Engr. Robenson Odcheo

1. GENERAL
MAINTENANCE &
REPAIR SHOP
[JoCh]

2. Machine Shop

3. Metalworking Lathe
Lathes are sized according to the
clearance from the center of the
chuck to the ways, ot “swing” and
according to the length of ways. The
swing varies from 3 to 60 inch.

4. Planer and Shaper
With the shaper, the cutting head
moves across the work to cut a flat
surface; with the planer, the bed
moves the work against a fixed cutter
head. Generally, the shaper is used
for smaller work. These machines are
selected to accommodate the size of
parts to be machined.

5. Milling Machine
This machine is called the
grandfather of all machines because
of its versatility. It can shape, bore,
drill, slot, and cut gearing. Within its
size limit, it can perform any
machining operation. Again the size
varies with the intended work.

6. Drills
There are two types of drills; the
standard drill press, and the
radial-arm drill press. Almost every
shop will need a standard drill press,
but for large parts, where many holes
are required, the radial-arm drill
press is a necessity. The standard drill
press is sized according to the
maximum hole it will drill; the radial
press by the diameter of the vertical
post as well.

7. Boring Mill
The horizontal boring mill is an
extremely versatile machine. akin to
the milling machine, in that it can line
bore between centers, plane, shape,
or perform usual lathe work. A high
precision machine is costly, it can do
work not possible on other machines.

8. Miscellaneous Equipment
1. Powered hacksaw-Used to cut metal shapes.
2. Grinders-Pedestal, portable, and tool post grinders are used for
cleaning up and to produce machine-ground finishes.
3. Portable line boring bar-Powered boring equipment used to line
bore parts too large to set up in machines, or which must be bored in
the field.
4. Presses-Presses are needed for press fit assemblies. They can be
vertical or horizontal, ranging from 50 tons to 1,000 tons in capacity.
5. Balancing machines-To provide static and dynamic balance for fans
and shafts.

9. Tool Room
The machine shop requires a great variety and sizes of cutters, drills,
reamers, etc. for its work. Space must be provided for the storage and
repair of this multitudinous and costly tooling. It is customary for the
tool room to repair and store small power tools such as drills, impact
wrenches, hydraulic jacks, etc. Workbenches and special tool grinders
are necessary for a well-equipped tool room.

10. General Considerations.
A machine shop will require uniform heating
and above-average lighting. An electric overhead crane is desirable to
service the machines. The layout of machines is important to provide
working room and to protect workmen from flying chips.

11. Welding &
Fabricating Shops

12. Standard D.C. Welding Machines
The most common welding machine
is the 300 amp., 440 v straight or
reverse-polarity d.c. welder. This
most versatile machine can weld in all
positions. Its drawback is that it is
slow and depends on the skill of the
operator for the quality of the weld.

13. Automatic Submerged Arc
Welding Heads
Automatic submerged-arc welding
heads automatically feed 3/32-in. to
3/16-in. bare wire using 750-1,500
amp. d.c. welders as a power source.
The flux is in the form of crushed
material containing the elements
needed in the weld. It covers the arc
during the welding process with the
rate of feed regulated by the
operator. The work is mounted
horizontally and is rotated by the
positioner.

14. Direct-current Heliarc Welding
Gas tungsten arc welding (GTAW),
also known as tungsten inert gas
(TIG) welding, is an arc welding
process that uses a non-consumable
tungsten electrode to produce the
weld.
Meredith named the process Heliarc
because it used a tungsten electrode
arc and helium as a shielding gas, but
it is often referred to as tungsten
inert gas welding (TIG). The American
Welding Society's official term is gas
tungsten arc welding (GTAW).

15. Alternating-current,
High-frequency Heliarc
Zinc, aluminum, and magnesium
alloys are extremely hard to weld.
The ac. high frequency heliarc is
similar to the d.c. heliarc process and
successfully welds these metals.

16. Direct-current, Semi-automatic Welding
The flux is contained in the core. This
process is excellent for building up
large areas such as shovel buckets,
wear plates, etc.

17. The Metalizing Process
The metalizing process is essentially
mechanical, depositing a stream of
metal onto a grooved surface.
It is most frequently used to build up
small shafts on electric motors, or
large bores where pulleys, couplings,
etc. are to be assembled with a press
fit. It is effective where stress or
shearing is not a factor.

18. Welding Positioners
The welding positioner holds the
piece to be welded in the proper
position for the best and fastest
weldment.
Positioners are generally powered
either electrically or hydraulically;
they will rotate a shaft or rollers at a
controlled speed for commercial and
fast submerged-arc build-up.

19. Carpenter,
Mason & Paint Shop

20. ● Ventilation
- must be sufficient to entrap all overspray and remove volatile fumes
● Paint Containment
-paint overspray can rarely be exhausted without removal from the air
because of its detrimental effect to the appearance of nearby buildings and
equipment
● Lighting
- high-intensity lighting is essential in a paint shop; mercury-vapor and
incandescent lamps alternated provide nearly normal light qualities
● Fire Hazard
- all electrical lights, fixtures, etc. must
be vapor-proof. Paint must be stored in steel cabinets and local ventilation
provided where painting equipment is cleaned

21. Electric Shop

22. Due to the size of the equipment and the nature of the work involved, a
considerable portion of the electrical maintenance will be performed
away from the electric shop proper.
Pole line construction and repair must be provided for. Many diverse
factors will affect power-line design, which in turn will have a direct
bearing on the maintenance procedure that will be followed.
Electronic equipment is finding an ever increasing amount of use;
therefore, provision for the repair and maintenance of this equipment
is necessary. This can be quite extensive if a large communication
system, as well as other associated instrumentation, is involved.

23. Drill Repair Shop
Blasthole drilling equipment, approach the electric
power shovel in complexity and size, and require nearly
as much as space for major overhaul. It is common to
use the same facilities for drill repair and shovel repair,
or to provide space near the machine shop and
fabricating shop

24. Shovel Repair Shop
Electric and diesel power shovels can be erected and
overhauled in the field, but efficiency and availability
dictate an adequate shop facility. The basic tools for
shovel overhaul are the same as for drills, except they
must be larger, The repair stall or bay must be high
enough to clear the boom and a pit be provided to
facilitate removing the center pintle.

25. Miscellaneous Repair Shop

26. Plumbing and Pipe Shop
The prime considerations for a pipe
shop are convenient pipe storage,
and layout platens for piping
fabrication.

27. Belt Repair
Conveyor belting for mine haulage or
plat use suffers cuts, rips, and war To
obtain maximum life, belts require
periodic repair.

28. Sheet Metal Shop (Tin Shop)
While generally combined with the
welding and fabricating shop, some
mine plant facilities have sufficient
ductwork for heating, ventilating, air
conditioning, and dust collecting to
justify a light-gauge sheet metal shop.
The usual shop will have sheet metal
brakes, power shears, nibblers, rolls,
benders, and special power tools for
forming mechanical joints

29. Surface Maintenance
| Labor Pool |
This shop maintains shop roads, it provides mobile
crane service, plows, and shovels snow, cuts grass,
collects scrap, sands roads, dispatches service trucks
from a common pool, and does digging, breaking
concrete, and all other hand work. This Shop often
functions as the labor pool for maintenance.

30. AREA
MAINTENANCE
SHOPS
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31. Plant/Crusher Repair Shop
Function is to provide daily running repairs, including
welding, and to make necessary repairs and
replacements during periodic down shifts.
Shops should be t located central to the plant
operations and preferably on the ground level to
facilitate handling supplies. Although bulky and heavy,
a covered storage area will permit orderly storage and
allow for maintenance of parts inventory.

32. Field Shovel Repair/
Electrical Repair Shop
Shovel and drill area maintenance can be
accomplished with a small building containing a
workbench, vise, grinder, welding machine, and
adequate portable tool storage.

33. General
Area maintenance shops can be as large or
small as the intended workload demands.
Working close to operations, they can give
fast effective service and can be nucleus of
a preventive maintenance program.