Machine: Finlay Terex C1550 Cone Crusher (10,356 hours)
Application: Crushing oversize from a 984 screen in a closed circuit to a minus 10mm
The machine had a failure due to maintenance activities when cutting the flame ring during a liner change. Over time the crushing head was cut through in several areas causing fatigue in the head which ultimately caused the failure when the machine was under load. The failure allowed dirt ingress into the eccentric, bearings and bevel gear, and also seized the main shaft into the lower frame.
As the cone section is the main component of the crusher and considering the age of the unit, the client faced the possibility of having to scrap the machine and purchase a new unit rather than repair the damaged machine.
OPS were engaged to strip the unit and assess the cost of a rebuild. The client ultimately decided to go ahead with this option. The main shaft was so badly jammed that it had to be machined out of the lower frame on the lathe. By conducting tests such as mag particle and NDT testing to identify parts that were still in tolerance and able to be reused, the OPS team was able to rebuild the chamber for approximately 19% of the cost to replace the unit. The client was able to recapitalise the crusher unit at a very low cost and keep the WDV of the machine below market price. This allowed them to continue to depreciate their machine knowing at any time they wanted to move the machine on they would recover their costs.
OPS also supplied a low cost spare chamber, allowing the client to continue crushing during the rebuild, and meet their contract requirements.