Fima S.A. Rev.

0
Installation, Operation and Maintenance Issued: 10/02/09
Manual
Volume 1 of 3 Ref.:P/ENG/C1191/1.8/Manual

8. MAINTENANCE
In order to achieve high plant availability the necessary plant maintenance will need to be
preformed at regular intervals.

8.1 COMBUSTION EQUIPMENT

The combustion system is built to ASA gas industry codes. Hence the operation of the burner
fuel train system is extremely safe, as it has built in safety features, which continuously monitors
the critical points and shuts down the burner if an unsafe condition arises. Therefore all lockouts
should be properly investigated before resetting to determine the reason for the lockout and
initiate maintenance or corrective measures if required.
The combustion equipment comprises fuel piping, valves, field instruments, burner and burner
control panel. Lockable isolation valves are provided at the start of each fuel line. Necessary
precautions required when carrying out work on the combustion system are:
a) Keep naked flames/cigarettes/welding/grinding away from vicinity.
b) Isolate instruments/valves electrically.
c) Isolate and lock fuel train isolation valve(s) when carrying out maintenance on fuel
system.
d) Purge fuel train lines with nitrogen gas before removing any valves or pipe spools.
e) If pilot is to be removed and withdrawn for maintenance take care with handling as the
end could be very hot.
f) If a UV sensor is to be removed take care as fitting on burner connection could be hot.

Caution
The maintenance contractor is to follow all safety instructions given in the safety
section of this manual before performing any maintenance on the Metso Minerals
(Australia) equipment.

8.2 OVERALL MAINTENANCE SCHEDULE

The following maintenance schedules provide an estimated guide for maintenance duties to be
carried out on the Dryers. Periodic maintenance is based on vendors’ recommendations and
experience, programmed around the scheduled plant shutdowns at 6 monthly intervals.
The expected wear and tear will be dependent on actual plant operational duties and loads. It is
the maintenance contractors’ responsibility to program necessary work for each scheduled
outage based on actual conditions and experience.
Lubricating requirements are detailed in Section 8.4 of this manual.
 Fima S.A. Rev.0
Installation, Operation and Maintenance Issued: 10/02/09
Manual
Volume 1 of 3 Ref.:P/ENG/C1191/1.8/Manual

8.2.1 Periodic Maintenance For Cyclones, Rotary Valves, Lined Ducting & Chutes

Period Details/Description
Six Monthly Visual inspection should be carried out where possible to determine wear
and tear over period of time. Repairs can be carried out if required.
Replace oil on rotary valve and screw feeder gearboxes.
Lubricate rotary valve drive chain
Inspect condition of rubber seal at base of cyclones (D1 only)
Annually Chutes, diverters, etc should be inspected closely and replaced at the first
opportunity with replacement spares.
Open up rotary valves and check tip clearance.
Inspect rotary valve transmission chain and sprockets for wear. Replace if
necessary.

8.2.2 Periodic Maintenance Schedule For Dryer, Fluoplate, Windbox, Combustion

Chambers & Burner Systems and Exhaust Ducting

Period Details/Description
Daily Walk around plant and look for any unusual signs such as peeling paint,
unusual noises, loose parts or product spillages.
Weekly Check purge air to burner pilot and main UV detectors is functioning
satisfactorily.
Check instrument air source drains are clear.
Check for loose connections and/or heat marks around burner and Dryer
unit. Investigate immediately if found.
Monthly Due to the possibility of contaminates in the fuel oil, monitor pressure at the
pressure gauge PI 204 and establish maintenance/cleaning schedule as
appropriate.
Six Monthly Check refractory for wear and tear and repair during major shutdown.
Remove UV detector and clean soot off lens.
Check Dryer Fluoplate tuyere caps for wear or damage and replace where
necessary.
Check burner spark plug, clean tips or replace depending on condition.
Check Fluoplate cooling air pipe and connection for loose bolts and general
wear.
Annually Check condition of 25mm Ceramic fibre rope on Windbox and Expansion
Chamber doors. Replace as necessary.
 Fima S.A. Rev.0
Installation, Operation and Maintenance Issued: 10/02/09
Manual
Volume 1 of 3 Ref.:P/ENG/C1191/1.8/Manual

8.2.3 Periodic Maintenance Schedule For Dampers, Actuators, Control Valves &
Instrumentation

Period Details/Description
Weekly Check damper actuators for leakage and note for repair during six monthly
shutdown.
Check instrument air filters, drain condensate if necessary.
Check control valves for leaks and deterioration around pneumatic actuators
and diaphragms.

Six Monthly Check operation of dampers by stroking all air cylinders to full extension and
observing wear and tear. Replace where necessary.
Instrumentation calibration should be checked during operation and replaced
during shutdowns. Instrumentation calibration checks should be performed
as per suppliers’ recommendations.

8.2.4 Maintenance of the Cooler

Period Details/Description
Weekly Visually inspect Coolers for any signs of material spillage or water leaks
Six monthly Lubricate plant. See Volume 2 for details
Annually Re-calibrate TE-600
Inspect outlet for signs of wear, replace parts as necessary.
Inspect individual cooling tubes for signs of wear or cracking..
Inspect the 25mm diameter rope on the expansion chamber access doors.
Replace if worn or if door is failing to seal.

8.3 MAINTENANCE PROCEDURE

8.3.1 Dryer Refractory

The Dryer consists of a refractory lined combustion chamber, windbox, and fluoplate, which
require periodic inspection and maintenance. An experienced refractory contractor must carry
out any repairs or maintenance to Dryer refractory. Failure to undertake proper repairs to the
refractory will decrease the performance of the Dryer and may lead to a premature failure of the
Dryer requiring costly repairs.

Caution
After each refractory repair or replacement is carried out, the dry-out procedure as
recommended by the refractory supplier must be observed when starting up the
Dryer.
Please refer to the drawing C1191-10006/1 for refractory placement and type. If the type or
brand of refractory list below is not available at the time of repair, please contact Metso Minerals
for an appropriate replacement.
A copy of this drawing is contained in Section 9 of this manual.
 Fima S.A. Rev.0
Installation, Operation and Maintenance Issued: 10/02/09
Manual
Volume 1 of 3 Ref.:P/ENG/C1191/1.8/Manual

8.3.2 Method Statement For Dryer End Cap Removal

From time to time it will be necessary to gain access to the internals of the combustion chamber
to check the refractory condition. For large dryers the access to the combustion chamber can be
gained by entering the manhole in the windbox or by removing the combustion chamber end
cap. For small dryers, it is suggested that personnel do not enter the internals. If repairs are
required, the unit should be stripped apart into major components.
This section should be read in conjunction with the Mechanical Installation Guidelines located in
Section 11 of this manual.
To remove the combustion chamber end cap and burner:
a) Before removing the combustion chamber end cap and burner for maintenance, remove
the UV detector, piping, valves, etc associated with the burner unit itself to allow for
crane access.
b) Undo and remove the bolts connecting the burner to the main combustion air duct.
c) Undo combustion chamber flange bolts and remove the refractory lined burner and end
cap using the lifting lugs provided. Carefully remove the cap and burner from flange
mating face to avoid breaking or dislodging the combustion chamber refractory.
d) When re-installing the combustion chamber end cap chip away all of the old 2mm thick
mortar between the End Cap and mating face on the combustion chamber. Replace with
a fresh 2mm deposit of mortar (refer to refractory drawings for details). Use ladder tape
on the flanges for a good seal to prevent hot gas leaks, before bolting up.
e) Reconnect air ducting and fuel train piping valves and instrumentation, replacing ladder
tape and flange gaskets as necessary.

Note
Ensure that flange match marks are lined up correctly.

Warning
When handling expansion board and ladder tape gaskets always read and follow the instructions
given on the ‘MSDS’ sheet

8.3.3 Burner Removal Procedure

Before removing the burner for maintenance, remove all UV Detectors, Piping, Valves, etc
associated with the burner unit itself to allow for crane access.
After disconnecting all major flanges carefully remove the burner using the lifting lugs provided.
Take care to ensure that the burner refractory is not damaged.
Care must be taken so as not to damage the gasket between the burner flange and combustion
chamber back plate. If the gasket is damaged it must be replaced to prevent hot air from
escaping.
More detailed instructions for removal of main pilot gas guns refer to Volume 3 of this manual.
 Fima S.A. Rev.0
Installation, Operation and Maintenance Issued: 10/02/09
Manual
Volume 1 of 3 Ref.:P/ENG/C1191/1.8/Manual

8.3.4 Dryer Fluoplate

The fluoplate is a flanged replaceable unit, which can be repaired as required or replaced as a
complete unit during a major shutdown. To remove the fluoplate:
Remove the exhaust ducting above the expansion chamber and feed conveyor chute
allowing expansion chamber to be lifted.
Disconnect the cooling air piping. In small dryers the cooling air inlet is located at the
side of the fluoplate. In large dryers the cooling air inlet is connected to the bottom of
the fluoplate inside the windbox.
Remove all bolts from the flange connecting the fluoplate to the windbox
If possible lift the expansion chamber together with the fluoplate using lifting lugs on the
expansion chamber. Only 100 mm lift is required.
Place rollers (heavy duty small diameter pipes) across the windbox flange.
Lower the expansion chamber with the fluoplate onto the rollers.
Remove all bolts connecting the fluoplate to the expansion chamber.
Lift the expansion chamber.
Slide out the fluoplate from under the expansion chamber
The fluoplate comes supplied with castable refractory on the underside (Windbox side) and with
tuyere caps fixed on the upper side.

8.3.5 Dryer Fluoplate Tuyere Cap

Critical to the performance of the Dryer is the condition of the Tuyere Caps, which are located on
the top of the Fluoplate inside the expansion chamber. Over time the tuyere caps will become
worn through the abrasive action of solids passing through the ports. Over time the wear will
lead to a decrease in Dryer performance and in cases of severe wear, deposits of material inside
the Windbox which will erode the Windbox refractory.
The condition of the Tuyere Caps should be monitored during the six monthly inspections, as
detailed in Section 8.2.2 of this manual.

New Tuyere Cap Worn Tuyere Cap

As the tuyere caps become worn, a hole may begin to appear in the top of the tuyere cap and
the side vents will become enlarged and rounded at the edges. As soon as a hole appears in the
top of a cap, or the ports have become significantly enlarged, it should be replaced.
 Fima S.A. Rev.0
Installation, Operation and Maintenance Issued: 10/02/09
Manual
Volume 1 of 3 Ref.:P/ENG/C1191/1.8/Manual

The Tuyere Caps are proprietary items of Metso Minerals carefully designed and tested. The
caps are manufactured using an investment casting process. Typically it can take 4-5 months to
produce replacement caps. Metso Minerals holds very limited stock of the specific caps. Due to
the long delivery times the stock levels mentioned in Section 11 must be maintained to ensure
plant availability and reliability.

Tuyere Cap Removal Procedure

Cap assembly

1 Remove the worn tuyere caps by grinding or gouging off the three tack welds. Grind off
all traces of weld so that the replacement can cap sit flat on the washer. If the washer is
significantly eroded it must be replaced or new one welded all round to the existing one.

Note
All material is stainless steel grade 304 or equivalent, so the use of an oxy torch will
not be practical.

2 Locate the replacement tuyere cap centrally about the jet trumpet and ensure that it is
sitting flat on the washer.
3) Tack weld the tuyere cap to the washer/ top plate using 3 equi spaced 6mm thick fillet
welds 10mm long. As a minimum a 309L stainless steel welding rod should be used.

Caution
Normal entry procedures detailed in section 3.4.1 will need to be followed. The
Dryers have tuyere caps raised off the top of the fluoplate, which are a trip hazard.
Plywood or similar should be used when working inside these Dryers to reduce the
risk of trips or falls.
 Fima S.A. Rev.0
Installation, Operation and Maintenance Issued: 10/02/09
Manual
Volume 1 of 3 Ref.:P/ENG/C1191/1.8/Manual

8.3.6 Cooler Tube Nest Repair

The tube nest carries the cooling water through a series of tubes. The temperature of the water
is used to cool the mineral via the fluidization process. It is composed of a number of tubes,
which are supported throughout the tube nest, to prevent them from moving.
They are immersed in a bed of fluidized mineral. Over a long period of time the abrasive action
of the mineral, or a weld failure may lead to a water leak. This will be immediately obvious as the
product will be damp and the inlet may block.
Once the leak has been confirmed the water supply to the cooler must be isolated. It will be
necessary to remove all the wet mineral from within the cooler internals in order to identify and
repair the source of the leak.
 Fima S.A. Rev.0
Installation, Operation and Maintenance Issued: 10/02/09
Manual
Volume 1 of 3 Ref.:P/ENG/C1191/1.8/Manual

8.3.7 Cooler Fluoplate Replacement

Over time the fluoplate tuyeres will become worn. The air outlet ports will become enlarged and
the ability of the air from the blower to fluidize the incoming mineral will decline, to the point
where the Cooler is constantly blocking and overflowing at the inlet.
Either, the expansion chamber and the tube nest should be raised or the windbox and the
fluoplate should be dropped, to gain access for inspection of the tuyeres. If only a few tuyeres
are worn, the weld at the top of the cap can be removed and a new cap fitted in its place
If the majority of the caps are worn it is more economical to replace the entire fluoplate. The
fluoplate is a flanged item that is supplied as a complete bolt in and bolt out assembly. To
replace it please follow the following steps:
Isolate the feed of mineral to the cooler. Keep down stream equipment running.
When the flow of material from the outlet has stopped, stop the fan.
Isolate and lock out on the control panel, the up and down stream conveyors.
Disconnect the ducting spool that enters the windbox.
Remove the pressure indicator PI 602
Use a forklift with gluts on the tines, to take the weight of the wind box. It may be necessary
to remove some of the angel bracing.
Remove the bolts joining the windbox, fluoplate and tube nest.
Lower the wind box and fluoplate down to a comfortable working height. Note that some
mineral may spill out.
Remove the old fluoplate
Clean up the windbox and tube nest flanges.
Remove any mineral in the windbox.
Lower new fluoplate in position and insert ladder tape gasket.
Using for forklift raise Windbox, to 5-10 mm below tube nest flange.
Feed in ladder tape gasket and install fasteners.
Reconnect ducting, applying a fresh gasket seal.
 Fima S.A. Rev.0
Installation, Operation and Maintenance Issued: 10/02/09
Manual
Volume 1 of 3 Ref.:P/ENG/C1191/1.8/Manual

8.4 LUBRICATION SCHEDULE

8.4.1 See detailed supplier data included in Volume 3 of this Manual