)___________________________
Plant Outlay (Place correct number next to correct component)

No Question Answer C NYC

3 Feed pumps
Discharge tank
Isa charger
Feed tank
Media hopper
Discharge pump

Isamill Chamber Main Components (Place correct number next to correct component)

No Question Answer C NYC

4 Non Drive Flange (NDE)
Displacement body
Shell Liner Shell
Rotor
Shaft/Key
Grinder disk

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Spacer
Drive End Flange (DE)
Shell Liner
No Question Answer C NYC
5 What is the “GOLDEN RULE”
before doing maintenance on Do a complete lockout procedure.
the Isamill Plant?
Wear the correct P.P.E

Use the correct tools

6 When would you do a risk

assessment on the plant? During stripping of the Isamill
components

Before doing any maintenance

After maintenance is completed

7 What are the factors to be

considered in the risk 1) ____________________________
assessment process?
____________________________
Write in short your own words
in the answer column. 2)_____________________________

_____________________________

3)_____________________________

_____________________________

4) _____________________________

_____________________________

5) _____________________________

_____________________________

6) _____________________________

_____________________________

7) _____________________________

_____________________________

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No Question Answer C NYC
8 What is the reason for doing a Assess all hazard conditions
risk assessment?
Minimizing hazards

Prevention of personal injuries.

9 What special service tools are Hydraulic power pack

supplied with the mill to aid in
handling the components? Heavy duty screw driver

Shaft lifting swiveling eye bolts

Shell/Mill frame swiveling eye bolts

Shaft support jack DE, c/w jacking

handle

Carpenter hammer

Shaft support jack NDE, c/w jacking

handle

Disc/rotor installation device

Ring spanner

Displacement body wear plate

assembly lifting tool

Shaft end cap hex keys

Wooden mallet

Flange liner alignment bolts

Disc hub lifting tool

Shell liner lifting tool

Shell liner measuring tool

10 Is it important to keep tools free Yes keep the tools free from rust
from grease and oil during use?
No lubricate moving components

Yes to prevent tools from slipping

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No Question Answer C NYC

11 Are any employees allowed to Yes the foreman in charge
operate the crane during the
lifting of Isamill components? Any employee to speed up the work

Only a competent certified

employee under DMR 18(11)

12 Is it important to know the S.W.L No will be safe for any load lift
of crane, slings, shackles and
eye bolt? Yes, to safely lift components

Only the crane operator has to know

that.

13 Why is it important to use a soft It is stronger than chains and wire

sling when lifting Isamill rope
components?
Prevent damage to Isamill
components

Can lift more weight

14 Is it important to de-pressurise Yes

the Isamill system before
maintenance? No

15 From what height must you use 1.5m

Fall Arrest equipment as
prescribed by the Occupational 2m
Health and Safety Act?
3m

16 Is it important to give clear and Yes very important

understandable instructions to
fellow employees during Isamill No the other person know what to do
maintenance?
No that is why we have induction
sessions
17 Is it important to do a lockout No not necessary hydraulics don’t
procedure on the Hydraulic work
power pack after extraction of
the Isamill grinder shell? Yes prevent anybody operating the
Hydraulic pack

No persons know not to use the

Hydraulic pack during maintenance

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No Question Answer C NYC

18 When must inspections be done Before maintenance starts on a daily
on P.P.E, Tools, and Lifting basis
equipment?
During maintenance

After completion of maintenance

19 When doing inspection on the grinder discs, what would the following markings
represent,
Use the letters at the bottom and place it in the correct box on the left side.

A B C D E F

No Question
20 What is the minimum disc width for:-
Mill Size New Size Answer C NYC
M5,000 90mm

21 What is the minimum disc diameter for:-

Mill Size New Size Answer C NYC
M5,000 1200mm

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22 What is the minimum flange liner thickness for:-
Mill Size New Size Answer C NYC
M5,000 30mm

23 What is the minimum shell liner thickness for:-

Mill Size New Size Answer C NYC
M5,000 30mm

24 What would you do if you find any Report it to the safety officer to
hazardous, notices or decals have it replaced
damage on the plant or machinery?
Will not be necessary to report
it, is not a hazardous risk

Plant and machines is built to

be safe

25 Is it important to work in groups, Yes it helps to prevent

pairs or to have a spotter during unforeseen hazards to a fellow
work operations? worker

No it prevents other workers

from doing their job

Sometimes it is necessary to
use other workers

26 Are you allowed to do any Yes if necessary

modifications on the machine?
Only the manufacturer of such
machine

Small modifications is allowed

27 Before cleaning the machine with Cover or seal all openings that
water or other cleaning agents........ should be protected from
moisture due to safety or
operational reasons. Especially at
risk are electric motors and
switch cabinets

Cover all openings to the

grinder discs and shaft for rust

Cover the rotor and

displacement body

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No Question Answer C NYC
28 Is it safe to walk under a suspended No
load?
Yes

Yes to take a quick shortcut

29 Is it wise to use a tagline while lifting Yes

mill components?
No

Sometimes
30 A chain or wire rope slings is safer Yes it won’t break easy
and stronger to lift grinding wheels?
Chain or wire rope slings don’t
slide easy

No it will damaged internal mill

components

31 Will you double check the grinder No not necessary the grinder
shell inside for any tools left inside wheels will grind it to small pieces
before closing the grinder shell
assembly? Yes tools would damage
internal components at startup

Will not cause any damaged to

internal components

32 How would you know which side is By the motor position

the Non Drive End (NDE)?
No motor fitted on the side

No Direct Entry

33 Would you Lock the Hydraulic Yes

Power Pack wheels preventing it
from moving? No

If standing on a gradient
34 Which calculation would you use to
determine the grinding disc D = C/π
diameter?
D = 2hr

D = R/π

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No Question Answer C NYC
35 What is the last action you would Take measurements of the final
take before closing the mill? closing conditions of the mill
components. Fill in the mill
maintenance log and determine
the hours to the next day.

Measurements of the shaft end

cap

Take measurements of the

displacement body

36 What must be done with rot able To be sent back to the relevant
items? fabricators

Place in store

Discard it
37 What is the torque of the Disc Hub connecting bolts.

38 What is the Torque of the Shaft End Cap Bolts

39 What Grease is used to lubricate the Shaft?

40 Why is it important to clean the parts before installing them onto the
IsaMill Shaft?

41 How Many Discs are there on the shaft.

42 How Many rings of packing are in the Gland?

43 When do you know when to replace a Disc.?

44 How many types of discs are there and how many of each type.

45 How many positions can the shell Liner be positioned.

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_______________________________ ___________________________

Observer Signature Employee Signature

END OF QUESTIONNAIRE ASSESSMENT

TASK OBSERVATION / INSPECTION

Date: _______________________________ Time: ______________________________

Site Name: _Las Bambas____________ Observer name: __Glenn Martin_______

Employee observed: ________________________________________________________

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