15 02 MAN CB - 02

MANDALAY RESOURCES – CERRO BAYO

BALL MILL NDT INSPECTION REPORT
January 2015 SHUTDOWN

CLIENT: MANDALAY RESOURCES

ATTENTION: Sebastian Romero / Marcelo Herrera Perez

INSPECTION DATES: 30th January – 3rd February 2015

EQUIPMENT: MOLINO BOLAS

REPORT NUMBER: 15 02 MAN CB 02

TECHNICIAN: Duncan Butterworth & Wayne Reader

Page 1 of 37
15 02 MAN CB - 02

Executive Summary SAG & Ball Mill Drive System Inspections

Australasian Gearing Services (AGS) were engaged to attend site during the shutdown effected end of
January / beginning February 2015, to assist with the programmed maintenance and overall asset
management of the drive systems of the grinding mills at Cerro Bayo.

Those mobilised to site from Perth, Australia were Wayne Reader (Principal AGS) and Duncan
Butterworth (Principal Weld Integrity).

The scope and primary objectives of our involvement was:

 To carry out a thorough NDT assessment of the SAG and Ball Mill open gearing (Girth Gear /
Pinion) via Magnetic Particle Inspection (MPI).
This was in order to determine:
o soundness of the Girth gears, particularly in Zone #1 (tooth area) the girth gears
o determine current condition of the gearing as a whole
o determine and deem suitability for continued use
o offer recommendations going forward, based upon findings of the assessment

 To carry out follow up inspections of gear reducer internals and overlay comparatively with
previous inspection results in November ’14 (when Ball Mill reducer was replaced).

 To complete mensuration of the girth gears, measuring and collecting remaining information
that was previously inaccessible during the November ’14 shutdown due to guarding etc
being intact at that time.

Arrival in Chile Chico was in the evening of 29th January where we were collected from the Ferry by
Sebastian Romero and first attendance on site was the morning of 30 th January.

Upon arrival to site the gears weren’t available for commencement of NDT assessment so this was
deferred until 31st January.

Given the delay, this time was utilised to carry out initial inspection of the gear reducer internals of both
the SAG and Ball Mill.
No change in condition was observed to the SAG mill gear reducer however there was deterioration to
the input pinion and bull gear of the previously refurbished ball mill reducer that was replaced, with new
internals in November ’14.

Completion of the mensuration of the girth gears was carried out also during the dwell time prior to
gaining access to the girth gears for NDT assessment.

Access was still unavailable due to issues / problems with the installation of the mill internals so NDT of
the SAG mill gear was again deferred until access was going to be available and final cleaning
completed on 1st February.

Access was gained to the SAG Mill girth gear in the morning of 1st February and completion of the NDT
of the girth gear and pinion was completed during this shift.
Night shift completed cleaning of the gear drive which allowed commencement of the NDT inspection
in the morning of 1st February.

Page 2 of 37
15 02 MAN CB - 02

Upon completion, the gear structure was deemed sound given that no major flaws or cracks were
observed at this time.
However the condition of the current active tooth flanks of both pinion and gear, are such that they can
be considered to have achieved well in excess of their anticipated designed service life and if left
unattended will see further deterioration that will inevitably lead to tooth cracking at the pitch line which
could I turn, expose the gear to potential tooth outbreak.
Other activities were completed throughout the shift also.

Night shift moved the inching drive which allowed commencement of the Ball Mill gearing NDT on 2nd
February.

Once mill rotation via the inching drive was reinstated, completion of cleaning of the girth gear and
pinion was carried out.

NDT of the Ball mill gearing was then eventually commenced and completed with the gear to be found
the girth gear to be sound and in fact, in remarkable condition for the time that it has been in service,
compared to the condition of the SAG mill gear.
The pinion however is suffering due to mismatched profiles and will require eventual replacement but
before any surface degradation is mirrored onto the girth gear.

Contact assessment of the Ball mill gear reducer was attempted however due to not having the correct
medium to utilise (Bearing Blue) to successfully carry out such a check, coupled with the inability to
false load the teeth to derive a reasonable contact pattern, the check was aborted.

Various other activities were completed and a wrap up meeting convened with all relevant parties /
stakeholders from Mandalay Resources, AGS and Mestranza Diesel in attendance.

Discussions centred around firstly, our findings of the NDT assessments of the SAG and Ball mill girth
gears and pinions and associated causes for current condition of each of the gear drives.
In addition, proposed recommendations were outlined and suggested for both machines’ ongoing
operation.
Sebastian assisted greatly with translation during the discussion.

Much emphasis was placed on the findings relating to the internals of the Ball Mill gear reducer and
associated damage that has occurred after only two months of operation.
The root cause for the damage observed appears to be consistent with adverse loading to the output
end of the gear mesh and will be discussed further in the body of the report.

Meeting closed just prior to 18.00 and we travelled back to Chile Chico via the company bus.

An informal dinner meeting was held when Toni arrived in Chile Chico where we had a further
discussion regarding our findings over the course of the shutdown.

We were collected at 7.30 by Marcelo who ensured that we made it to the Ferry on time to commence
our journey back to Perth, Australia.

Wayne Reader
Australasian Gearing Services

Page 3 of 37
 15 02 MAN CB - 02

BALL MILL MAGNETIC PARTICLE INSPECTION TEST REPORT

-
Page: 2 of 19
Report Number: 15 02 MAN CB - 02 Report Date: 12/02/2015
Attachment: 0
Client: Mandalay Resources Attention: S Romero / M Perez
Address: Cerro Bayo, Patagonia Region, Chile Clients Job #: 0011
Work Description: P/O: PO14 - 15
Location: Cerro Bayo Mine Site
Magnetic Particle
Magnetic Inspection
Particle of Train
Inspection of 2 Date of test: 01/02/15
BALL Mill
Ball Girth
Mill Gear
Girth & Pinion
Gear Technician (s): Duncan Butterworth & Wayne Reader
Magnetising Method: Magnetic Flow Material: Cast Steel
Procedure Number: MT-001 Surface Cond: Machined
Test Specification: AS 1171-1998 Demagnetised: No
Acceptance Criteria: Report Findings
Welding Process: N/A
Test Restriction: Nil
Equipment Used: Y6 Articulated Yoke
Media / viewing conditions: Min 1000 lux Artificial Light / Black ink on a white background
Positions Examined:

A magnetic particle examination was carried out to 100% of the gear teeth surface areas:
 Girth Gear Teeth (287 Teeth)
 Pinion Gear Teeth (23 Teeth)

Refer to Table 1 & 2 for teeth tested.

Results of Inspection:

Girth Gear
Uniform contact surface conditions were observed to each tooth through the full circumference of the
Girth Gear, very little damage was observed.
NSD - No Significant Discontinuities has predominantly been utilised to categorise the damage due
to the consistency of the contact surface conditions of the girth gear teeth.
A number of teeth were noted to have been subjected to impact and entrapment of foreign material
resulting in peening at the lands of teeth Nos: #113 & #262, & #287 as well as few contact surface
anomalies.
One particular area centre of face has been subjected to one piece of foreign material (approx. 8mm
in dia) being entrapped and passed through mesh, having affected each of the teeth on both
members.
Refer to pages #4 - #21 for detailed results.
Pinion
Pinion surface conditions and inspection results were consistent with the findings of the Girth
inspection results.
Fatigued material was evident at the DE of each of the pinion teeth with the formation of pitting at the
pitch line.

Duncan Butterworth Wayne Reader

AINDT Level 3 Technician Gearing Specialist

Page 4 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
1
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
2
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
3
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
4
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
5
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
6
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
7
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
8
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
9
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
10
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
11
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
12
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
13
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
14
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
15
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
16
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
17
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
18
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
19
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
20
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
21
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
22
Non Load Face NSD -- 1st February ‘15

Page 5 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
23
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
24
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
25
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
26
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
27
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
28
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
29
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
30
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
31
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
32
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
33
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
34
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
35
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
36
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
37
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
37
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
38
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
39
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
40
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
41
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
42
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
43
Non Load Face NSD -- 1st February ‘15

Page 6 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
44
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
45
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
46
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
47
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
48
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
49
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
50
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
51
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
52
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
53
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
54
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
55
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
56
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
57
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
58
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
59
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
60
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
61
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
62
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
63
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
64
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
65
Non Load Face NSD -- 1st February ‘15

Page 7 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
66
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
67
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
68
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
69
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
70
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
71
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
72
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
73
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
74
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
75
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
76
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
77
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
78
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
79
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
80
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
81
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
82
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
83
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
84
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
85
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
86
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
87
Non Load Face NSD -- 1st February ‘15

Page 8 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
88
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
89
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
90
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
91
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
92
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
93
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
94
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
95
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
96
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
97
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
98
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
99
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
100
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
101
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
102
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
103
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
104
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
105
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
106
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
107
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
108
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
109
Non Load Face NSD -- 1st February ‘15

Page 9 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
110
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
111
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
112
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
113 Impact Damage on 1st February ‘15
Non Load Face 1
Land - NDE
Load Face NSD - 1st February ‘15
114
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
115
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
116
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
117
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
118
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
119
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
120
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
121
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
122
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
123
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
124
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
125
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
126
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
127
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
128
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
129
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
130
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
131
Non Load Face NSD -- 1st February ‘15

Page 10 of 37
15 02 MAN CB - 02
TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
132
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
133
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
134
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
135
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
136
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
137
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
138
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
139
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
140
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
141
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
142
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
143
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
144
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
145
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
146
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
147
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
148
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
149
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
150
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
151
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
152
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
153
Non Load Face NSD -- 1st February ‘15

Page 11 of 37
15 02 MAN CB - 02
TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
154
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
155
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
156
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
157
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
158
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
159
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
160
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
161
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
162
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
163
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
164
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
165
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
166
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
167
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
168
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
169
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
170
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
171
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
172
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
173
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
174
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
175
Non Load Face NSD -- 1st February ‘15

Page 12 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
176
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
177
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
178
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
179
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
180
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
181
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
182
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
183
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
184
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
185
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
186
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
187
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
188
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
189
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
190
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
191
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
192
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
193
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
194
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
195
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
196
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
197
Non Load Face NSD -- 1st February ‘15

Page 13 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
198
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
199
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
200
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
201
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
202
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
203
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
204
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
205
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
206
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
207
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
208
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
209
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
210
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
211
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
212
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
213
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
214
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
215
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
216
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
217
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
218
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
219
Non Load Face NSD -- 1st February ‘15

Page 14 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
220
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
221
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
222
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
223
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
224
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
225
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
226
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
227
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
228
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
229
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
230
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
231
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
232
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
233
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
234
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
235
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
236
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
237
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
238
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
239
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
240
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
241
Non Load Face NSD -- 1st February ‘15

Page 15 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
242
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
243
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
244
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
245
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
246
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
247
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
248
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
249
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
250
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
251
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
252
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
253
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
254
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
255
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
256
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
257
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
258
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
259
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
260
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
261
Non Load Face NSD - 1st February ‘15
Impact Damage on 1st February ‘15
Load Face 2
Land - Centre
262
Impact Damage on 1st February ‘15
Non Load Face 3
Land - DE
Load Face NSD - 1st February ‘15
263
Non Load Face NSD -- 1st February ‘15

Page 16 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
264
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
265
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
266
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
267
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
268
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
269
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
270
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
271
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
272
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
273
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
274
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
275
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
276
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
277
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
278
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
279
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
280
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
281
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
282
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
283
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
284
Non Load Face NSD - 1st February ‘15
Load Face NSD - 1st February ‘15
285
Non Load Face NSD -- 1st February ‘15

Page 17 of 37
15 02 MAN CB - 02

TABLE 1 Girth Gear

Tooth Number Location Results Photo # Date Tested

Load Face NSD - 1st February ‘15
286
Non Load Face NSD - 1st February ‘15
Impact Damage on 1st February ‘15
Load Face 4
287 Land - Centre
Non Load Face NSD - 1st February ‘15

Legend: CD - Contact Damage. MiP - Micro Pitting. MaP - Macro Pitting. SS - Sporadic Spalling.
KC – Crack Formation. PLC – Pitch Line Cracking. MiS – Micro Shrinkage. MaS – Macro Shrinkage.
GA – Gasseous Inclusion.NGA – Non Gasseous Inclusion. MML - Minor Material Loss.
AW – Abrasive Wear. RA - Relieved Area. LD – Linea Discontinuity.
NSD - No Significant Discontinuities

Photo # 1: Impact Damage on the Non Drive End Non Load face corner of Tooth Number 113

Page 18 of 37
15 02 MAN CB - 02

Photo # 2: Impact Damage on the Centre Non Load face of Tooth Number 262

Photo # 3: Impact Damage on the Drive End Non Load face of Tooth Number 262
Page 19 of 37
15 02 MAN CB - 02

Photo # 4: Impact Damage on the Drive End Load face of Tooth Number 287

Photo # 5: General view of MPI background being applied to the girth gear teeth
Page 20 of 37
15 02 MAN CB - 02

TABLE 2 Pinion

Tooth Number Location Results Photo # Date Tested

Load Face MaP / CD - 1st February ‘15
1
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
2
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
3
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
4
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
5
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
6
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
7
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
8
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
9
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
10
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
11
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
12
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
13
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
14
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
15
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
16
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
17
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
18
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
19
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
20
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
21
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
22
Non Load Face NSD - 1st February ‘15
Load Face MaP / CD - 1st February ‘15
23
Non Load Face NSD -- 1st February ‘15

Page 21 of 37
15 02 MAN CB - 02

Ball Mill Drive System Open Gearing – Current Condition

During the course of inspecting the pinion and girth gear the following observations were made
relative to the condition of the two members:

Pinion

It was reported that the pinion currently in service was installed in an as new condition and
married with the previously utilised girth gear contact flank, approximately 18 months prior to this
inspection.
Although there are some early signs of deterioration with fatigue due to specific overload,
predominantly at the drive end of the pinion as well as some abrasive wear taking place, in
general, the pinion is in reasonable condition.
However, considering the short period of time that the pinion has operated, coupled with the
current (good) condition of the girth gear, there should be a mechanism put in place to arrest
further deterioration so as to maximise the remaining service life of the pinion.
Not unlike the situation with the SAG mill, part of the reason some of the deterioration can be
attributed to attempting to match two members where one has already been previously utilised
but the majority of the issues with this drive lay with the lubrication, ingress of fine abrasives but
also some mechanical misalignment having been in play at some stage.

The main modes of damage observed with this drive that would be detrimental to successful long
term operation are characterised as follows:
 Abrasive wear (three body abrasion) due to the introduction of abrasive contaminants and
wear debris into mesh.
 Pitch line overload and fatigue with the early development of pitch line pitting at the drive
end of the face width.

General view of pinion contact surface conditions

Page 22 of 37
15 02 MAN CB - 02

General view of DE contact surface conditions of pinion

General view of NDE contact surface conditions of pinion

Page 23 of 37
15 02 MAN CB - 02

General view of previously relieved area of active flank of pinion

Enhanced view of DE pinion depicting longitudinal misalignment between pinion and gear

Page 24 of 37
15 02 MAN CB - 02

Enhanced view of DE pinion depicting longitudinal misalignment between pinion and gear

Girth Gear

The Girth gear has been in service since the mine’s inception at Cerro Bayo.
In fact, this is the first time since initial operation commenced that the gearing has been stripped
of lubricant and the condition assessed in any form.
Until the pinion that is currently in service was installed approximately 18 months ago, the original
pinion operated with the original active flanks.
As discussed whilst on site, given the duration of time that the gear has been in operation and
even after being coupled with a new replacement pinion some 18 months ago, the girth gear is in
remarkable condition with little damage, all things considered, with the tooth profile remaining
intact (something almost unheard of).

As the gear is in such good condition, the rate of decline of the pinion appears relatively slow and
has been restricted as mentioned previously, to some pitting starting to occur at the DE of the
face width (due primarily to an overload condition that must have been in play previously and
appears now to have been rectified).
As well as this, some abrasive wear has occurred during normal operation due to ingress of fine
contaminants and as a consequence, an edge and root wear step is starting to develop, which
ultimately will see the vibration levels start to increase over time if left unattended.

Given this I would suggest that the gear drive in its current state (particularly now that it has been
cleared of residual lubricant and likewise any abrasive particulate matter that may have been
harboured in said lubricant), would be suitable for continued use with long term service potential
after a small amount of rectification.
This will be discussed further in the report.
Page 25 of 37
15 02 MAN CB - 02

General view of girth gear contact surface conditions. Note machining witness still visible.

Enhanced view NDE depicting evidence of a slight pitch line overload toward the rim face

Page 26 of 37
15 02 MAN CB - 02

Enhanced view DE depicting evidence of a slight pitch line overload toward the rim face

General view of MPI results. Note no flaws or anomalies observed.

Page 27 of 37
15 02 MAN CB - 02

General view of area of damage to #262 presumed to have occurred during pinion installation
This damage was relieved during the course of the shut down

Gear Mesh

Tooth Contact and Load Distribution

As mentioned previously, the Girth gear has been in service since the mine’s inception at Cerro
Bayo with one pinion replacement carried out approximately 18 months ago.
Although we have not witnessed firsthand, the condition of the pinion that was removed, I’m
assuming that it was also in reasonable condition when replaced.
As mentioned previously, I would like to take a look at any photographs of the previously utilised
pinion if they are readily available.

The current contact and load distribution between the two meshing members appears reasonable
and the values measured below indicate that alignment conditions are good.

Backlash measurement was carried out with results as follows:

Drive End Non Drive End

CL <0.02mm <0.02mm
BL 1.95mm 2.00mm

If there are any (most recent) dynamic results (infra red readings) available, if I could be furnished
with a copy that would be greatly appreciated so that I can look at dynamic vs static
comparatively

Page 28 of 37
15 02 MAN CB - 02

Gear Reducer

A post installation follow up inspection of the gear reducer was carried out, so as to assess first
and foremost, the condition of the replacement internals that were installed in November ’14, after
two months operation.

Initial inspection of the externals and seal carrier peripherals deemed that the seals all remain
intact with no leaks observed.
The breather was noted to be in good condition and had not reached expiry so was deemed
suitable for continued use.

The inspection hatch was then removed to gain access to the internals and an immediate flag
was raised due to some unexpected damage being noted at the output end of the active flanks of
the input pinion, as well as corresponding damage to the active flanks of the output (bull) gear.
Closer investigation of the defect (as best as is available via the access hatch) was made and the
damage categorised as either early stages of destructive pitting or potentially, localised case
crushing.
Further and even closer examination would be required to absolutely define the exact mechanism
of failure that is occuring however under either scenario, these type of failures occur when the
basic fatigue load capacity of the material has been exceeded, either due to application of too
much torque or poor load distribution along the tooth or between several pairs of teeth.

In this instance, given the adverse loading to the output end of both members and the strange
longitudinal contact (as depicted through the lead angle on the bull gear teeth), this will almost
certainly be the major contributing factor to the failure mechanism being seen.

General view of active flanks of input shaft – note area of overload

Page 29 of 37
15 02 MAN CB - 02

Enhanced view of active flanks of input shaft – note area of overload

Further enhanced view of active flanks of input shaft – note area of overload

Page 30 of 37
 15 02 MAN CB - 02

General view of active flanks of output shaft – note odd longitudinal contact and area of overload

Enhanced view of active flanks of output shaft – note area of overload

Page 31 of 37
15 02 MAN CB - 02

Further enhanced view of active flanks of output shaft – note area of overload

General view of unsuccessful contact test due to inability to static load

Page 32 of 37
15 02 MAN CB - 02

General view of breather / air filter

General view of gear reducer depicting clean seal carriers (void of oil leaks)
Page 33 of 37
15 02 MAN CB - 02

Discussion and Recommendations

Open Gear Drive

To recap on our findings, we have determined during the course of these inspections, the
following:

 The mill and associated gear drive system has been in operation for the last 20 years
(approx.) since installation in 1995.
 Having had no exposure to the drives at Cerro Bayo until August 2014, our comments
and recommendations can only be at best, from that period onward.
 The gear had operated with the original pinion until approximately 18 months ago. The
exact reasoning behind the replacement is a little grey at this point due to the gear being
in as good a condition as it currently is (some photographs of the previously utilised
contact flanks would be useful).
There are a few surface anomalies that require attention so as to arrest any further
degradation as outlined previously.
 The same open gear lubrication, associated delivery system and operating philosophy
has been utilised since the commissioning of the mill and to date, appears to have
served the machine well.
 The active flanks of the girth gear are in remarkable condition for the time that the mill
has been in service and if looked after and remain incident free, should serve well for a
number of years to come.
 Zone #1 of the gear structure was NDT assessed and at the time of assessment, was
deemed to be sound from an MPI inspection perspective (no detrimental surface
discontinuities were uncovered).
 The inactive flank is unused and was found to be in an “as new” condition.

We have determined that the girth gear is sound and suitable for continued use however so as to
ensure or retard the potential of any further degradation, we would highly recommend some
remedial work be carried out to the pinion to relieve any fatigued material that would eventually
lead to progressive pitting and spalling.
It is also recommended that any remedial work be carried out only by an experienced gear
specialist.
If you so desired, we could assist in this area but would provide specific particulars under a
separate cover to this report.

We have determined the SAG mill pinions are symmetrical therefore we also require that the
same clarification be made for the ball mill pinions.
Should they not be symmetrical, there will need to be another replacement pinion manufactured
given that there is no spare available at present.

Please note: as you have no other new spare pinion, if the pinions are in fact not reversible,
Cerro Bayo’s “exposure to risk” profile alters / increases considerably.

Should there be some sort of pinion failure experienced now, we would have to resort to
reinstalling the previously utilised pinion, at least in the short term.
Not knowing the current condition could also present a problem so this also needs to be
ascertained.

Page 34 of 37
15 02 MAN CB - 02

Open Gear Lubrication

Also during our wrap up meeting, the question was posed as to whether I thought the lubricant /
lubrication of the drives is suitable.

This is quite a subjective area and I would prefer this left for the most part, to an alternate forum.
However, I will say that although there are more technologically upmarket lubricants and
dispensing systems available in the market place today, consideration needs to be offered to the
fact that the drives at Cerro Bayo have been operating on the current lubricant and associated
equipment since 1995.

If there is a desire to maintain the existing lubricant, at a minimum, an assessment should be

made as to whether some improvements can be made as far as overall protection of the drive is
concerned.
Again, this is another area that we specialise in and we can assist advice all the way through to
associated equipment supply if required.

Gear Reducer

The overall history surrounding the grinding mill gear reducers at Cerro Bayo remains somewhat
clouded.

During the course of the shutdown in November ‘14, whilst the newly refurbished gear reducer
was being replaced, the soleplates were manually checked for flatness and identified as not being
flat and true (potentially in both planes).

As previously reported, rudimentary assessment was made with a straight edge longitudinally
(parallel to the mill operational centreline) and perpendicular to the rotating members of the
reducer.
The soleplates were found to be notably lower in elevation toward the centreline of the gear
reducer, with the outer extremities obviously higher.
The inboard gap previously measured was in excess of 0.4mm on the inboard side of both
soleplates, which equates to a significant discrepancy across the width of the gear reducer
(coupling face to coupling face – particularly considering the additional output shaft extension).

We have been led to believe by MD personnel during the course of the wrap up meeting that
when the reducer was refurbished in Concepcion, the underside of the case was milled flat and
utilised as a datum (as is typical in new reducer manufacture and refurbishment alike) to the rest
of the re machining tasks that were carried out.
Although there has been no dimensional documentation (MDR / Rebuild report) that has been
made available to support this to date, there were some photographs circulated in a document
that confirmed adequate tooth contact post rebuild (presumably in a relaxed condition).

Given that this is a single reduction parallel reducer, coupled with the fact that the mesh was
confirmed as being acceptable after reassembly at MD (again, presumed in a relaxed condition
with new input and output gears), there clearly have to be other factors that are contributing to the
misalignment of the two members whilst the gear reducer is in operation while the soleplates are
known to be an issue.

Page 35 of 37
15 02 MAN CB - 02

So, if we can rely on the verbal affirmation as being correct, that the datum was established first
and then the rest of the re machining was carried out after this, we can be sure this would
certainly offer a best case scenario toward the best possible outcome as far as the gear reducer
installation is concerned
However when torqued down, the likelihood of a bend or twist being induced into the gear case is
extremely high and not something that can be readily improved by shimming the underside of the
gear reducer landing pads, due to the soleplate irregularities.

Inducing such stresses and resultant twist across the gear case is really the only way that this
mesh could see a misaligned condition and subsequent localised overload to one end of the gear
set, such as we have seen occur with this installation.

Knowing that we have a flatness / trueness issue, there are two potential scenarios that need to
be given consideration to alleviate the problem at hand, otherwise we will continue to see
repeated reducer failures going forward.

1. Removal and replacement of the entire soleplate

2. In situ machining of the existing soleplates to secure flatness and trueness.

At this point in time we believe that the best course of action is to consider option #2 given that it
will be quicker and far less expensive than supply and total replacement of the soleplate even
before we consider the extended down time that would be involved to effect option #1.

There is a requirement to rectify the problem sooner than later and the following should be
considered as a minimum going forward, at least until all issues are resolved:
 If there is an unplanned shutdown experienced, the gear reducer inspection hatch
should be opened and the internals photographed and forwarded to us for immediate
assessment to determine if there is any further degradation taking place.
At a minimum, a quick shut should be planned for a monthly check if possible.
 Have the refurbished reducer shipped immediately to Cerro Bayo from MD (assuming it
has been completed) so that it is available for immediate replacement if required.
 Plan at a minimum to have a quarterly (or in line with scheduled maintenance outages)
inspection carried out relative to the open gears as well as the reducers
 Commence planning with MD (or others) relative to supply of personnel and equipment
to effect the suggested in situ machining at our earliest and most practical opportunity
We can work in tandem or head up any potential rectification works if you so desire us
to do so.
 Procure a second spare gear reducer

As requested by site personnel, I have also obtained a quotation for a drop in replacement
gear reducer from FALK Australia.

This will be submitted as an attachment / appendix to this report

Page 36 of 37
15 02 MAN CB - 02

Conclusion

I believe that we have covered the majority of the tasks that we set out to achieve over the course
of the shutdown and look forward to your response to our submission.
If there are any questions, anything that you may feel that I have missed or anything that we can
be of further assistance with, please don’t hesitate to contact myself at your earliest convenience.

Best regards

Wayne Reader
Australasian Gearing Services

Page 37 of 37