Slurry hydraulic recalibration · hydrocyclone cut-size audit · mill-liner rotation scheduling · wear-rate reliability reporting for hard-rock and aggregate plants.
Contract scopes written for metallurgy and reliability teams — not generic “maintenance packages.” Each tier names the audit, the wear action and the document pack your engineer of record expects.
| Tier | Inclusion | Hydraulic / Wear Audit | Documentation |
|---|---|---|---|
| T1 Mill Discharge | 24/7 dispatch · wet-end warranty window | Quarterly impeller & liner thickness survey | ISO 9001 audit pack + oil ISO 4406 log |
| T2 Classification | Scheduled apex / vortex-finder kits | Monthly cut-size sample vs flotation feed D50 | Cyclone wear-rate trend chart |
| T3 Crushing Wear | Jaw / mantle change-out planning | CSS verification & liner tonnage tracking | Crusher wear-rate vs throughput report |
| T4 Tailings / Dewatering | Pump & thickener interface support | Seal water, underflow density & NPSH check | Dewatering circuit reliability brief |
Field engineers treat each mill stop as a controlled experiment: measure the duty that actually runs, stage the wear kit that matches that duty, then leave a paper trail metallurgy and procurement can both defend in an audit.
Document slurry SG, solids %, circulating load and crusher t/h into the contract so every dispatch ticket maps to a named duty, not a vague “pump check.”
Measure pump BEP offset, sump NPSH margin and hydrocyclone D50 against flotation or mill targets under actual load — not nameplate assumptions.
NDT shell thickness, impeller clearance and liner bolt torque; stage rebuild kits before the next planned mill stop.
MTBF / MTTR / ISO 4406 cleanliness and wear-rate trends submitted monthly to the client engineer of record.
On copper and gold concentrators we typically align liner rotations with planned SAG or ball-mill stops so wet-end rebuilds do not create a second outage. Quarry wash plants receive a lighter cadence focused on sand-pump impeller life and cyclone apex drift, because those circuits run fewer solids but longer calendar hours between major shutdowns.
Field notes also capture hydraulic system pressure at the gland water manifold, sump geometry that governs NPSH margin, and jaw opening / discharge opening settings when crusher wear parts are on the same service ticket. Output capacity in t/h is logged beside liner millimeters so metallurgy and maintenance argue from the same spreadsheet. When sites debate OEM-only spares versus engineered equivalents, we document bolt circles, shaft sleeves and measured wear rates instead of brand slogans — the transparency buyers need before freezing a multi-year parts contract.
Primary crushing tickets also record the jaw-versus-impact choice: jaws remain the default when feed size swings and crews want a simple CSS adjust at the discharge opening; impact crushers are only staged when asphalt-grade cubicity justifies shorter liner life. Vibration frequency on the screen deck after either machine is logged so wear on sand pumps is not blamed on the wrong upstream setting.
Service limitations are explicit: T1 mill-discharge dispatch assumes a named duty curve is already on file; classification cut-size audits need slurry samples within 4 hours of draw; and crusher wear planning cannot override structural frame cracks — those require OEM structural review before any mantle or jaw kit ships.
PDF, 28 pages — hydraulic audits, cut-size sampling plans and liner rotation templates used on contracted mill circuits.