The document outlines a project to overhaul an old mining system by replacing old machines to increase efficiency, durability, and production rate. The old system included a feeder, two bucket elevators, a crusher, screen, and outlet hoppers that were deteriorated. The new system will install a new feeder, bucket elevator, screen, outlet, and hoppers. The maintenance team's scope includes manufacturing new larger hoppers, installing a new electrical panel and control system, adjusting the filter system, and adding new walkways and handrails to simplify movement. This overhaul is estimated to save $80,000 compared to outsourcing the work. The new setup is expected to decrease breakdowns and make equipment movement easier

1. Prepared by / Mohamed Khamis

2. Aim of the project
 Complete overhauling for the system by
replacing the old machines by new ones.
 To increase the overall efficiency of the
system , increase its durability , decrease
break down rate and increase productivity
and production rate .

3. old system arrangement and its situation
Feeder
Bucket
Elevator .1
Crusher
Bucket
Elevator .2
Screen
Outlet
Hoppers

4. Machine Picture of the machine Condition
Old feeder
the feeder body and its
vibrating cart were
completely depreciated
Old Screen
The screen needs complete
overhauling for its body and
its decks

5. Machine Picture of the machine Condition
Old Buckets
The two buckets body and
its components such as
upper and lower drums and
its gear boxes were very
depreciated.
Old Filter
The filter efficiency was
very low , due to complex
suction tree ( bad
engineering design and
selection ).

6. New system arrangement
Feeder
Bucket
Elevator
Screen
Outlet
Hoppers

7. Machine Picture of the machine Condition
New feeder
Completely new feeder with
new vibrating cart and new
grizzly screen .
New Bucket
Elevator
New bucket elevator with
new drive unit and larger
capacity .

8. Machine Picture of the machine Condition
New Screen
Completely new screen with
different drive mechanism
and with larger capacity .
.
New Outlet
hoppers
Completely new hopper
with larger capacity
and new chaises .

9. RGS maintenance team scope
1. Manufacturing new hoppers
Manufacturing 3 new hoppers with the following dimensions
- Length = 2m - width = 1.5 m - height = 1.5 m - thickness = 10mm
- Each hopper capacity = 4 ton.
- Manufacturing a new chaises for all hoppers .
Task Specification Material & labor
cost
Combi offer
Manufatering 3
new hoppers with
chaises
• length = 2m
•Width = 1.5m
•Height = 1.5 m
•Chaises ( H20
beam , length=
3.75m
40,000 EGP 72,000 EGP
We already saved 32,000 EGP

10. 2. Electrical preparation
 Completely new power panel and control panel with its accessories such as
contactors , circuit breakers ,,,,,,,,ETC.
 Automatic operation by applying timing sequence .
 Completely new cables tray with new cables and new distribution .
Control panel Power panel

11. Task Specification Materials , labor
cost
External offer
Power panel Dim 1x2x0.5 m 8,000 EGP 13,000 EGP
Control panel Dim 1x2x0.5 m 14,000 EGP 20,000 EGP
Cable trays &
cables & lighting
160 m cable trays
With cables
8 spots
4,000 EGP 10,000 EGP
We already saved 17,000 EGP

12. 3. Filter Adjustment
 Relocate the filter and the fan to simplify the suction tree .
 Technical adjustment to increase filter efficiency by changing inlet and outlet pipes
location and adjust its elevation .
 Only 3 suction points ( on bucket , screen and hoppers will increase the filter
efficiency.
Task Specification Material &labor
cost
External offer
Relocate filter
Adjust suction
tree
•Adjust filter input
&output and fan
elevation
•Install new suction
points
12,000 EGP 25,000 EGP
We already saved 13,000 EGP

13. 4. Walkers , Handrails , Stairs and Scales chaises
 Manufacturing a new walkers for technicians to make their movement more easier , handrails and
stairs were attached to this walkers .
 Manufacturing a new chaises for scales with a simple design and high quality
Task Specification Material &labor
cost
External offer
• manufacturing new
walkers with
handrails and stairs
•Manufacturing new
scales chaises
•20 square meter
walkers , 5 stairs
and handrails .
• H10 beam chaises
with its frame and
hocks
25,000 EGP 43,000 EGP
We already saved 18,000 EGP

14. Task Saved Amount
1 New Hoppers 32,000 EGP
2 Electrical preparation 17,000 EGP
3 Filter Adjustment 13,000 EGP
4 Walkers , chaises' 18,000 EGP
Total Saving 80,000 EGP
Total Saving

15. Advantages of the new Amendment
 To simplify the system and production line by
decreasing no. of machines without affecting on its
productivity .
 And to decrease break down ratio .
 And to make the movement of handling equipments
more easier
 The old situation let the crusher take the first shock
and this condition lead to hard impact on its drums .
 On the old situation we have to change its drums
every 2 months , and we have to change 4 or 6
bearings every month , and this is a huge extra cost .
 The current situation will increase the crusher
durability as we installed it after the screen .