63746_MATERIALDEESTUDIOPARTEIIDIAP67-100

34 AREA 05-PROCESS LINE “A” f)

ShutShut- Down: Down: The motor motor may be shut-do shut-down wn “norma “normally lly”” operating operating either the “Local” or “Remote” “Remote” stop switches switches (PB1-05-0203-2 or PB2-05-0203-2). In addition, the motor will shut down automatically under either of the following conditions: 1.

g)

If oil level in main reservoir reservoir drops drops below a predetermined level.

2.

If oil level in either of the bearing inlet reservoirs drops below a pre-determined level.

3.

If oil level in in both bearing bearing inlet reservoir reservoirs s does not reach a pre-determined level within 10 seconds after initial start – up.

Instrumen Instrumentatio tation: n:

AREA 05-PROCESS LINE “A”

67

AREA: 05-CONCENTRATOR EQUIPMENT Nº AND TITLE:05-0205D-SV REGRIND BALL MILL # 1 PNEUMATIC CLUTCH EQUIPMENT LOCATION DRAWING Nº: 05-30-027 ELEMENTARY AND INTERCONNECTION INTERCONNECTION DRAWING Nº: 05-0205D P&D DRAW ING Nº: 00-50-012 a)

Power Source: 460V “Ball Mills “A” MCC-P5C (05-8903).

b)

Controls: Controls: The clutch utch operatin operating g solenoid valve valve (05-0205D (05-0205D-SV) -SV) is provided with a “Local” Disengage switch (PB1-05-0205D) and a “Remote” control switch is installed in control panel CC-5M which is located in the control room of the “Concentrator Building”. The “Local” control switch is located in Vendor furnished control panel (LC-RA-2).

c)

Status Status Indication: cation: Status Status indication indication is provid provided ed bye means means of of a “Red” engage light and a “Green” disengage light, both of which are integral to the “Remote” control switch (PB2-05-0205D).

d)

Interlocks Interlocks:: The clutch clutch operating operating solenoid solenoid control control circuit circuit is interloc interlocked ked with the “Regrind Ball Mill” motor (05-0205-M) and the “Regrind Ball Mill” compressed air system.

e)

Start-Up Start-Up (Engage) (Engage):: Energizing zing of of the clutch clutch operating operating solenoi solenoid may be initiated ated by operating operating the “Remote” “Remote” engage switch (PB2-05(PB2-050205D). The clutch will engage provided the following conditions are met: 1. “Regrind Ball Mill” #1” motor (05-0205-M) is running. 2. “Regrind Ball Mill” # 1” compressed air is up to operating pressure. 3. All components are functioning normally.

f)

Shut-down Shut-down (Disengage) (Disengage):: The clutch may be be disengage disengaged d “normally” “normally” by operating either the “Local” or “Remote” disengage switches (PB1-050205D). 0205D). In addition, the clutch will disengage disengage automatically automatically under either of the following conditions: 1. If the “Regrind Ball Mil #1” : motor is stopped. 2. If the “Regrind Ball Mill” #1” compressed air drops below operating pressure.

Mgtr. Amador Soto Gallufe – Consultor Intercade

68 AREA 05-PROCESS LINE “A” AREA: 05-CONCENTRATOR EQUIPMENT Nº AND TITLE:05-0205D-H1 REGRIND BALL MILL # 1 LUBE OIL HEATER EQUIPMENT EQUIPMENT LOCATION LOCATION DRAWING Nº: 05-30-027 ELEMENTARY AND INTERCONNECTION DRAW ING Nº: 05-0201C P&D DRAWING Nº: 00-50-012 a)

PowerSource: 460V “Ball Mills “A” MCC-P5C (05-8903).

b)

Controls: The controls controls for for the lube lube oil heater heater consists of a low-level low-level lube oil contact (CR3-05-0205-2) (CR3-05-0205-2),, an oil over-temperature over-temperature switch (TS1-050205-H), all connected in series with the heater contactor coil (42-050205-H)

c)

Status Indication: Indication: Status indication is provided provided bye means of of a “Red” “Red” operating light at the local control panel LC-RA (light is out when heater isoff).

d)

Interlocks: Interlocks: The heater control control circuit rcuit is interlocked interlocked with the “Lube “Lube Oil” system through the low-level switch (LLS-3-05-0205-2) energizing TS105-0205-Hand the heater over-temperatureswitch over-temperatureswitch TS2-05-0205-H. TS2-05-0205-H.

e)

Start-Up Start-Up:: Since Since the only controls ntrols on this heater heater are are the lube oil and heater temperature switches and the oil level relay (CR3-05-0205-2), the heaterwill operate automaticallythe automaticallythe following conditionsare met:

AREA 05-PROCESS LINE “A” 2.

Oil temperature exceeds operating temperature.

3.

Heater temperature exceeds operating temperature.

1. Main breaker power power is on 2. Oil level level in reservo reservoir ir is above above operatin operating g level (CR3-05 (CR3-05-020 -0205-2 5-2 energized). 3. Lube oil temperatureis below operating temperature. 4. Heater temperature temperature is below operating temperature. 5. All componentsare functioningnormally f)

Shut-dow Shut-down n : The heate heaterr may be shut shut off off manually manually bye bye means means of the main power circuit breaker only (at the MCC). MCC). The heater will shut off automaticallyunder either of the following conditions: 1. Oil in reservoir reservoir drops below operating level (CR3-05-0205-2) (CR3-05-0205-2) de energized.


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35 12.0 GRINDING AND FLOTATION 12.5.1 PRIMARY GRINDINGCIRCUITS A&B (cont’d) CONSOLE CC-5M/UA – 5000M Feeder 1A Malf.(motor)alarm Feeder 2A Malf.(motor)alarm Feeder 3A Malf.(motor)alarm Feeder 1B Malf.(motor)alarm Feeder 2A Malf.(motor)alarm Feeder 3A Malf.(motor)alarm Feeder 1A Hydr. Malf.alarm Feeder 2A Hydr. Malf.alarm Feeder 3A Hydr. Malf.alarm Feeder 1B Hydr. Malf.alarm Feeder 2A Hydr. Malf.alarm Feeder 3A Hydr. Malf.alarm

69

12.0 GRINDING AND FLOTATION 12.5.1 PRIMARY GRINDINGCIRCUITS A&B (cont’d)

04-0701-M 04-0702-M 04-0703-M 04-0704-M 04-0705-M 04-0706-M 04-0701-M 04-0702-M 04-0703-M 04-0704-M 04-0705-M 04-0706-M

B. BALL MILL FEED BELL CONVEYORS (04-0602&04-0603) 1) BELT STOPPED ALARM If the belt conveyor stops for any reason, including normal shutdown, the BELT STOPPED ALARM in annunciator UA5000M will activate. 2) EMERGENCY STOP ALARM The belt conveyor is equipped with an emergency stop pullcord located along the path of the belt. The EMERGENCY STOP ALARM in annunciator UA-5000M will activate if the conveyor has been stopped by someone pulling the pulicord switches.

The belt scale system control the feed rate to ball mill feed belt converyors. Both belt scale systems are identical, the first belt scale systems are identical, the first belt scale system serves ball mill feed belt conveyor 04-0602 for grinding circuit “A”, the other serves ball mill feed belt conveyor 04-0603 for grinding circuit “B”. The following operationdescription applies to both feed rate control systems: The ore on the ball mill feed conveyor is weighed by an electronic belt scale. The load-cell-type belt scale is equipped with local feed rate indicator, tonnage totalizer and transmission circuits for remote instrumentation. The belt scale will furnish rwo types of output signals to the grinding control panel, CP-5M/5F; one is an analog signal for remote recording and control, and one is a digital (pulse) signal for remote totalization. Fine ore feed rate is controlled by the feed rate indicating controller which provides a signal to the variable speed drives fo the fine ore feedersthrough bias stations for each feeder unit. The signal is also transmitted to a ratio controller. The feed rate signal multiplied by the set ratio (solids to liquid) will provide the correct water/ore ratio signal which will control the water flow (Gallons per minute). 2. OPERATING CONTROLS (FOR LOCAL CONTROL BOX)

3) ANNUNCIATOR ALARM NUMBERS CONSOLECC-5M/UA-5000M B el t S to pp ed A la rm EmergencyStop Alarm

“A” CKT “B”CKT CONVEYOR CONVEYOR 04- 06 02M 04- 0603M 04-0602M 04-0603M

“Power On-Off” switch. Warning: switch to “Power Off” will erase all belt scale readings. Run, span, zero selector switch Start test (momentary) pushbutton used to clear the calibration counter and to set the test duration counter to zero when running “zero” and “span” calibration test.

C. BELT SCALES (04-4501 & 04-4502) 1) DESCRIPTION OF OPERATION


12.0 GRINDING AND FLOTATION

70

12.0 GRINDING AND FLOTATION 12.5.1 PRIMARY GRINDINGCIRCUITS A&B (cont’d)

12.5.1 PRIMARY GRINDINGCIRCUITS A&B (cont’d) Test duration and calibration counter .

The water flow rate to the ball mill is also recorded at control panel CP-5M/5F.

“Auto zero” momentary pushbutton, only to be used as per v endors instructionfor belt scale calibration.

INSTRUMENT & CONTROL NUMBERS

INSTRUMENT & CONTROL NUMBERS “A” CKT C ON VE YO R FIELD ELEMENTS 04-0602 Weight Element WE-5001 Sp eed Sensor W E/ST-5001 LOCAL CONTROL BOX Feed Rate indicator Tonn ag e to tal ize r Feed rate signal Integrator (A/D)

W I-5001 W QI -50 01B W T-5001 W QY-5001

GRINDINGCONTROL PANEL CP-5M/5F T on ag ge t ot al iz er W QI -5 00 1A F eed r ate r ecor der W R- 500 1 F ee d r at e c on tr ol le r W IC -5 00 1 Ratio station WFI-5001 Bias station SY-5001 ABC

“A” CKT C ON VE YO R 04-0603 WE-5101 W E/ST-5101

W I- 5101 W QI- 5101 B W T-5101 W QY-5101

“A”CKT BALL MILL 0 5- 02 01

“B”CKT BALL MILL 0 5- 02 02

FIELD Flow elemt Flow transmiter Control valve

FE-5002 FT-5002 FV-5002

FE-5102 FT-5102 FV-5102

CONTROLPANEL CP-5M/5F Ratio station Flow controller water Flow recorder water Flow square r oot station

WFI-5001 FIC- 5002 FR-5002 FY- 5002

WFI-5101 FIC- 5102 FR-5102 FY- 5102

1ST STAGE BALL MILLS (05-0201 & 05-0202) W QI -5 10 1A W R- 5101 W IC -5 10 1 WFI-5101 SY-5101 ABC

ORE/WATERRATIO CONTROL SYSTEM (FIC-5002& FIC-5102) DESCRIPTION OF OPERATION: Ore on the ball mill feed conveyor is weighed, speed compensated and feed rate and tonnage is displayed locally and on control panel CP-5M/5F. The 4-20mA rate signal from the scale is also routed to a ratio controller on CP-5M/5F. The rate signal multiplied by fixed ratio (solids to liquid) is used to provide the correct water/ore ratio. This ratio signal is supplied to the water flow controller which regulates water addition to the ball mill.

The process control philosophy for both ball mills is identical. The operationdescription applies to both Ball Mill circuits. BALL MILL DRIVE MOTOR POWER MONITORING The ball mill power draw is measured and transmitted to the concentrator controm room for recording and overload alarm annunciation on control console CC-5M.

FIELD (MCC) Powe primary element Power trasmitter

“ A” C K T “ B” C KT BALL MILL BALL MILL 05-0201 05-0202 JE-5004 JT-5004

JE-5104 JE-5104



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36 71

12.0 GRINDING AND FLOTATION 12.0 GRINDING AND FLOTATION

12.5.1 PRIMARY GRINDINGCIRCUITS A&B (cont’d)

12.5.1 PRIMARY GRINDINGCIRCUITS A&B (cont’d) “ A” CKT C ON VE YO R C ON TR OL P A NE L C P- 5M /5 F 0 5- 02 01 Power recorder JR-5004 O ve rl oa d se tp oi nt s wi tc h J SH – 5 00 4

a. BALL MILL LUBE SYSTEM PACKAGE The following alarm windows are activated from the vendor supplied Lube System Package. For vendor supplied Lube System Package, se Vendor (MINE& SMELTER CORP).Dwg.Nº. 108479.

“A” CKT C ON VE YO R 0 2- 02 02 JR-5101 0 5- 02 02 M

C ONS OLE C C- 5M /UA -500 0M Flow elemt Flow transmiter

2) BALL MILL BEARING TEMPERATURE MONITORING

The monitoring and alarm system is equipped with an integral alar acknowledge and test feature as well as an analog temperature indicator, and individual selector switches to permit direct readings of the equipmenttemperatures and setpoints.

FIELD C oo li ng w at er f lo w s wi tc h

“A” CKT F SL -5 01 5

CONSOLECC-5M/UA-5000M Low Cooling water flow alarm

FAL-5015

“B” CKT F SL -5 11 5

FAL-5115

c. GEAR SPRAY LUBE SYSTEM For information on the automatic gear spray system see Vendor (LINCOLN)drawings:

The first stage Ball Mill Temperature Monitors are located in control panel CP-5M/5F: “A” CKT C ON VE YO R 0 5- 02 02 T I/ TA H- 51 08

“ B” CK T 05-0202 05-0202

b. COOLINGWATER FLOW SWITCH The cooling water flow from each Lube System Package is monitored, and low water flow will activate an alarm on console CC5M.

The temperature monitoring and alarm system for each ball mill continouosly measure and compare the alarm setpoints with actual bearing and motor temperatures. On deaviation from setpoint, the monitor will actuate the annunciator section of the monitor to alert the operator.

“ A” CKT C ON VE YO R C ON TR OL P A NE L C P- 5M /5 F 0 5- 02 01 T em pe ra tu re m on it or T I/ TA H- 50 08

“ A” CK T 05-0201 05-0201

MSI Nº. 204125 & 204126 MSI Nº. 105609 & 105610 4.

BALL MILL AIR CLUTCH SYSTEM For local instrumentsseee Vendor (BARBER GREENE CO.) Dgw. Nº CP-3090

F.

1ST STAGE CYCLONE FEED SUMPS (03-2701 & 03-2702)

3) BALL MILL LUBE SYSTEM

1) LEVEL CONTROL Make water is added to the cyclone feed sumps in order to maintain the desired feed-pulp density. The controlling parameter for makeup water addition is sumplevel.


72 12.0 GRINDING AND FLOTATION




The sump levels and measured with ultrasonic level detectors and are controlled by indicating controllers which regulate the process water control valves.

LOCAL (MCC) P um p N º 2 p ri ma ry e le me nt Pump Nº 2 transmitter

FIELD ELEMENTS Level sensor/transmiter L ev el i nd ic at or /t ra ns mi te r Level control valve

CONTROLPANEL CP-5M/5F P um p N º. 1 c ur re nt i n di ca to r Pum p Nº. 2 transm itter

“A” CKT LE/LT-5006 L IX -5 00 6 LV-5006

CONTROLPANEL CP-5M/5F Sum p level controller LIC- 5006

“B” CKT LE/LT-5106 L IX -5 10 6 LV-5106

FIELD Flow Element Flow transmiter

“A” CKT FE-5005 FT-5005

CONTROLPANEL CP-5M/5F Square r oot extr actor FY- 5005 W ater flow recorder FR-5005 G.

“A” CKT I E – 5 00 7 IT – 5007

“B” CKT I E – 5 10 7 IT – 5107

I I – 5 00 7 II – 5011

I I – 5 10 7 II - 5111

0 5- 15 02 M 0 5- 15 62 M

1ST STAGE CYCLONE CLUSTER (05-0501 & 05-0502) The 1st stage cyclone clusters are equipped with the following pressureg auges: FIELD Input p ressure g aug e Input p ressure g aug e I np ut p r es su re g a ug e ( cl us te r) Input p ressure g aug e Input p ressure g aug e

FY- 5105 FR-5105

The following instrumentation is used to measure and display cyclone feed pump motor current and pump status. LOCAL (MCC) P um p N º 1 p ri ma ry e le me nt Pum p Nº 1 tr ansm itter

H.

“B” CKT FE-5105 FT-5105

1ST STAGE CYCLONE FEED PUMPS (05-1501 & 05-1561) (05-1502 & 05 - 1562)

“B” CKT I E- 51 11 IT-5111

CONTROLCONSOLE CC-5M/UA-5000M N º 1 F ee d P um p M al f. A l ar m 0 5- 15 01 M N º 2 F ee d P um p M al f. A l ar m 0 5- 15 61 M

LIC-5106

2) WATERFLOW RECORDERS The makeup water flow required to maintain sump level, is measured and recorded at the concentrator control room.

“A” CKT L E/ LT -5 00 6 IT-5011

I.

“A” CKT PI- 5009A PI- 5009B P I- 50 09 PI- 5009C PI- 5009D

“B” CKT PI-5109A PI-5109B P I- 51 09 PI-5109C PI-5109D

2ND STAGE BALL MILL WATER CONTROL SYSTEMS (FIC-5027 & FIC-5127) 1.

DESCRIPTION OF OPERATION: The second stage ball mill requires dilution water to adjust pulp density prior to grinding. The water to adjust pulp density prior to grinding. The water flow rate is measured and recorded,and the controller maintains a manually set flow rate.



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37 73 12.0 GRINDING AND FLOTATION


12.5.1 PRIMARY GRINDING CIRCUITS A&B (cont’d) 2)

12.5.1 PRIMARY GRINDING CIRCUITS A&B (cont’d)

INSTRUMENTS & CONTROL NUMBERS

FIELD Flow element Flow transmiter Control Valve

“A” CKT FE-5027 FT-5027 FV-5027

“B” CKT FE-5127 FT-5127 FV-5127

CONTROLPANEL CP-5M/5F Flow controller FIC – 5027 Flow recorder FR – 5027 F low sq uar e ro ot s tat ion F Y – 50 27 J.

C ON SO LE C C -5 M/ UA -5 00 0M Overload alarm Flow transmiter 2.

FIC-5127 FR-5127 F Y- 512 7

2ND STAGE BALL MILLS (05-0203 & 05-0204)

The ball mill power is measured and converted to standard (420mA) signal for recording and overload alarm annunciation at concentrator control room.

C ON TR OL P A NE L C P- 5M /5 F Temperaturemonitor 3.

“A” CKT J E- 5025 JT-5025

CONTROLPANEL CP-5M/5F Power recorder JR-5025 A la rm s et po in t s wi tc h J SH -5 02 5

BALL MILL TEMPERATURE MONITORING The temperature monitoring and alarm system for each ball mill will continuosly measure and compare the alarm set-ponts with actual bearing and motor temperatures. On deviation from setpoint, the monitor will actuate the annunciator section of the monitor to alert the operator to the alarm source.

The second stage Ball Mill temperature monitors are located in control panel CP-5M/5F:

BALL MILL DRIVE MOTOR POWER MONITORING

FIELD (MCC) P ow er p ri ma ry e lem ent Flow transmiter

“B” CKT 0 5- 02 04 JAH-5125 05-0204M

The temperature monitoring and alarm system is quipped with and integral alarm acknowledge and test feature, as well as an analog temperature indicator and individual selector switches to permit direct readings of the equipmenttemperature.

Both second stage ball wills have indentical process control philosophy, and the same operation description applies to both ball mill circuits. 1)

“A” CKT 0 5- 02 03 JAH-5025 05-0203M

“B” CKT JE -512 5 JT-5125

“ A” C K TI/TAH-5026

“ B” C KT TI/TAH-5126

BALL MILL LUBE SYSTEM a. BALL MILL LUBE SYSTEM PACKAGE The following alarm windows are activated from Vendor supplied Lube System Package. For instrument inside the Lube system Package see Vendor (MINE & SMELTER CORP.) Dwg. Nº 108479.

JR-5125 J SH -5 12 5

C ON SO LE C C -5 M/ UA -5 00 0M Lube sys. Filter Dirty-Alarm Lube Oil Malf . Alarm

“ A” CK 05-0203 05-0203

“ B” C KT 05-0204 05-0204




12.5.1 PRIMARY GRINDING CIRCUITS A&B (cont’d) b.


COOLINGWATER FLOW SWITCH The cooling water flow from each Lube System Package is monitored, and low water flow will activate an alarm on console CC-5M. FIELD Cooling water flow switch

c.

“A” CKT FLS-5040

“B” CKT FLS-5140

CONSOLE CC-5M/UA -5000M Low cooling water flow alarm FAL-5040

FAL-5140

The sump levels and measured with ultrasonic level detectors and are controlled by indicating controllers which regulate the process water control valves. FIELD Level sensor/transmiter L ev el i nd ic at or /t ra ns mi te r Level control valve

CONTROLPANEL CP-5M/5F Sump l evel controller LIC-5030

GEAR SPRAY LUBE SYSTEM For information on the automaticc gear spray system see Vendor (LINCOLN)drawings:

K.

FIELD Flow Element Flow transmiter

BALL MILL AIR CLUTCH SYSTEM For local instruments see Vendor (BARBER GREENE CO.) Dwg. Nº CP—3090.

The sump levels are measured witch ultrasonic level detectors and are controlled by indicating controllers which regulate the processwater control valves.

LIC- 5130

“A” CKT FE-5029 FT-5029

CONTROLPANEL CP-5M/5F Square r oot extractor FY-5029 W ater flow recorder FR-5029

2ND STAGE CYCLONE FEED SUMPS (03-2705 & 03-2706) 1) LEVEL CONTROL Makeup water is added to the cyclone feed sumps in order to maintain the desired feed-pulp density, The controlling parameter for makeup water addition is sump level.

“B” CKT LE/LT-5130 L IX -5 13 0 LV-5130

2) WATER FLOW RECORDERS The makeup water flow, used to maintain sump level, is continuosly measuredand is recorded at the control room.

MSI Nº. 204125 & 204126 MSI Nº 105609 & 105610 4.

“A” CKT LE/LT-5030 L IX -5 03 0 LV-5030

L.

“B” CKT FE-5129 FT-5129

FY-5129 FR-5129

1ST STAGE CYCLONE FEED PUMPS (05-1503 & 05-1563) (05-1504 & 05 - 1564) The following instrumentation is used to measure and display cyclone feed pump motor current and pump status: LOCAL (MCC) P um p N º 1 p ri ma ry e le me nt P um p N º 1 f ie ld t ra ns mi tt er P um p N º 2 f ie ld t ra ns mi tt er P um p N º 2 f ie ld t ra ns mi tt er

“A” CKT I E – 5 00 7 I T – 5 03 1 I E – 5 03 3 I T – 5 03 3

“B” CKT I E – 5 13 1 I T – 5 13 3 I T – 5 13 3 I T – 5 13 3



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38 75 12.0 GRINDING AND FL>OTATION



12.5.1 PRIMARY GRINDINGCIRCUITS A&B (cont’d) C ON TR OL P A NE L C P- 5M /5 F P um p Nº 1 cur rent i ndi cat or P um p N º 2 c ur re nt i nd ic at or

“ A” C KT I I- 5031 I I- 50 33

CONTROL CONSOLE CC-5M/UA-5000M N º 1 F ee d P um p m al f. A l ar m N º 2 F ee d P um p m al f. A l ar m

0 5- 15 03 M 0 5- 15 04 M 0 5- 15 63 M 0 5- 15 64 M

M. 2ND STAGE CYCLONE CLUSTER (05-0503 & 05-0506) The second stage cyclone clusters are equipped with the following pressure gauges: FIELD Input P ressur e Gauge Input P ressur e Gauge Input P ressur e Gauge Input P ressur e Gauge InputPressure Gauge (cluster) Input P ressur e Gauge Input P ressur e Gauge Input P ressur e Gauge N.

C ON TR OL P A NE L C P- 5M /5 F pH probe pH transmitter Solenoid valve Control valve

“ B” C KT I I- 5131 I I- 51 33

“A” CKT PI-5032A PI-5032B PI-5032C PI-5032D PI-5032 PI-5032E PI-5032F PI-5032G

“ B” C KT AE-5135 AT-5135 AEV-5035 AV-5135

2. TANK AGITATOR ALARMS CONSOLECC-5M/UA-5000M Agitator Malf . Alarm O.

“B” CKT PI-5132A PI-5132B PI-5132C PI-5132D PI-5132 PI-5132E PI- 5132F PI-5132G

05-2001M

05-2002M

ROUGHERFLOTATION FEED SUMP (05-2711 & 05-2712) Ph INSTRUMENTATION The pH measurement signal for each feed sump is transmited to the control panel where it is alarmed (high & low pH) and recorded. FIELD pH probe pH transmitter

CONDITIONERTANK (05-1201 & 05-1202) 1. pH CONTROL SYSTEM The milk of lime addition to the conditioning tanks is based on ph measurement in the overflow box of each tank. The pH-signal is sent to a controller and recorder in control panel CP-5M/5F. The controller operates a solenoid valve, wich in turn actuates the milk of lime control valve.

“ A” C KT AE-5035 AT-5035 AEV-5035 AV-5035

“A” CKT AE-5401 AT-5401

“B” CKT AE-5421 AT-5421

CONTROLPANEL CP-5M/5F pH recorder high/low pH setpoint switch

AR-5401 ASH/L5401

AR-5421 ASH/L-5421

CONSOLECC-5F/UA-5400F High/low pH alarm

AAH/L-5401

AAH/L-5421

P. FINE ORE STORAGE DUST COLLECTOR (04-0801) (AREA 04) The following instruments are part of the dust collection control system:


12.5.2 ROUGHER/SCAVENGER FLOTATION

12.5.1 PRIMARY GRINDING CIRCUITS A&B (cont’d) FIELD Slurry tank level sensor Low water flow switch

FE-5127 FT-5127

CONSOLECC-5M/UA-5000M Low water flow alarm

76



A. ROUGUERI FLOTATION CELLS Rougher I consists of two (2) banks of flotation cells for each circuit. The level of each bank is measured by a static pressure type level probe. Two dart valves, for level adjustment, are controlled automatically by the level control signal. The system also has a manual control option.

FAL-4013

The level controller for each bank is mounted close to the dart valves. All dart valves will fail open upon instrument air failure. See Vendor (WEMCO)drawing Nº 8041680-14 for moreinformation.

Q. ANNUNCIATOR/ALARMSYSTEMS The alarms for primary grinding circuits are annunciated on UA5000M.See drawing Nº 05-40-014.

( BAN K 1)

( BAN K 2)

( BAN K 1)

( BAN K 2)

B.

F IE LD “ A” CK T l ev el c ont rol ler l ev el con tr ol v al ve level control valve

NUM BER 05- 2601 t hr u 05-2603

N UM BE R L IC -5403 L V- 5403A LIC-5403B

l ev el c ont rol ler l ev el con tr ol v al ve level control valve

05- 2604 t hr u 05-2606

L IC -5404 LV -540 3A LIC-5404B

FIELD “B” CKT l ev el c ont rol ler l ev el con tr ol v al ve level control valve

05- 2607 t hr u 05-2609

L IC -5423 L V- 5453A LIC-5423B


05- 2610 t hr u 05-2612

L IC -5424 LV -542 4A LIC-5424B

ROUGHER II FLOTATION CELLS 1) LEVEL CONTROL Rougher II consists of two banks of flotation celis for each circuit. The level of each bank is measured by a static pressure type level probe. Two dart valves (for level adjustment) are controlled automatically by the level control signal. The system also has a manual control option.



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12.5.2 ROUGHER/SCAVENGER FLOTATION cont`d


A. ROUGUERI FLOTATION CELLS The level controller for each bank is mounted locally close to the dart valves. All dart valves will fail open upon instrument air failure. See Vendor (WEMCO)drawing Nº 8041680-14.

( BAN K 1)

( BAN K 2)

( BAN K 1)

( BAN K 2)

2)

A. ROUGUERI FLOTATION CELLS CONTROL PANEL CP-5M/5F “A” CKT pH recorder “A”CLT pH high/lo w pH setpoin t swit ch “B” CKT pH recorder “B”CKT pH high/low pH setpoint swit ch

AR-5407 ASH/L-5407 AR-5427 ASH/L5427

CONTROLCC-5F/UA-5400F “A” C KT high/low pH alarm “B” C KT high/low pH alarm

AAH/L- 5407 AAH/L- 5427

F IELD “ A” C KT l ev el c ont rol ler l ev el co ntr ol v al ve level control valve

CE LL NUM BER 05 -261 5 t hr u 05-2618

I NS TRUM ENT NUM BER LIC -540 5 LV -54 05A LV-5405B

l ev el c on tr ol le r l ev el co ntr ol v al ve level control valve

0 5- 26 19 t hr u 05-2622

L IC -5 40 6 LV -54 06A LV-5406B

FIELD “B” CKT l ev el c ont rol ler l ev el co ntr ol v al ve level control valve

05 -262 3 t hr u 05-2609

LIC -542 5 LV -54 25A LV-5423B

C. SCAVENGER I FLOTATION CELLS 1)LEVEL CONTROL Scavenger I consist of two (2) banks of flotation cells for each circuit… The level of each bank is measured by a static pressure type level probe. Dart valves (for level adjustment) are controlled automatically by the level control signal. The system also has a manual control option.

l ev el c ont rol ler l ev el co ntr ol v al ve level control valve

05 -261 0 t hr u 05-2612

LIC -542 6 LV -54 26A LV-5426B

The level controller for each bank is mounted locally close to the dart valves. All dart valves will fail open upon instrument air failure. See Vendor (WEMCO) drawing Nº. 8041680-14.

pH INSTRUMENTATION The pH measurement signal for flotation cells is transmitted to the control panel where it is alarmed (high/low)and r ecorded. CELL NUMBER 0 5- 26 15 t hr u 2 61 8 05-2615 thru 2618 0 5- 26 23 t hr u 2 62 6 05-2623 thru 2626

FIELD “A” CKT “ A” C K T p H p ro be “A”CKT pH transmitter “ B” C K T p H p ro be “B”CKT pH transmitter

INSTRUMENT NUMBER A E- 54 07 AE-5407 A E- 54 27 AE-5427

FIELD “A” CKT Level controller Level control valve Lev el control valv e

CELL NUMBER 05-2633 thru 05-2636

Level controller Level control valve Lev el control valv e

05-2637 thru 05-2640

INSTRUMENT NUMBER LIC-5408 LV-5408A LV- 5408B LIC-5409 LV-5409A LV- 5409B



2)

FIELD “B” CKT Level Controller Level Control valve Level Contr ol v alve

CELL NUMBER 05-2641 thru 05-2641

Level Controller Level Control valve Level Control valve

05-2645 thru 05-2648

78



12.5.2 ROUGHER/SCAVENGER FLOTATION (cont’d) INSTRUMENT NUMBER LIC-5428 LV-5428A LV-5428B

D.

SCAVENGER II FLOTATION Scavenger II consist of three (3) banks of flotation cells for each circuit. The level of each bank is measured by a static pressure type level probe. Dart valves (for level adjustment) are controlled automatically by the level control signal. The system also has a manual control option.

LIC-5429 LV-5429A LV-5429B

The level controller for each bank is mounted locally close to the dart valves. All dart valves will fail open upon instrument air failure. See Vendor (WEMCO)drawing Nº. 8041680 – 14.

pH INSTRUMENTATION F IE LD “ A” CK T l ev el c ont rol ler l ev el con tr ol v al ve level control valve

CE LL NUM BER 05- 2649 t hr u 05-2651

I NS TRUM ENT N UM BE R L IC -5410 L V- 5410A LV-5410B

( BAN K 2)


05- 2652 t hr u 05-2654

L IC -5411 LV -541 1A LV-5411B

( BAN K 3)

l ev el c on tr ol le r l ev el con tr ol v al ve level control valve

0 5- 26 55 t hr u 05-2658

L IC -5 41 2 LV -541 2A LV-5412B

FIELD “B” CKT l ev el c on tr ol le r l ev el con tr ol v al ve level control valve

0 5- 26 59 t hr u 05-2661

L IC -5 43 0 LV -543 0A LIV-5430B


0 5- 26 65 t hr u 05-2668

L IV -5 43 2 LV -543 2A LV-5432B

The pH measurement signal for flotation cells is transmitted to the control panel where it is alarmed (high/low)and recorded. ( BAN K 1) FIELD “ A” C K T p H p ro be “A”CKT pH transmitter “ B” C K T p H p ro be “B”CKT pH transmitter

CELL NUMBER 0 5- 26 37 t hr u 2 64 0 05-2637 thru 2640 0 5- 26 45 t hr u 2 64 8 05-2645 thru 2648

CONTROL PANEL CP-5M/5F “A” CKT pH recorder “A”CKT high/low ph setpoint switch “B”CKT high/low ph setpoint switch “B” CKT pH recorder

INSTRUMENT NUMBER A E- 54 13 AE-5413 A E- 54 33 AE-5433

AE-5413 ASH/L-5413 ASH/L-5433 AR-5433 ( BAN K 1)

CONSOLECC-5F/UA-5400F “A” CKT high/low pH alarm “B” CKT high/low pH aarm

AAH/L-5413 AAH/L-5433

( BAN K 2)

E.

ENNUNCIATOR/ALARMSYSTEMS The alarms for rougher/scavenger flotation are annunciated on UA-5400F. See drawing Nº. 05-40-015



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12.5.3 CLEANER FLOTATION & REGRIND

12.5.3 CLEANER FLOTATION & REGRIND (cont’d)

A. REGRINDCOLLECTION SUMP (05-2722) Makeup water is added to the collection sump to maintain the desired feed-pulp density. The selected flow rate is set from manual controller located on control panel CP-5M/5F.

The feed sump level is maintained by adding fresh water to the sump. The ultrasonic level sensor measures the sump level and supplies level signal to the level controller. The flow of the fresh water is also measured and the flow r ate is displayed on the control oanel.

The sump level is measured by an ultrasonic level detector; high and low level alarms are displayed on the control console in concentrator control room.

FIELD INSTRUMENTS Level sensor/transmitter L ev el i nd ic at or /t ra ns mi tt er Water control valve Water flow sensor W ater f low transmitter

The status of the three regrind transfer pumps is monitored, and alarm will be annunciated if any one of the three pumps malfunction. One pumpis stand-by. FIELD INSTRUMENTS S on ic l ev el se nso r/t ra nsm itt er S um p l ev el i nd ic at or & t ra ns mi tt er High setpoint switch Low setpoint switch Water control valve

L E/ LT- 5205 L IX -5 20 5 LSH-5205 LSL-5205 HV-5200

B.

SUMP 05-2714 LE/LT-5222 L IX -5 22 2 LV-522 FE-5223 FT-5223

REGRINDCYCLONE FEED PUMPS (05-1505 & 05-1565) (05-1506 & 05-1566) The following instrumentation is used to measure and display cyclone feed pump motor current and pump status:

CONSTROLPANEL CP-5M/5F Process water controller

HIC-5200

CONSOLECC-5M/UA-5000M Sump level high alarm Sump level low alarm Transfer p ump #1 malf. alarm Transfer p ump #2 malf. Alarm Transfer p ump #3 malf. Alarm B.

SUMP 05-2713 LE/LT-5212 L IX -5 21 2 LV-5212 FE-5213 FT-5213

FIELD (MCC) Pump N º. 1 prim . elem ent Pump Nº. 1 transmitter Pum p Nº. 2 prim. elem ent Pump Nº. 2 transmitter

LAH-5205 LAL-5205 05-145OM 05-1541M 05-1570M

SUMP 05-2713 IE-5218 IE-5218 IE- 5219 IT-5219

SUMP 05-2714 IE-5228 IE-5228 IE- 5229 IT-5229

REGRINDCYCLONE FEED SUMPS (05-2713 & 2714) The two feed sump level control systems are identical and this operationdescription applies to both sumps.





C ON TR OL P A NE L C P- 5M /5 F Pu mp N º. 1 cu rr en t indi cat or L ev el i nd ic at or /t ra ns mi tt er

D.


SUMP 0 5- 27 13 I I - 521 8 I I - 5 21 9

SUMP 0 5- 27 14 I I - 52 28 I I - 5 22 9

1)

REGRINDCYCLONE CLUSTERS (05-0509 & 05-0510) The regrind cyclone clusters are equipped with the following pressure gauges:

FIELD Input p ressure g auge Input p ressure g auge Input p ressure g auge I np ut p r es su re g a ug e ( cl us te r) Input p ressure g auge D.

BALL MILL I C LU ST ER 05-0509 PI-5214A PI-5214B PI-5214C P I- 52 14 PI-5214D

BALL MILL II C LU ST ER 05-0510 PI-5224A PI-5224B PI-5224C P I- 52 24 PI-5224D

REGRINDCYCLONE MILLS (05-0205 & 05-0206) The process control philosophy for both ball mills is identical and the same operation description applies to both Ball Mill control systems.

2)

BALL MILL DRIVE MOTOR POWER MONITORING The ball mill power is measured and converted to standard (4-20 mA) signal for recording and overload alarm annunciation at control room.

FIELD (MCC) Power prim ary elem ent Power transmitter

BALL MILL I 05-0205 JE-5210 JT-5210

BALL MILL II 05-0206 JE-5220 JT-5220

CONTROLPANEL CP-5M/5F Power recorder Ov er loa d set poi nt sw it ch

JR-5210 JS H- 5210

JR-5220 J SH -522 0

CONSOLECC-5M/UA-5000M Overload alarm Failur e (motor) alarm

JAH-5210 05-0205M

JAH-5220 05- 0206M

BALL MILL TEMPERATURE MONITORING The temperature monitoring and alarm system for each mill will continuosly measure and compare the alarm setpoints with actual bearing and motor temperatures. On deviation drom setpoint the monitor will actuate the annunciator section of the monitor to alert the operatorto the alarm source. The monitoring and alarm system us equipped with an integral alarm acknowledge and test feature, and an analog temperature indicator and individual selector switches, to permit direct readings of the equipment temperatures. The regrind Ball Mill Temperatures Monitors are located in control panel CP-5M/5F:



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12.5.3 CLEANER FLOTATION & REGRIND cont’d


FIELD T em pe ra tu re m on it or 3)

BALL MILL I 05-0205 T I/ TA H- 52 11

a. LUBE OIL SYSTEM PACKAGE The following alarm windows are activated from Vendor supplied Lube System Package. For instruments inside the Lube System Package see Vendor (MINE & SMELTER CORP) drawing Nº 108479. BALL MILL I BALL MILL II C ON SO LE C C -5 M- UA -5 00 0M 0 5- 02 05 0 5- 02 02 Lube Sys. Filter Dirty-alarm 05-0205 05-0206 Lube Oil Malf. alarm 05-0205 05-0206 COOLINGWATER FLOW SWITCH The cooling water flow from each Lube Oil System Package is monitored by a flow switch. Low water flow will activate an alarm in the control room.

CONSOLECC-5M/UA-5000M Low water f low alarm

4)

BALL MILL II 05-0202 TI /T AH -5 22 1

BALL MILL LUBE SYSTEM

FIELD C oo li ng w at er f lo w s wi tc h

81


BALL MILL I 05-0205 F SL -5 21 6

BALL MILL II 05-0202 0 5- 52 26

FAL-5216

FAL- 5226

BALL MILL AIR CLUTCH SYSTEM For local instruments see Vendor (BARBER GREENE CO.) drawing Nº CP-3090.

F. CONCENTRATE SCAVENGER I SUMP (05-2727) LEVEL CONTROL The sump level is measured by ultrasonic level detector. This level signal is used to Start/Stop vertical sump pumps as well as to generatehigh level alarm at the control room. One pump is stand-by. FIELD S oni c l ev el s ens or /t rans mi tte r S um p l ev el i nd ic at or & t ra ns mi tt er High/low setpoint switch High setpoint switch Pump selector switch

LE /L T- 548 8 L IX -5 48 8 LSH-L-5488 LSH-5488 HS-5488

CONSOLECC-5F/UA-5400F Sump level high alarm

LAH-5488

G. 1ST CLEANER FEED SUMP (05-2717) 1) LEVEL CONTROL The sump level is measured by ultrasonic level detector. This level signal is used to Start/Stop vertical sump pumps as well as to generate high level alarm at the control room. One pump is standby.

C. GEAR SPRAY LUBE SYSTEM For information on the automotive gear spray system, see Vendor (LINCOLN)drawing: MSI Nº. 204125 & 204126 MSI Nº. 105609 & 105610

FIELD S oni c l ev el s ens or /t rans mi tte r S um p l ev el i nd ic at or & t ra ns mi tt er High/low setpoint switch High setpoint switch Pump selector switch

LE /L T- 548 5 L IX -5 48 5 LSH-L-5485 LSH-5485 HS-5485

CONSOLECC-5F/UA-5400F Sump level high alarm

LAH-5485





I. 1ST AND 2ND CLEANER FLOTATION CELLS The 1st and 2nd cleaner consist of two (2) banks is measured by an static pressure type level probe. Dart valves (for level adjustment) are controlled automatically by the level control signal. The system has a manual control option.

2) pH INSTRUMENTATION The pH measurement signal from the sump is transmitted to the control room whereit is alarmed (high/low) and recorded.

H.

FIELD pH probe pH transmiter

AE-5436 AT-5436

CONTROLPANEL CP-5M/5F pH recorder h ig h/l ow p H set poi nt sw it ch

AR-5436 AS H/ L- 5436

The level controller for each bank is mounted locally close to the dart valves. All dart valves will fail upon instrument air failure.

( BAN K 1)

2ND AND 3RD CLEANER FEED SUMP (05-2718 & 05-2719) LEVEL CONTROL The sump level is measured by ultrasonic level detector. This level signal is used to start/stop vertical sump pumps as well as to generate high level alarm at the contro room. One pump is standby.

FIELD Sonic level sensor/trans Sumplevel indicator & trans High/low setpoint switch Pump s elector switch

( BAN K 2)

2ND CLEANER 3RD CLEANER (05-2718) (05-2719) SUMP SUMP LE/LT-5486 LE-LT-5487 LIX – 5486 LIX-5487 LSH/L-5486 LSH/L-5487 HS-5486 HS-5487

( BAN K 1)

( BAN K 2)

J.

CONSOLECC-4F/UA – 5400F Su mp l ev el h ig h al ar m

LA H- 5486

82


LA H- 5487

F IE LD ( 1S T C LN ) l ev el c ont rol ler l ev el con tr ol v al ve level control valve

C EL L N UM BE R 05- 2672 t hr u 05-2675


05- 2675 t hr u 05-2675

L IC -5439 LV -543 9A LV-5439B

FIELD (2ND CLEANER) l ev el c on tr ol le r 0 5- 26 82 l ev el con tr ol v al ve t hr u level control valve 05-2685

L IC -5 44 1 LV -544 1A LIV-5441B


L IV -5 44 2 LV -544 2A LV-5442B

0 5- 26 86 t hr u 05-2688

I NS TR UM EN T N UM BE R L IC -5438 L V- 5438A LV-5438B

3RD CLEANER FLOTATION CELLS (05-2692 through 05-2695) 1)

LEVEL CONTROL The 3rd cleaner consist of one (1) bank of flotation cells. The level of the bank is measured by an static pressure type level probe. Dart valves (for level adjustment) are controlled automatically by the level control signal. The system has a manual control option.



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42

12.5.3 CLEANER FLOTATION & REGRIND cont`d The level controller for the bank is mounted locally close to the dart valves.All dart valves will fail open upon instrument air failure.

2)

A.

CONCENTRATE THICKENER (05-1203) Thickener instrumentation includes overtorque shutdown switches, and a torque recorder.

alarms,

safety

The concentrate a thickener discharge rate is controlled manually by the setting of the underflow discharge valve. Thickener dirve motor and the two underflow pumps are alarmed for motor malfunction-

pH INSTRUMENTATION The pH measurement signal from the flotation cells is transmitted to the control panel where it is alarmed (high/low pH) and recorded.

K.

12.5.4 THICKENING AND FILTERING

INSTRUMENT NUMBER LIC-5447 LV-5447A LV-5447B

FIELD “B” CKT Level Controller Level Control valve Level Control valve

83



F. CONCENTRATE SCAVENGER I SUMP (05-2727) LEVEL CONTROL The sump level is measured by ultrasonic level detector. This level signal is used to Start/Stop vertical sump pumps as well as to generate high level alarm at the control room. One pump is stand-by. FIELD INSTRUMENTS Rake torque sensor Rake torque indicator and transmitter High-High torque switch High torque switch Motor torque indicator

FIELD pH probe pH transmitter

AE-5445 AT-5445

PANEL CP-5M/5F pH recorder high/low ph setpoint switch

AR-5445 ASH/L-5445

CONSOLECC-5F/UA-5400F High/low pH alarm

AH/L-5445

OE-5450 OIT-5450 OSHH-5451 OSH-5453 OI-5452

CONTROL PANEL CP-5M/5F Rake torque recorder High torque a setpoint switch

ANNUNCIATOR/ALARMSYSTEMS The alarms for Regrind area are annunciated on UA-5000M. See drawing Nº 05-40-014. Alarms for Cleaner Flotation area are displayed on UA-5400F. See drawing Nº 05-40-015

OR-5450 OSH-5450

CONSOLE CC-5F/UA – 5400F High torque alarm Drive motor malf. Alarm U’flow pump #1 malf. alarm U’flow pump #2 malf. Alarm

OAH-5450 05-2101M 05-1521M 05-1522M

FIELD Capacitance level probe High/ow setpoint switch

LE/5456 LSH/L-5456

CONTROL CONSOLE CC-5F/UA-5400F Low level alarm High level alarm

LAL-5456 LAH-5456


12.0 GRINDING AND FLOTATION 12.5.4 THICKENING AND FILTERING (cont’d) C.

12.5.4 THICKENING AND FILTERING (cont’d)

CONCENTRATE FILTERS (05-2301 & 05-2302) The filter feed Distributor gravity feeds the two concentrate drum filters, the feed rate to each drum filters is manually adjusted. If one of the filters is shutdown, an air actuated shut-off valve will close off the corresponding drum filter feed line. The liquid level of each filter is measured by a capacitance type level switch wich will transmit high and low level alarms to console CC-5F.

FIELD (COMPRESSORROOM) Seal water pres.switch(ala rm) Seal water pres.switch (shutdown) S ea l w at er s ol en oi d v al ve S ea l w at er s ol en oi d v al ve E.

A high filter cake storage level will be detected by a tilt switch, wich will then activate corresponding alarm on console CC-5F. Filter failure alarms are also displayed on the annunciator.

FIELD INSTRUMENT Shut-off valve Shut-down h and switch C ap ac itan ce l ev el p rob e High/low setpoint switch Tilt switch

FILTER #1 05-2301 HV-5457 HS-5457 LE- 5458 LSH/L-5458 LSH-5481

CONTROLCONSOLE CC-5F/UA-5400F Low level alarm LAL-5458 High level alarm LAH-5458 H ig h s to ra ge l ev el a la rm L AH -5 48 1 Filter failure a larm 05- 2301M D.

84


FILTER #2 05-2302 HV-5459 HS-5459 LE -546 0 LSH/L-5460 LSH-5482

F.

P UM P #1 05-1536 PSL-5464 PSL-5465 E V- 54 70 A E V- 54 70 B

PU MP #2 05-1537 PSL-5474 PSL-5475 E V- 54 80 A E V- 54 80 B

VACUUM RECEIVERS (05-1401 & 05-1402) Both vacum receivers are equipped with pressure gauges and pressure transmitters. The receiver v acuum is displayed on control panel CP-5M/5F.

FIELD (COMPRESSORROOM) Pressure transmitter

RECEIVER PT-1401 PT-5468

CONTROLPANEL CP-5M/5F Vacuum receiverpres.indicator

PI-5468

RECEIVER PT-1408 PT-5478

PI-5478

ANNUNCIATOR / ALARM SYSTEMS The alarms for Thickening and Filtering are annunciated on UA5400F. See drawing Nº- 05-40-015

LAL-5460 LAH-5460 L AH -5 48 2 05- 2302M

VACUUM PUMPS (05-1536 & 05-1537) The filtration vacuum pumps, together with the drum filter blower and air compressors,are located in the compressorroom. The vacuum pumps are equipped with local protectiv e instrumentation and safety shutdown interlocks. The seal water supply is equipped with low pressure alarm safety shutdown switches. Both vacuum pumps will activate alarms in control console CC-5F on pump motor malfunction.



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43 12.0 GRINDING AND FLOTATION 12.5.5 TAILINGS AND WATER TANKS A. TAILINGS THICKENER (06-1201) Tailings thickener instrumentation includes overtorque alarms, safety shutdownswitches, and torque recorder.

12.5.5 TAILINGS AND WATER TANKS cont’d C.RECLAIM WATER PUMPS (06-1501, 1502, 1503 & 1504) The four reclain water pumps, which deliver water to the Process W ater Tank (00-1202), are controlled by level signals from the process water tank. A sequential controller, located in MCC Room #6, controls the start/stop sequence of each pump. All pumps will shutdown on low level in settling pond or no high-high level in Process Water Tank (00-1202).

The tailings thickener discharge rate is controlled by manual setting of the U’flow discharge valve. Remote recording and control instrumentation for the tailings thickener are located in the concentrator control room. An alarm condition will be signaled on control console CC-5F if the thickener drive motor malfunctions. FIELD INSTRUMENTS Rake torque sensor Rake torque transmiter H ig h t or qu e s wi tc h ( no rm al o v er lo ad ) High-hightorque switch(motorshutdown) Horn silence pushbotton Stalled overload indicating ligth and horn normal overload indicating light Hightorque switch(overloadshutdown) CONTROLPANEL CP-5M/5F Thickener torque recorder High torque setpoint switch

FIELD INSTRUMENTS (AT SETTLING POND) Level sensor element

LE-6016

OE-6001 OY-6001 O SH -6 00 2 OSHH-6003 HS-6004

Low level switch

LSL-6016

OSH-6001A

Control Philosophy: Low level: start one pump High level: stop one pump High – high level: stop all pumps

LOCAL INSTRUMENTS (MCC ROOM #6) Sequential controller for pumps (06-1501,02, 03 & 04)

OR-6001 OSH-6001 D.

CONTROLCONSOLE CC-5F/UA-5400F High torque alarm Drive motor malf. Alarm B.

PROCESS WATER TANK (00-1202) The process water tank is equipped with a level gauge board and a differential pressure-type level transmitter. The 4-20mA tank level signal is transmitted to concentrator control room where it is recorded and annunciated for high and low alarm conditions.

OAH-6001 06-2101M

RECLAIM WATER SETTLING POND (00-2101) Makeup water is added to settling pond in order to replenish water lost to process. The makeup water flow is controlled by a local level controller actuating the electrically operated makeup water control valve. FIELD INSTRUMENTS Level sensor element Level transmitter Level controller Level control valve

85


In addition, the level signal is routed from the concentrator control room to MCC Room #6 (reclain water settling pond), where it is displayed and used to generate the sognal for the reclaim water pumpsequential control.

LE-6010 LT-6010 LC-6010 LV-6010




12.5.5 TAILINGS AND WATER TANKS cont’d

12.5.5 TAILINGS AND WATER TANKS cont’d

FIELD INSTRUMENTS (AT TANK) Level gauge board Tank l ev el in id icat or & t ran sm itt er LOCAL INSTRUMENTS (AT MCC #6) Tank level indicator Low l ev el sw it ch ( sta rt s one p um p) Hi gh l ev el s wi tc h (s to ps one p um p) High-highlevel switch(stops all pumps)

LI-0004 L SL -000 4 L SH -000 4 LSHH-0004

CONTROLPANEL CP-5M/5F Tank level recorder High/low lev el setpoint switch Tank at low level – ligth; semi-graphic Tank at high level – ligth; semi-graphic CONTROL CONSOLE CC-5M/UA-5000M High level alarm Low level alarm

FIELD INSTRUMENTS (AT TANK) Level gauge board Tan k l ev el i ni di ca tor & tr ansm it ter High/low level switch Level control valve Flow switch

LI-0003 LI T- 000 4

LR-0004 LSH/L-0004

LAH-0004 LAL-0004

F.

E. FIRE PROTECTION (AND FRESH WATER) TANK (00-1201) The fire and fresh water tank is equipped with a level gauge board and a differential pressure type level transmitter. The tank level signal is transmitted to concentrator control room where the tank level is recorded and annunciated for high and low level alarm conditions. In addition, a conductivity type level switch is used to sense the tank level to control (open/ close) motorized valve for adding river water. An electrically controlled valve is provided on the supply line to the fire protectiontank as no instrumentair is available. The eight inch diameter fire protection water linea leaving the tank is equipped with a flow switch. On high water flow rate, this switch will annunciate any usage of emergency water and will also serve as a fire alarm.

CONTROLPANEL CP-5M/5F Tank level recorder Tank at low level – light; semi-graphic Tank at high level – ligth; semi -graphic High/low level setpoint switch

LSHH-0002

CONTROLE CONSOLECC-5M/UA-5000M High level alarm Low level alarm High water flow alarm

LAH-0002 LAL-0002 FAH-0006

LAH-0002

POTABLE WATER TANK (00-1203 & 00-1204) Each Potable Water Tank is eqquiped with a level gauge board and an altitude type level control valve.

FIELD Level gauge boad Pilot valve Level control valve G.

LI-0001 LI T- 0002 LSH-L0005 LV-0005 FSH-0006

TANK 00-1203 LI-0017 LV-0016 LCV-0016

TANK 00-1204 LI-0019 LV-0018 LCV-0018

ANNUNCIATOR/ALARM SYSTEMS The alarms for Tailings Thickener area are annunciated on UA5400F. See drawing Nº 05-40-015. Alarms for Water Tanks are annunciated on UA-5000M. See drawing Nº 05-40-015.



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44 87 12.0 GRINDING, FLOTATION, THICKENING AND FILTERING

12.0 GRINDING, FLOTATION, THICKENING AND FILTERING

12.6 PROTECTIVE RELAYS

12.7 ELECTRICAL INTERLOCKS

In general, electrical power equipment such as transformers, substations, switchgear and motor control centers are provided with protective devices to ensure against damage to equipment and materials in the event of electrical overload or fault conditions.

Electrical interlocks for each item of equipment are described in Section 12.5, ELECTRICAL CONTROLS.

Motor control centers are provided with thermal overload relays to protect their associated motors.

Start-up prevented due one more start-up conditions not being satisfied (permissivestart).

For description of transformers, substation, switchgear and motor control centers, refer to Section 8.0, titled “Plant Electrical Power System”

Shut-down is initiated by an interlock when the “operating” status of that interlock has changed either by deliberate intent or by reason of mal-function in the system.

Electrical interlocks are normally provided to prevent start-up or to cause shutdown of a p articular piece of equipment.


12.0 GRINDING, FLOTATION, THICKENING AND FILTERING 12.8

PRE-STARTUP EQUIPMENT AND SYSTEM CHECKS On termination of erection and before starting up a machine, a careful check should be carried out to make sure the machine has been properly installed, adjusted and serviced and that the machine and operating area are free of remnants of construction materials. A complete record should be made of this work. All deficiences should be recorded, including a full description of the problem and action required. Upon completation of the r emedial action, a second check should be made to insure the deficiency has been corrected and the machine or system is in satisfactory working condition. Prior to starting any machine or system, the operator should become fully familiar with the manufacturers’ installation, servicingand operating instructions.


88

EQUIPMENT TRIAL RUNS (No Load) On completion of all necesary checks, the Plant may be released sor the trial runs. The idle run of the machines should be carried out in accordance with (including period of time) manufacturers’ installation, servicing and aoperating instructio ns. The starting procedure is supervised on the spot. In the event deficiences become evident during the start-up procedure, teh respective machine is stopped at once and the faults are corrected. Once the machine is started, make sure that all bearings are adequately lubricated, taht all oil and grease pumps are properly working and that the control devices, especially for oil, grease, cooling water, etc, respond properly. Checks during these trial runs that the electrical interlocking system has been executed in accordance with the plans. Check in particular wheter or not the control devices are included in the interlocking system and all equipment protection and personnel safety devices function properly. During the idle tun period the equipment must be continuosly monitored, and the individual machines cheked for quiet and noise-free operation. In the case of jerky operation or loud unusual noise, the bearings and lubricating devices on the respective machine must be checked over. Check also the driving elements, such as V-belt drives, chain drives, etc., to remedy the causes for the faulty behavior of the machine. If necessary, take the respective unit immediately out of operation and carry out a step-by-step check of the installation of the machine. Periodically check foundations for movement and vibration and for loosening of assembly and anchor bolts. Check that suitable clearance is maintained between stationary and moving/rotating parts. A complete record should be kept of this work. All entries should be recorded in conjuctio n with time of run. Record should include a complete description of all problems and action required. Satisfactory completion of remedial action should be recorded. As proviously stated under Section 12.8, the operator should, prior to starting any machin e or system, become fully familiar with the manufacturers`installation, servicing and operating instructions.



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45 12.0 GRINDING, FLOTATION, THICKENING AND FILTERING 12.9

EQUIPMENT TRIAL RUNS (No Load) (cont’d)


The following are for specific reference: A.

89

EQUIPMENT TRIAL RUNS (No Load) (cont’d) After the break-in run is completed, fill the grinding mill with water and check for and stop all leakage from liner bolts.

Grinding Mills The mill should the be charged with grinding media, graded in size. Initial charge should be approximately 65 percent of total charge. A cushio n charge of material should be placed in the liners before charging the grinding media.

Some local heat may occur on the grinding mill trunnion bearings until they seat themselves. This heating will be observed to be confined to narrow bands on the trunnion surfaces and may wander back and forth over the width of the trunnions. As the surfaces “seat”, a uniform heat will develop over the trunnion surfaces and then will gradually decrease. Observe the contact pattern formed on the grease coated mill gear and pinion. A uniform contact pattern should be developing. If the temperature of the trunnion should exceed vendor’s recommended maximum stop the mill and allow it to cool before restarting. The mill Power Recorder and Temperature Monitor should be closely observed during the break-in period. It will be noted that each rise in temperature of main bearings will be accompanied by an increase in mill power. Complete break-in will be indicated by a bottoming of power consumption.

Mills should not be operated without a continuous and uniform rate of new feed. B.

Slurry Pumps Do not attempt to start a pump until drive rotation has been verified. Operation with seal water, either low in quantity or pressure can cause serious damage. Seal water requir ements, including quatinty and pressure are defined in the manufacturers’ installation, operation and maintenance data. Do not operate pump if solids hace settled and pump cannot be turned by hand, noe with restricted or plugged suction or discharge lines (or conbination of both).

The mill drive motor should undergo an initial trial run with the load uncoupled. The bearing temperature should be monitored, especially during the initial period of operation. In this period of time, the rate of bearing temperature rise is more indicative of trouble than the absolute bearing temperature. If the rate of bearing temperature rise appears excessive, shut the motor down and inspect the bearings. Records of the steady state uncoupled vibration and bearing temperatures should be kept for comparison with coupled and loaded running conditions. The trial run for the grinding ball mill is to be without grinding media (before grinding media is charged to the mill) to allow bearings and drive to “work in” under partial loading.


12.0 GRINDING, FLOTATION, THICKENING AND FILTERING 12.10 12.10.1

PLANT START-UP, OPERATION AND SHUTDOWN GENERAL Upon satisfactory completion of the trial runs, commissioning of this portion of the plan may commence. The following start-up procedures assume that start-up occurs immediately or very shortly after completion of the test runs. If this is not the case or if work has been performed on any of the equipment, checks defined under Section 12.8 should be made as required to insure the system or item of equipment is ready for operation. Normal start-up involves making the prerequisite field checks and then starting the equipment according to a systematic procedure. The entire concentrator, first stage grinding through and including concentrate loadout and tails disposal, must be considered as an operating unit for start-up. There us no appreciable storage throughout. Therefore, before starting any specific section the next section or section must be prepared to receive the process flow. Initial start-up procedures as defined are with the automatic sampling system not in operation. When the sampling system is to be brought on line and the procedures for initial sampling shall be established by the Plant Superintendent, in conjuntion with the Plant Metallurgist.

12.0 GRINDING, FLOTATION, THICKENING AND FILTERING 12.10 12.10.

PLANT START-UP, OPERATION AND SHUTDOWN PLANT START-UP, OPERATION AND SHUTDOWN (cont’d) B. Control Stations The control and monitoring of the operation of first and second stage grinding, including the individual ítems of equipment are performed from control panel CP-5M/5F and Control Console CC5M installed in the control room of the Concentrator. In addition, local control panels are provided for each: 1. Mill bearing lubrication system 2. Mill gear lubrication system 3. Mill air clutch system Each system is furnished as a package unit, complete with required controls and instrumentation. C.Start-Up 1.

Determine that the plant communication system is in satisfactory working condition, that each area of operation is properly staffed and prepared for start-up, equipment and system checks are complete and the system is ready f or operation.

2.

Review the status of the Fine Ore Stockpile and Fine Crushing and Screening System. Is there sufficient ore reserve in the stockpile and sufficient ore supply to complete the scheduled run.

3.

Review status of the flotation system. Is it prepared to receive process flow.

4.

Contact operating personnel at location to establish;

12.10.2 FIRST AND SECOND STAGE GRINDING A. General Start-up, operation and shutdown procedures are for that portion of the plant extending from reclaiming of ore from Fine Ore Storage 04-6001 to and including the Conditioner Tanks 05-1201, 05-2001, 05-1202 and 05-2002. First and second stage grinding consists of two independent lines. To afford better control, specially for initial start-up, only one line should be started at a time. As the operation of that line stabilized, the other line can then be started. The following procedures are applicable for either circuit.

90

a) b)

System properly staffed. Electrical power is available to all motor startes and control panels and that other utilities; ie: water and compressed air are available to equipment as required.



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46 91 12.0 GRINDING, FLOTATION, THICKENING AND FILTERING 12.10.

PLANT START-UP, OPERATION AND SHUTDOWN (cont’d)

12.0 GRINDING, FLOTATION, THICKENING AND FILTERING 12.10.


c)

Grinding mills are filled to overflow with water.

14.

Start the conditioner tank agitator. The tank should be filled with water to a level above the impeller before starting the agitator.

d)

Automatic process samplers are off and the cutters are out of the path of material flow.

15.

Start the second stage ball mill motor. Observe mill power recorder and temperature monitor for abnormal readings.

16.

Start the first stage bal mill motor. Observe mill power recorder and temperature monitor for abnormal readings.

e)

Pump sumps have adequate head of water.

f)

Mills are clear of personnel and obstructions.

g)

Reagent are or will be available at the various points of use and controls are set for stablished flow rate.

17.

Check all annunciators to ensure that all systems are clear to engage the mill clutches.

Turn “Remote-Local” selector switches to Local for the Reclain Belt Feeders and Ball Mill Feed Conveyor. Advise local operator, under local control, to start the feeders and conveyor and load the mill feed system to approximately normal load, then stop the feed system.

18.

Set Feed Rate Controller (5001 or 50101) to approximately 60 percent of circuit rated capacity.

19.

Engage the first stage ball mill air clutch. Observemill power recorder and temperature monitor for abnormal readings.

6.

Return “Remote/Local” selector switches for this mill feed system to remote.

20.

Start the Ball Mil Feed Belt conveyor.

21. 7.

Contact the operator in the Fine Crushing and Screening Control Room and determine status of the Fine Ore Storage Dust, Collecting System. If not already in operation, advise the operator at that location to start the dust collecting system.

Start the appropiate number of reclain Belt Feeders. Use manual speed control. Observe f eed rate recorder.

22.

Monitor the First Stage Cyclone Feed Sump Level Indicating Controller (LIC5006 or LIC5106). When the level starts to rise, indicating discharge of pulp from the mill, start the Cyclone Feed Pump, and observe pump current.

23.

Engage the second stage ball mill air clutch. Observe mill power recorder and temperature monitor for abnormal readings.

24.

Monitor the Second Stage Cyclone Feed Sump Level Indicating Controller (LIC5030 or LIC5130). When the level starts to rise, indicating discharge of pulp from the mill, start the Second Stage Cyclone Feed Pump.

5.

8.

Advise the local operator to activate the Belt Scales (04-4501 and 04-4502).

9.

Set the setpoints of all flow controllers and othe control devices to the initial established values and start all process recorders.

10. Advise the grinding mill operator(s) to start the lubrication systems for the first and second stage grinding mills. It is preferable after a prolonged shut-down to start these systems locally and observe that the system are functioning properly. For short duration shutdowns, the systems should be left running. The systems may also be started from central control console CC-5M.






One of the first and second stage grinding circuits is now in operation. The same producers should be f ollowed for the other circuit.

c.

D.

Good Operation

Operation 1.

Switch belt feeders to “Auto” mode and after operations have been stabilized, gradually increase the feed rate by aproxymately 15 percent increments at first and then less as the rated capacity is approached.

a. b. c.

As the rate is increased, monitor the power draw of motors to see that none of them are operating under an overload. 2.

Rates and equipment settings specified are optimim for start-up. Conditions will change with ore charactetistics. Operatings rates and settings must be established through experience and testing.

3.

If the load in the circuit (solids to classifier) is maintained at a fairly constant level an the mill power maintained at the proper level, the product rate and size will normally be satisfactory.

4.

4.

High level of noise resulting from the balls pounding the lining. An excessive amount of fines in the mill discharge. Very little oversize being returned from the classifier.

An Overloaded Mill a.

b.

Mill discharging at a high rate and the discharge containing a high proportion of material of new feed size. An appreciable drop in power below that indicated for normal operation or an underloaded mill.

A continuous regular dull mill noise without any distinguishing noise from balls hitting the shell-a rumble. Uniformity of mill discharge as to consistency and sizing. Uniformity of classifier oversize returns.

For initial start-up, the mills should be operated for 48 hours with the 65 percent of total grinding media charge to furter allow bearings and drive to “work-in” and during which time preliminary adjustments can be made. The charge should then be gradually brought up to the rated charge.

The experience obtained from this might indicate a change in the top size of media or in the make-up of the charge. The last 20 percent of the charge can then be added to bring about the desired changes. Another reason for recommending that the mill initially operate with about 80 percent charge is to watch the mill horsepower and if the mill power indicates that teh desired power will be drawn with a slig htly lees charge than originally recommended, this can be taken into account in the addition of the last 20 percent.

Conditions of the grinding mill are indicated by:

b. c.

A large return of oversize from the classifier, accompanied by a reduction in rate of classifier product.

It is recommended that the first few weeks of operation be with up to approximately 80 percent of the total recommended charge.

An Underloaded Mill a.

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E.

S hu td ow n 1.

Normal or scheduled Shutdown Normal or scheduled shutdown sequence is generally in the same order as the startup sequence. The following important points or exception must be considered.



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PLANT START-UP, OPERATION AND SHUTDOWN (cont’d) a.

12.10

The conditioner tank agitator must remain in operation as long as there is a slurry in the tank. For shurdown the tank (and system) must be flushed out with clear water or the tank drained.

c.

The following important point or exception must be considered. a.

If the mill is to be down for anu appreciable time, turn on the lubricating oil heaters. It is to be noted that prior to starting a mill, the lubricating oil temperature for both systems should be at least 32 degrees C for satisfactory operation.

A. General Start-up, operation and shutdown procedures are for that portion of the plant extending from the Rougher Feed Pump receiving slurry from the Conditioner Tanks to the Final Tailings Sump 052721 and Final Concentrate Sump 05-2726. Rougher, Rougher I, Rougher II, Scavenger I and Scavenger II flotation consist of two indeoendent circuits A and B . Each of these lines receive feed from the corresponding grinding circuit A and B. The grinding circuit started will then dictate the flotation circuit to be started. The following procedures are applicable to either circuit. B.

Control stations The control and monitorng of the operation of this section of the plant are performed from Control Panel CP-5MFand Control Console CC-5F, installed in the control room in the Concentrator Building.

Un planned (Emergency) Shutdown Abnormal situation such as: low speed stop, emergency stop switch actuation, crusher lube system malfunction, plugged c hute etc, that will, if operation continues, cause immediate damage to equipment or affect the flow of material are interlocked with the specific item of equipment or affect the flow of material are interlocked with the specific item of equipment or affect the flow of material are interlocked with the specific item of equipment and all critical upstream equipment for inmediate shutdown. After having checked the cause of the shutdown and ascertained that the cause of the shutdown has been corrected, the stopped equipment can be re-started, generally in the order of previously defined start-up procedures.

Do not start a cyclone feed pump if solids have settled and the pump cannot be turned by hand. It is then necessary to drain the sump and flush out the pump.

12.10.3 FLOTATION

Length of down-tim e will determine operatio n or nonoperation of the grinding mill main trunnion bearing and pinion bearing lubrication systems should be kept operating. If the shutdown time is to be of long duration, the lubrication unit may be shutdown if it is so desired. Regardless, allow the trunnion bearing lubrication system to operate for several minutes after the m ill is shut down.

d.

93


The cyclone feed sumps and pumps must be clear of all solids before shutdown. This can be accomplished by flushing the system with clear water before system shutdown or draining the sumps.

b.

2.

12.0 GRINDING, FLOTATION, THICKENING AND FILTERING

C.

Start – Up 1.

For initial start-up, it is assumed that the regrind system will not be started and be by-passed until the flotation, dewatering and siltration systems are started and operation stabilized.

2.

In defining start-up procedures, ir must be assumed that the flotation operator has been advised of planned start-up of first and second stage grinding with sufficient time for preparation of his section to receive the slurry flow.






This preparation shall include: a.

Ensure that the system is properly staffed for start-up.

b.

Establish electrical power is available to all motor starters and control panels and that other utilities; ie : water and plant and instrument compressed air, are available to equipment as required.

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3.

l.

Check and ensure that mechanism air intakes are at proper setting. Generally, these are 100 percent open for roughers and 30 to 40 percent open for cleaners.

m. n.

Ensure correct dart valve positions in flotations feed. All pump sumps have adequate head of water.

Upon notification that the first and second stage grinding is to be started, at Control Panel CP-5M/5F:

c.

Reagents are or will be available at the variuous points of use and controls are set f or stablished flow rate.

a.

Start all flotatio n machine sequence.

d.

The dewatering, filtering and tailings disposal sections will be prepared to receive the flotation concentrate and tails.

b.

Set “Local/Remote” selector swit ch for the appropiate rougher flotation feed pump to “Local”.

e.

All automatic process samplers are off and the cutters are out of the path of material flow.

c.

Start flotation pH recorders. Adjust pH controller to desired setpoints and place controllers in “Auto” mode.

f.

Ensure all manually operated dart valves in flotation machines are closed.

g.

Ensure all “Auto/Manual” selector switches on automatic pulp level controllers are in the “auto” position and all pneumatically actuated dart valves are operable and in “Auto” position.

h.

Establish that all flotation machines are filled with water to the required operating depth. Mechanisms should not be started until the cell liquid level is above the top row of holes in the disperser.

motors in predetermined

The remaining start-up operations are performed by the local operators. 4. Upon flow of pulp from the conditioner tank, start the rougher flotation feed pump. 5. When the pulp reaches a specific bank of cells, start required flow of reagents, flow of froth and launder spray water. 6. As the tails and concentrate from a specific line of cells discharges to a sump, start the transfer pump serving that sump.

i.

Ensure that froth sprays and launder sprays are operable.

j.

Check and ensure all froth bars are set at normal levels.

7. When pump flow approaches normal rates, open all manually operated dart valves in flotation machines and lock actuating levers in predetermined position.

k.

Check and ensure flotation cell weirs are set to a level below froth lip level.

8. Adjust reagents and air to provide the desired froth characteristics and overflow rate, 9. Adjust level control sensors to provide the optium operating froth depth.



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48 12.0 GRINDING, FLOTATION, THICKENING AND FILTERING



12.10

PLANT START-UP, OPERATION AND SHUTDOWN (cont’d) Normal or scheduled shutdown is generally in the same order as for start-up. The following important points must be considered.

Should xtreme surging of flotation feed slurry be experienced during start-up, it is recommended that weir bars in the connection and discharge boxes be removed until the weir is level with the slurry level in the cell which provides the desired froth depth. Large flow surges will then pass over the weir and will not cause flooding of the froth launders. It is not recommended that the controller settings be changed to provide fast surge relief. This will r esult in very poor control for nomal operation long after the feed surge problem is solved. D.

Metallurgical variations incurred in start-up are usually confined to two items; variation in recovery or variation in grade of concentrate from that anticipated. Prior to start-up, the decision should be made on wheter grade of concentrate or recovery is of prime importance. The operator may then concentrate more on one if necessary to get the plant in operation.

2.

Under normal operations, actual values will change. Factors such as characteristics or ore, degree of grinding and amount of reagents used will alter results. A table convering variables of flotation is entered at the end of this section.

3.

A target operation should be developed, then conditions adjusted through experience and metallurgical controls to attempt to meet this target. The operator has the responsability for setting control parameters with automatic control of some primary variable after that.

4.

E.

a.

Allow time for all flotation cell activity to cease and for all flotation cell activity to cease and for pulp in flotation machinesto be reducedto the desired degree of dilution.

b.

Pulps in sumps and pumps must be purged of solids to degree that they will not be “sanded-up” upon shutdown. Otherwise, sumps and pumps must be drained and flushedput with water.

c.

Thorouhly purge with water the final concentrate pumping line.

Operation 1.

2.

Unplanned(EmergencyShutdown) There are no shutdown interlocks between equippment in the flotation system. All transfer pumps are provided with spare. Therefore, except for some sanding which may generally be cleared without shutdown, no malfunction of any piece of equipment would seriously impede the flow of pulp and thereby require emergencyshutdown. Should a spontaneous shutdown of the entire flotation system be required, the system including cells, sumps and pumps should be drained and flushed out with water prior to restart.

12.10.3 REGRIND

After operation is stabilized, motor amp readings, pulp specific gravity and approximate air intake setting should be recorded for base line data.

A. General The regrind section consists of two independent circuits. To afford better control, especially for initial start-up, only one circuit should be started at a time. As the operation of that line is stabilized, the other line can then be started. The following proceduresare applicableto either line.

Shutdown 1.

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Normal or Scheduled Shutdown



PLANT START-UP, OPERATION AND SHUTDOWN (cont’d) B.

Control Stations The control and monitoring of the regrind section, including the individual items of equipment, are performed from Control Panel CP-5M/5F and Control Consoles CC-5M & 5F, installed in the Control room in the Concentrator Building. In addition, local control panels are providedfor each: 1. 2. 3.

C.

Mill bearing lubrication system. Mill gear lubricationsystem. Mill air clutch system


PLANT START-UP, OPERATION AND SHUTDOWN (cont’d) 3.

Set the setpoints of all flow controllers and other control devices to the initial established values and start all process recorders.

4.

Set the “Remote/Local” selector switches to “Local” for the mill lubrication system pumps (low and high pressure).

5.

Advise the grinding mill operator to start the bearing and gear lubrication system for the regrind mill. It is preferable after a prolonged shutdown to start these systems locally and observe that the system are functioning properly. For short duration shutdowns, the systems should be left running. The bearing lube system may also be started at central control console CC-5F.

Each system is furnished as package unit, complete with required controls and instrumentation.

The lubrication systems should be started from the local control panels in the following order.

Start - Up

a.

1.

Determine that the plant communication system is in satisfactory working condition, that each area of operation is properly staffed and prepared for start-up, equipment and system checks are complete and the system is ready for operation.

2.

Contact operating personnel at location to establish: a. b.

c. d. e. f.

System properly staffed. Electrical power is avalaible to all motor startes and control panels and that other utilities; ie: water and compressed air are available to equipment as required. All grinding mills are filled to overflow with water. All automatic process samplers are off and the cuttersare out of the path of material flow. All pump sumohave adequate head of water. All mills are clear of personnel and obstructions.

96

b)

If not already on, turn on the main bering and pinion bering lubrication system oil heater. (Oil heater would normally br turned on a day in advance of start-up, depending on the ambient temperature). The heater is primarily provided to maintain an oil temperature of 32 degress C when the mill is shutdown. After the mill is started, except for exceptionally cold climates, the heater should be turned off. Depress the “Start” lube pump push-button starting the low pressure trunnion bearing lube oil system pump.

c)

Depress the “Start” lube jacking pumo push-button, starting the main bearing high pressure jacking pump. The jacking pump is interlocked with the low pressure trunnion bearing lube system to insure that system is in operation before starting the high pressure system.

d)

Start the gear spray lubrication system.



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Turn the “Remote/Local” selector switch for the appropriate Regrind Transfer Pump to “Local” Verify that an operator is positioned at this sumo and pump.

Normal or scheduled shutdown sequence is generally the reverse of the start-up sequence. The following important points ir exceptions must be considered.

7.

Advise the local operators that the system is to be started. Sound the “Start” warning alarm.

8.

Start the regrind ball mill motor. Check that the graphic display running ligth is on and check all annunciators to ensure that all systems are clear to engage the mill clutch. Observe mill power recorder.

a. Sumps and pumps handling pulp must be clear of all solids before shutdown. This can be accomplished by flushing the system with clear water before system shutdown or draining the sumps.

Advise the flotation operator to divert feed to the regrind section.

10.

Local operator is to start the regrind transfer pump as pulp begins to discharge to the regrind collection sump.

11.

When the regrind transfer pump graphic display running light comes on, engage the regrind ball mill air clutch. Observe mill power recorder and temperature monitor for abnormal readings-

12.

b. Length of down-time will determine operation or non-operation of the grinding mill main trunnion bearing lubrication systems after shutdown. If the shutdown time is to be of short duration, the lubrication systems should be kept operating. If the shutdown time is to be of long duration, the lubricantion system to operate for several minutes after the mill is shutdown. c. If the mill is to be down for any appreciable time, turn on the lubrication oil heaters. Its is to be noted that prior to starting the mill, the lubricating oil temperature for both systems should be at least 32 degrees C for satisfactory operation. 2.

Monitor the regrind cyclone feed sump level indicator (LIC 5212 or LIC 5222). When the level starts to rise, indicating discharge of pulp from the mill, start the regrind cyclone feed pump. Observe feed pump motor corrent.

The same procedures should be followed for Circuit Nº2. Operation Basic operating parameters are as specified for First and Second Stage Grinding. E.

Unplaned (Emergency) Shut-Down Abnormal situations such as: low speed stop, emergency stop switch actuation, crusher lube system malfunction, plugged chute, etc. That will. If operation continues, cause inmediate damage to equip ment or affect the flow of materia l, are interlocked with the specific item of equipment or affect the flow of material, are interlocked with the specific item of equipment and all critical upstream equipment for inmediate shutdown. After having checked the cause of the shutdown and ascertained that the cause of the shutdown has been corrected, the stopped equipment can be restarted, generally in the order of previously defined start-up procedures.

The regrind section is now in operation-

D.


6.

9.

97

The following important point or exception must be considered.

Shut Down 1. Normal or Scheduled Shutdown



PLANT START-UP, OPERATION AND SHUTDOWN (cont’d) a.

Do not start a pump handling pulp if solids have settled and the pump cannot be turned by hand. It is the necessary to drain the sump and flush out the pump.

12.10.4 CONCENTRATE THICKENING AND FILTERING


PLANT START-UP, OPERATION AND SHUTDOWN (cont’d) c.

Establish that flocculant is or will be available at the Final Concentrate Sump 05-2726 and filter aid available at the Filter Feed Distributor 05-1601.

d.

Advise the thickener operator to check that:

A. General Start-up, operation and shutdown procedures are for that portion of the plant extending from the Final Concentrate Sump 05-2726 to and including Final Concentrate Storage.

1.

B. Control Stations The control and monitoring of the operation of this section of the plant is performed from Control Panel CP-5M/5Fand Control Console CC-5F, installed in the control room of the Concentrator Building. In addition, local control panels are provided for the Concentrate Thickener and the Concentrate Filtering Systems.

3.

C.Start-Up 1.

In defining start-up thickening-filtering planned startup of sufficient lead time the feed.

procedures, it must be assumed that the operator(s) has been advised of the the grinding and flotation sections, with for preparation of this section to receive

This preparation shall include: a. Determine that the plant communication system is in satisfactory working condition, that each area of operation is properly staffed and prepared for start-up, equipment and system checks are complete and the system is ready for operation. b. Check with the appropriate foreman to determine that electrical power is available to all motor starters and control panels and that other utilities; ie: water and compressed air, are available to equipment as required.

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2.

The thickener is clear of any objects that would bind the rakes. The rake drive has been operated for a short time. That the rakes are not bound and there was no high torque condition. There is some clear water in the bottom of the tank, preferably enough to fill the cone bottom.

e.

Check with filtering system operator that all equipment is prepared for operation.

f.

Determine that seal water is available at all pumps, including the vacuum pump.

g.

Determine that fresh water supply is available at correct pressure.

h.

Advise the filter operator to set dart valves in the Static Distributor 05-1601 so that the outlets to the filters are closed and the overflow return line to the Final Concentrate Sump is open.

The following start-up procedures are for temporally recycling the thickener underflow back to the thickener feed. Otherwise, it will be necessary to dispose of the underflow until it is of suitable density for f iltering. i.

Set the setpoints of all flow controllers and other control devices to initial estimated valves Start thickener torque recording.

j.

Establish that reclain water system is prepared t o r eceive the thickener overflow,



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Turn the “Remote/Local” selector switch for the Final Concentrate Pump 05-1519 to “Local”. This pump is to be started locally..

b.

2.

When the system is ready, advise the flotation operator that the thickening and filtering section is prepared for start-up.

c.

3.

Upon notification that the flotation section is to be started, start the thickener rake mechanism. Observe torque recorder.

4.

Locally start the Final Concentrate Pump as the slurry starts to discharge to the Final Concentrate sump.

k.

Check the interface of the slugde level. It should be down at approximately the rake level. If it should rise above this level, add more flocculant to improve the thickening. It is important to keep the interface down f rom the start. The underflow pump must be operated at suffic ient capacity to prevent deposition of the coarse material in the underflow line.

As the density of the solids reach normal operating conditions, the underflow is ready for filtering. 7.

Start the filter agitator. Start the filter drum. The filter agitator and drum should be started before any feed is sent to the filter.

5.

Monitor the final Concentrate Pump “Running” Light. When it comes on, start the Concentrate Thickener Underflow Pump 051521.

8.

6.

Start the flow of flocculant to the Final Concentrate sump.

9.

When the feed level in the tank is just below the cloth and before it touches the cloth, start the vacuum pump. This will prevent introducing slurry underneath the cloth on the filter drum. Check cloth tracking and also observe vacuum receiver pressure.

The objetive is to get the thickener “in balance” as soon as possible. “In balance” means the screen analysis and tonnage of the underflow are the same as the feed.

10.

Start Drum Filter Blower.

11.

Start Filtrate Pump.

As the thickener is being f illed:

12.

Balance the flow into the filter tank with the filtration rate of the filter. In normal operation, avoid excessive overflow of the filter tank.

The Concentrate Thickener is now in operation, with the underflow recycling back to the Final concentrate Sump by way of the Filter Feed Static Distributor Overflow.

a.

Watch the underflow density and torque on the thickener rakes. On initital start-up there are no settled fines and whatever coarse material is present in the feed rapidily settles and can sand out on the thickener bottom. This coarse material, with no fines for lubrication, does not flow. It is difficult to rake and can cause excessively high torques initially until fines have a chance to settle and mix with the coarse material.

99

D.

Operation General The operating goal is to produce the maximum amount of filter cake with minimum moisture content. Thickener Control of the thickener operation is done primarily by control of the thickener underflow concentration.



PLANT START-UP, OPERATION AND SHUTDOWN (cont’d) The rate of underflow withdrawal should the be adjusted according to the underflow concentration. It is important that the underflow withdrawal rate is high enough to remove settled solids at a tonnage equal to the feed solids tonnage. What goes in must come out. If sufficient solids are not removed from the thickener underflow, they will build up in the machine and eventually overflow. If flocculants are used to increase thickener capacity, the thickener pulp level can be monitored and the amount of flocculant used adjusted accordingly. This reduces flocculant consumption to a minimum. If flocculants are used to improve overflow clarity, overflow turbidity measurements may be used to indicate flocculant dosage requeriments. The rake mechanism is normally kept in continuous operation. If for saome reason the rakes are to be shut off for an hour or more, the settled solids should first be pumped out of the machine. If the thickener overflow turbidity is higher than anticipated: 1. Satisfactory flocculation may not have been obtained. The flocculation system should be checked. 2. The underflow rate may be too low and a large amount of solids may have accumulated in the tank. The underflow rate must be increased.


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PLANT START-UP, OPERATION AND SHUTDOWN (cont’d) If the underflow is too thin: 1. The slugde is being withdrawn too fast. Decrease the discharge rate. 2. An island or ring of non-fluid solids may have formed near the center of the machine. This ring rotates with the rake. Solids that settle outside of this ring are no transported to the underflow and eventually this situation will result in an overloaded thickener. If the ring cannot be dislodged by high pressure water hoses – applied beneath the surface – or air lines, the unit must be drained and cleaned out. Island formation is usually caused by the use of an excessively high flocculant dosage or inadequate flocculant preparation and addition. 3. If the underflow pumping rate is too high, it is possible to pull thin slurry out of the center of the machine so fast that other settled sludge farther out will not sluff off into the underflow trench. This action is commonly called rat holing. It can be eliminated by using a lower underflow trech. This action is commonly called rat holing. It can be eliminated by using a lower underflow discharge rate. If the underflow line plugs with thick sludge, close the line with high pressure water. When the line is free, resume underflow pumping at an increased rate until the inventory of thick solids has been removed. If the unit cuts out on overload: 1. Check general mechanical condition of mechanism. Check lubricating oil level in mechanism.

3. The feed rate to the thickener may be too high, exceding the capacity of the thickener. Either the feed rate must be cut back or the flocculation system improved to increase the capacity of the thickener.

2. The solids may be overthickening because they have remained in the tank too long. Too much water has been eliminated and the underflow is no longer fluid. Consequently, the rake mechanism is encountering a large load. The underflow rate is too low and it should be increased.

4. Splashing of the feed over the feedwell skirt or excess turbulence in the feedwell may be causing short circuiting. Check drawings to determine if feedwell and feed launder are properly installed.

3. Solids are being fed to the thickener faster than they are being removed. As a result, the rake enconters a larger and larger load. The discharge rate should be increased.



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