Sie sind auf Seite 1von 92

Toromocho Tailings Pipelines

Tailings Pipelines Project Overview


The Tailings Pipelines were designed in two phases:
Initial Phase
Design to Startup:
Nominal Capacity:
Design Capacity:

2009 to 2014
124,000 dry t/d
155,000 dry t/d

Expansion Phase
Design Completed:
Nominal Capacity:
Design Capacity:

2015
54,000 dry t/d
70,000 dry t/d

11/11/2015

Toromocho Tailings Pipelines

Slide 2

Tailings Pipelines Project Overview


Initial System Design

Located in the District of Morococha, Yauli Province, Junin Region,


Peru.
The Toromocho project mines copper, molybdenum, and silver with
respective grades of 0.48%, 0.019%, and 6.88 grams per ton
Ore Reserve is estimated to 1526 million metric tons
Pump Station elevation is 4523 masl and terminates 4.7 km
distance at 4777 masl (up hill).
Due to pressure requirements the pump station uses 10 of the
largest positive displacement pumps (8 + 2 mode) operating in
parallel
Due to number of pumps it is the largest pump station of its kind
Estimated Annual production:
One million metric tons of copper,
Ten thousand metric tons of molybdenum
Four million ounces of silver
And ~ 44 million metric tons of tailings

Expansion System Design


~26 million metric tons annually of tailings

Stand alone system adding four additional pumps operating in


parallel

11/11/2015

Toromocho Tailings Pipelines

Slide 3

Initial Tailings Pipeline


Process Design Criteria:
Scope: from flange on P/S suction headers
Capacity:
Nominal = 5176 t/h
Design = 6470 t/h
Pump Station Elevation: 4,520 masl
Highest Discharge Elevation:
Phase I: 4,777 masl
Phase II: 4,890 masl
Pipeline length:
Phase I: 4,707 m
Phase II: 5,400m
Tailings Slurry Concentration:
Minimum = 69%
Maximum = 71%
Actual experience tailings thickened to 65%
Design Life:
30 years

11/11/2015

Toromocho Tailings Pipelines

Slide 4

Initial Tailings Pipeline

Slurry Characteristics:
Sample taken from Pilot Testing
Solids SG:Sample 1 and 2 = 2.77 (used for
design) to 2.92
Handling Tests: Shutdown / Restart ability
are good, no serious problems are
foreseen

11/11/2015

Toromocho Tailings Pipelines

Slide 5

Initial System Operating Range


Initital Toromocho Tailings System - Sample 2
7000

Contingency
Design Tonnage

6500

62.0%
63.0%
Limiting Velocity

6000

Q 5.8 pumps

Throughput, dry t/h

61.0%

5500

5000

64.0%

65.0%

Nominal Tonnage

66.0%
67.0%

4500

68.0%

Operating Range

69.0%
70.0%

4000

Nominal
Q 10 pumps

3500Limiting Velocity

Design Tonnage
Q 8 pumps

3000
2500

60.0%

3000

3500

4000

4500
Flow,

11/11/2015

5000

5500

6000

m3/h

Toromocho Tailings Pipelines

Slide 6

Initial System 10 Pumps Operating @ 100 %


Diameter

34.000

NPS

Cw

68.80% %

Capacity

158,939 dry t/d

Sfac

1.100

10.000
Initital Toromocho Tailings System - Sample 2
7000

Contingency
Design Tonnage

6500

62.0%
63.0%
Limiting Velocity

6000

Q 5.8 pumps
61.0%

He = 0

Throughput, dry t/h

1.000

5500

5000

64.0%

65.0%

Nominal Tonnage

66.0%
67.0%

4500

68.0%

Operating Range

69.0%
70.0%

4000

Nominal

3500Limiting VelocityRec

0.100

Q 10 pumps
Design Tonnage
Q 8 pumps

3000
2500

60.0%

3000

3500

4000

4500

Flow,

5000

5500

m3/h

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 5400.0
Q 5400.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Initial

11/11/2015

2.792
2.792

Cw, %

68.8%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
6,622 dry t/h
6,622 dry t/h

24.369
18.660

#Pumps

m/km
m/km

10

Toromocho Tailings Pipelines

1000000
w-dot
w-dot

10000000
158,939 dry t/d
158,939 dry t/d

-dH/dX, NWT
-dH/dX, NWT

11.437
10.528

Speed, %

100%

m/km
m/km

Slide 7

6000

Initial System 10 Pumps Operating @ 100 %


Diameter

34.000

NPS

Cw

67.50% %

Capacity

153,653 dry t/d

Sfac

1.100

10.000
Initital Toromocho Tailings System - Sample 2
7000

Contingency
Design Tonnage

6500

62.0%
63.0%
Limiting Velocity

6000

Q 5.8 pumps
61.0%

He = 0

Throughput, dry t/h

1.000

5500

5000

64.0%

65.0%

Nominal Tonnage

66.0%
67.0%

4500

68.0%

Operating Range

69.0%
70.0%

4000

Nominal

3500Limiting VelocityRec

0.100

Q 10 pumps
Design Tonnage
Q 8 pumps

3000
2500

60.0%

3000

3500

4000

4500

Flow,

5000

5500

m3/h

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 5400.0
Q 5400.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Initial

11/11/2015

2.792
2.792

Cw, %

67.5%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
6,402 dry t/h
6,402 dry t/h

18.209
15.319

#Pumps

m/km
m/km

10

Toromocho Tailings Pipelines

1000000
w-dot
w-dot

10000000
153,653 dry t/d
153,653 dry t/d

-dH/dX, NWT
-dH/dX, NWT

10.849
10.054

Speed, %

100%

m/km
m/km

Slide 8

6000

Initial System 10 Pumps Operating @ 100 %


Diameter

34.000

NPS

Cw

60.00% %

Capacity

125,946 dry t/d

Sfac

1.100

10.000
Initital Toromocho Tailings System - Sample 2
7000

Contingency
Design Tonnage

6500

62.0%
63.0%
Limiting Velocity

6000

Q 5.8 pumps
61.0%

He = 0

Throughput, dry t/h

1.000

5500

5000

64.0%

65.0%

Nominal Tonnage

66.0%
67.0%

4500

68.0%

Operating Range

69.0%
70.0%

4000

Nominal

Rec
3500Limiting Velocity

0.100

Q 10 pumps
Design Tonnage
Q 8 pumps

3000
2500

60.0%

3000

3500

4000

4500

Flow,

5000

5500

m3/h

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 5400.0
Q 5400.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Initial

11/11/2015

2.792
2.792

Cw, %

60.0%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
5,248 dry t/h
5,248 dry t/h

8.877
8.584

#Pumps

m/km
m/km

10

Toromocho Tailings Pipelines

1000000
w-dot
w-dot

10000000
125,946 dry t/d
125,946 dry t/d

-dH/dX, NWT
-dH/dX, NWT

8.747
8.351

Speed, %

100%

m/km
m/km

Slide 9

6000

Initial System 8 Pumps Operating @ 72.5 %


Diameter

34.000

NPS

Cw

60.00% %

Capacity

73,049 dry t/d

Sfac

1.100

10.000
Initital Toromocho Tailings System - Sample 2
7000

Contingency
Design Tonnage

6500

62.0%
63.0%
Limiting Velocity

6000

Q 5.8 pumps
61.0%

He = 0

Throughput, dry t/h

1.000

5500

5000

64.0%

65.0%

Nominal Tonnage

66.0%
67.0%

4500

68.0%

Operating Range

69.0%
70.0%

4000

Nominal

Rec
3500Limiting Velocity

0.100

Q 10 pumps
Design Tonnage
Q 8 pumps

3000
2500

60.0%

3000

3500

4000

4500

Flow,

5000

5500

m3/h

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 3132.0
Q 3132.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Initial

11/11/2015

1.619
1.619

Cw, %

60.0%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
3,044 dry t/h
3,044 dry t/h

3.633
3.731

#Pumps

1000000
w-dot
w-dot

m/km
m/km

Toromocho Tailings Pipelines

10000000
73,049 dry t/d
73,049 dry t/d

-dH/dX, NWT
-dH/dX, NWT

3.257
3.095

Speed, %

73%

m/km
m/km

Slide 10

6000

Initial System 8 Pumps Operating @ 72.5 %


Diameter

34.000

NPS

Cw

67.00% %

Capacity

87,964 dry t/d

Sfac

1.100

10.000
Initital Toromocho Tailings System - Sample 2
7000

Contingency
Design Tonnage

6500

62.0%
63.0%
Limiting Velocity

6000

Q 5.8 pumps
61.0%

He = 0

Throughput, dry t/h

1.000

5500

5000

64.0%

65.0%

Nominal Tonnage

66.0%
67.0%

4500

68.0%

Operating Range

69.0%
70.0%

4000

Nominal

Rec
3500Limiting Velocity

0.100

Q 10 pumps
Design Tonnage
Q 8 pumps

3000
2500

60.0%

3000

3500

4000

4500

Flow,

5000

5500

m3/h

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 3132.0
Q 3132.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Initial

11/11/2015

1.619
1.619

Cw, %

67.0%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
3,665 dry t/h
3,665 dry t/h

13.402
10.830

#Pumps

1000000
w-dot
w-dot

m/km
m/km

Toromocho Tailings Pipelines

10000000
87,964 dry t/d
87,964 dry t/d

-dH/dX, NWT
-dH/dX, NWT

4.018
3.722

Speed, %

73%

m/km
m/km

Slide 11

6000

Initial System 8 Pumps Operating @ 100 %


Diameter

34.000

NPS

Cw

68.80% %

Capacity

127,151 dry t/d

Sfac

1.100

10.000
Initital Toromocho Tailings System - Sample 2
7000

Contingency
Design Tonnage

6500

62.0%
63.0%
Limiting Velocity

6000

Q 5.8 pumps
61.0%

He = 0

Throughput, dry t/h

1.000

5500

5000

64.0%

65.0%

Nominal Tonnage

66.0%
67.0%

4500

68.0%

Operating Range

69.0%
70.0%

4000

Nominal

3500Limiting VelocityRec

0.100

Q 10 pumps
Design Tonnage
Q 8 pumps

3000
2500

60.0%

3000

3500

4000

4500

Flow,

5000

5500

m3/h

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 4320.0
Q 4320.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Initial

11/11/2015

2.234
2.234

Cw, %

68.8%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
5,298 dry t/h
5,298 dry t/h

23.053
16.932

#Pumps

1000000
w-dot
w-dot

m/km
m/km

Toromocho Tailings Pipelines

10000000
127,151 dry t/d
127,151 dry t/d

-dH/dX, NWT
-dH/dX, NWT

7.672
7.060

Speed, %

100%

m/km
m/km

Slide 12

6000

Pipeline Routing and Impoundment

11/11/2015

Toromocho Tailings Pipelines

Slide 13

11/11/2015

Toromocho Tailings Pipelines

Slide 14

Impoundment and Tailings Dam

11/11/2015

Toromocho Tailings Pipelines

Slide 15

Impoundment and Tailings Dam

11/11/2015

Toromocho Tailings Pipelines

Slide 16

Impoundment and Tailings Dam

11/11/2015

Toromocho Tailings Pipelines

Slide 17

Impoundment and Tailings Dam

11/11/2015

Toromocho Tailings Pipelines

Slide 18

11/11/2015

Toromocho Tailings Pipelines

Slide 19

11/11/2015

Toromocho Tailings Pipelines

Slide 20

11/11/2015

Toromocho Tailings Pipelines

Slide 21

11/11/2015

Toromocho Tailings Pipelines

Slide 22

11/11/2015

Toromocho Tailings Pipelines

Slide 23

11/11/2015

Toromocho Tailings Pipelines

Slide 24

11/11/2015

Toromocho Tailings Pipelines

Slide 25

11/11/2015

Toromocho Tailings Pipelines

Slide 26

11/11/2015

Toromocho Tailings Pipelines

Slide 27

Discharge Points

11/11/2015

Toromocho Tailings Pipelines

Slide 28

Discharge Points

11/11/2015

Toromocho Tailings Pipelines

Slide 29

Discharge Points

11/11/2015

Toromocho Tailings Pipelines

Slide 30

Discharge Points

11/11/2015

Toromocho Tailings Pipelines

Slide 31

System Hydraulics

11/11/2015

Toromocho Tailings Pipelines

Slide 32

Initial System SS Hydraulics


Conventional Slurry

11/11/2015

Toromocho Tailings Pipelines

Slide 33

Initial System SS Hydraulics


Bingham Plastic Slurry

Conventional Slurry

11/11/2015

Toromocho Tailings Pipelines

Slide 34

Pump Duty

Geho: TZPM 2000 (largest PD pump)


Continuous Service
Flow Capability: 655 m3/h each
Initial System used 540 m3/h each
Expansion System used 650 m3/h each
Pressure Capability:
Normal:
8,100 kPa
w/ GLORES modification: 11,000 kPa

11/11/2015

Toromocho Tailings Pipelines

Slide 35

Pump Station Design

11/11/2015

Toromocho Tailings Pipelines

Slide 36

Pump Station Design

11/11/2015

Toromocho Tailings Pipelines

Slide 37

Pump Station Design

11/11/2015

Toromocho Tailings Pipelines

Slide 38

Pump Station Design

11/11/2015

Toromocho Tailings Pipelines

Slide 39

Pump Station Design

11/11/2015

Toromocho Tailings Pipelines

Slide 40

Pipe Stress Analysis

11/11/2015

Toromocho Tailings Pipelines

Slide 41

Toromocho Tailings Pipelines

Pipe Stress Analysis


Several unique difficulties in Mechanical Design of Toromocho Tailings
Pump Station
Tailings pump station is situated on an earthwork bench and the space
available for piping was not sufficient to accommodate the preferred
pump station design
Pump station is located in harsh, mountainous conditions 4,520m above
sea level
Pump station will experience high pressures and flows and the
possibility of large pressure fluctuations

11/11/2015

Toromocho Tailings Pipelines

Slide 42

Toromocho Tailings Pipelines


Pipe Stress Analysis

Preferred Pump Discharge Arrangement


11/11/2015

Toromocho Tailings Pipelines

Slide 43

Toromocho Tailings Pipelines

Pipe Stress Analysis


Preferred pump station layout

Pump discharge will incorporate bends to take the pipe from the pump
discharge nozzle to the station floor. Once on the floor the piping will
connect to the anchored discharge manifold
Piping is much easier to restrain because pipe supports can be mounted
directly to platforms on the floor
Pipe bends between the discharge nozzle and the discharge manifold
create flexibility in the piping

11/11/2015

Toromocho Tailings Pipelines

Slide 44

Toromocho Tailings Pipelines

Pipe Stress Analysis


The Toromocho Tailings Pump Station is located on an bench only about
40m wide
BRASS developed a station arrangement in which the discharge manifold
is at the same elevation as the discharge nozzle
Eliminated the space between the pump discharge and manifold taken
up by the two pipe bends
Reduced piping flexibility to absorb temperature expansion and
contraction

11/11/2015

Toromocho Tailings Pipelines

Slide 45

Toromocho Tailings Pipelines


Pipe Stress Analysis

Straight Discharge Pipe

11/11/2015

Toromocho Tailings Pipelines

Slide 46

Toromocho Tailings Pipelines


Pipe Stress Analysis
The mine owners elected to save material and construction costs by leaving
the tailings pump station exposed to the elements without any protective
structure.
Toromocho mine site sees large temperature changes both between day
and night and between seasons. The mine site can experience
temperatures as low as -4C and as high as 25C with an average
temperature of 7C
Such a large change in temperatures will result in significant pipe
expansion and contraction

11/11/2015

Toromocho Tailings Pipelines

Slide 47

Toromocho Tailings Pipelines


Pipe Stress Analysis
Pipe Expansion

Simplified calculation for the expansion and contraction of pipe


For a 5.5m, 12in NPS piece of pipe (same diameter and approximate
length as the pump discharge pipe) and an ambient temperature of 7C,
expansion almost 2 mm

=
=
=
=
11/11/2015

Toromocho Tailings Pipelines

Slide 48

Toromocho Tailings Pipelines


Pipe Stress Analysis

This is a seemingly small change in length. When the Elastic


Modulus of the pipe is considered the force that can be
developed is easily enough to overstress piping and pump
nozzles if the system is too rigid.

11/11/2015

Toromocho Tailings Pipelines

Slide 49

Toromocho Tailings Pipelines


Pipe Stress Analysis
The stiffness and location of pipe supports were carefully analyzed and
many iterations of the design were considered before a final solution was
reached
Caesar II simulations were run to analyze the pipe stresses
Two main over stress issues needed to be solved. Both issues were most
severe when low temperature pipe contraction was considered
straight pump discharge lines pull the discharge manifold laterally
large S-bend located after the discharge manifold stretched by the
contracting manifold
11/11/2015

Toromocho Tailings Pipelines

Slide 50

Toromocho Tailings Pipelines


Pipe Stress Analysis

S-Bend
11/11/2015

Toromocho Tailings Pipelines

Slide 51

Toromocho Tailings Pipelines


Pipe Stress Analysis
To reduce stress on the manifold and pump nozzles, BRASS used flexible
supports which allow the manifold piping to move laterally as the pipe
contracts
Over stress issue at the S-bend not as easy to fix
Possible solution: fix the manifold piping with very rigid supports
Prevent the manifold piping from pulling on the S-bend as
strongly

Has the effect of increasing the pump nozzle loads to


unacceptable levels
11/11/2015

Toromocho Tailings Pipelines

Slide 52

Toromocho Tailings Pipelines


Pipe Stress Analysis
After a number of design iteration BRASS discovered that a special support
needed to be designed
Support must be very rigid in the axial direction of the piping and
simultaneously flexible in the lateral direction
Developed large plate oriented in the direction of the pipe axis
Reinforcing ribs were added to achieve the required lateral and vertical
stiffness.
Support is located near the middle of the discharge manifold

11/11/2015

Toromocho Tailings Pipelines

Slide 53

Toromocho Tailings Pipelines


Pipe Stress Analysis
BRASS engineers needed to complete a vibrational or harmonic analysis of
the pump station. PD pumps and other oscillating equipment cause
harmonic excitations in piping
Excitation is in the form of pressure pulsations
BRASS coordinated vibrational analysis with GEHO engineers specializing
in pressure pulsation
With a combination of pump phase synchronization and properly
charged dampers the total pressure pulsation is less than 2% of the
maximum pressure for the GEHO TZPM2000 pumps

11/11/2015

Toromocho Tailings Pipelines

Slide 54

Toromocho Tailings Pipelines


Pipe Stress Analysis
Even small pressure pulsations can cause large deflection in piping if the
excitation frequency of the pump is close to the natural frequency of the
piping
The first mode of vibration of the piping should be signifigantly greater
than the pumps nominal frequency of excitation and must be greater
than the pumps maximum excitation to ensure no resonant vibration
will take place

11/11/2015

Toromocho Tailings Pipelines

Slide 55

Toromocho Tailings Pipelines


Pipe Stress Analysis

Frequency of Excitation Calculation


i(rpm)n
fe
60
f e : Frequency of Excitation (Hz)
i

: Numbers of pistons

rpm : Rotations per minute


n

11/11/2015

: Fundamental frequency, n=1,2,3..

Toromocho Tailings Pipelines

Slide 56

Toromocho Tailings Pipelines


Pipe Stress Analysis
The pumps nominal frequency of excitation is 4Hz and maximum
frequency of excitation is 5 Hz
Upon first analysis BRASS found that the piping natural frequency was
too low, due to the flexible supports
A number of iterations were made to adjust the stiffness and location of
supports to increase the piping natural frequency
The piping natural frequency was increased to approximately 6Hz. This is
high enough to prevent resonant vibration.

11/11/2015

Toromocho Tailings Pipelines

Slide 57

Toromocho Tailings Pipelines


Pipe Stress Analysis

The stress and flexibility analysis of the Toromocho


Tailings Pump Station presented numerous unique
engineering challenges. BRASS Engineering
International was able to develop a design which
overcame the space limitations, harsh environment,
and possible harmonic resonance of the pipe caused
by pressure pulsation.

11/11/2015

Toromocho Tailings Pipelines

Slide 58

Pre-com, Com, Startup

11/11/2015

Toromocho Tailings Pipelines

Slide 59

Pre-com, Com, Startup

Low, Medium, and High Pressure Pre-charge

Nitrogen charged Pulsation dampeners

11/11/2015

Toromocho Tailings Pipelines

Slide 60

Pre-com, Com, Startup


Early pre-commissioning problems

Urethane lined pipe was welded on causing the lining to be compromised

11/11/2015

Toromocho Tailings Pipelines

Slide 61

Pre-com, Com, Startup

Photo shows field constructed Y on pump discharge line

11/11/2015

Toromocho Tailings Pipelines

Slide 62

Expansion System Design

11/11/2015

Toromocho Tailings Pipelines

Slide 63

Expansion System Design


Process Design Criteria:
Scope: from bottom of thickeners
Capacity:
Nominal = 2250 t/h
Design = 2916 t/h
Pump Station Elevation: 4,520 masl
Highest Discharge Elevation: 4,777 masl
Pipeline length: 4707 m
Tailings Slurry Concentration:
Minimum = 60.0%
Maximum = 68.8%
Based upon existing system the actual
experience tailings thickened to 65%
Design Life: 5 years

11/11/2015

Toromocho Tailings Pipelines

Slide 64

Expansion System Design

Slurry Characteristics:
Sample taken from existing operation
Solids SG:
Sample 1: 2.89
Sample 2: 2.84
Handling Tests: Shutdown / Restart ability
are good, no serious problems are
foreseen
11/11/2015

Toromocho Tailings Pipelines

Slide 65

Expansion System Operating Range

11/11/2015

Toromocho Tailings Pipelines

Slide 66

Expansion System Design


Operating Range

Toromocho Tailings System Expansion - Sample 2


3500

Contingency
Q 2.4 pumps
62.0%

3000

Design Tonnage

63.0%
Limiting Velocity

Throughput, dry t/h

61.0%
64.0%

2500

65.0%

Nominal Tonnage

66.0%
67.0%

2000

Operating Range

68.0%
69.0%
70.0%
Nominal

1500

Q 4 pumps

Limiting Velocity

Design Tonnage
Q 3 pumps

1000
1300

60.0%

1500

1700

1900

2100
Flow,

11/11/2015

2300

2500

2700

m3/h

Toromocho Tailings Pipelines

Slide 67

Expansion System 4 Pumps Operating @ 100 %


Diameter

24.000

NPS

Cw

68.80% %

Capacity

77,370 dry t/d

Sfac

1.100

10.000
Toromocho Tailings System Expansion - Sample 2
3500

Contingency
Q 2.4 pumps
62.0%

3000

Design Tonnage

63.0%
Limiting Velocity
61.0%

Throughput, dry t/h

1.000

He = 0

64.0%

2500

65.0%

Nominal Tonnage

66.0%
67.0%

2000

Operating Range

68.0%
69.0%
70.0%
Nominal

1500

Q 4 pumps

Limiting Velocity

Rec

Design Tonnage

0.100

Q 3 pumps

1000
1300

60.0%

1500

1700

2100

1900

2500

2700

m3/h

Flow,

2300

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 2600.0
Q 2600.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Expansion

11/11/2015

2.800
2.800

Cw, %

68.8%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
3,248 dry t/h
3,224 dry t/h

34.202
46.561

#Pumps

m/km
m/km

Toromocho Tailings Pipelines

1000000
w-dot
w-dot

10000000
77,959 dry t/d
77,370 dry t/d

-dH/dX, NWT
-dH/dX, NWT

15.713
17.960

Speed, %

100%

m/km
m/km

Slide 68

Expansion System 4 Pumps Operating @ 100 %


Diameter

24.000

NPS

Cw

65.00% %

Capacity

69,982 dry t/d

Sfac

1.100

10.000
Toromocho Tailings System Expansion - Sample 2
3500

Contingency
Q 2.4 pumps
62.0%

3000

Design Tonnage

63.0%
Limiting Velocity
61.0%

Throughput, dry t/h

1.000

He = 0

64.0%

2500

65.0%

Nominal Tonnage

66.0%
67.0%

2000

Operating Range

68.0%
69.0%
70.0%
Nominal

1500

Q 4 pumps

Limiting Velocity

Rec

Design Tonnage

0.100

Q 3 pumps

1000
1300

60.0%

1500

1700

2100

1900

2500

2700

m3/h

Flow,

2300

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 2600.0
Q 2600.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Expansion

11/11/2015

2.800
2.800

Cw, %

65.0%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
2,936 dry t/h
2,916 dry t/h

20.244
30.402

#Pumps

m/km
m/km

Toromocho Tailings Pipelines

1000000
w-dot
w-dot

10000000
70,464 dry t/d
69,982 dry t/d

-dH/dX, NWT
-dH/dX, NWT

14.036
15.560

Speed, %

100%

m/km
m/km

Slide 69

Expansion System 4 Pumps Operating @ 100 %


Diameter

24.000

NPS

Cw

60.00% %

Capacity

61,170 dry t/d

Sfac

1.100

10.000
Toromocho Tailings System Expansion - Sample 2
3500

Contingency
Q 2.4 pumps
62.0%

3000

Design Tonnage

63.0%
Limiting Velocity
61.0%

Throughput, dry t/h

1.000

He = 0

64.0%

2500

65.0%

Nominal Tonnage

66.0%
67.0%

2000

Operating Range

68.0%
69.0%
70.0%
Nominal

1500

Q 4 pumps

Limiting Velocity

Rec

Design Tonnage

0.100

Q 3 pumps

1000
1300

60.0%

1500

1700

2100

1900

2500

2700

m3/h

Flow,

2300

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 2600.0
Q 2600.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Expansion

11/11/2015

2.800
2.800

Cw, %

60.0%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
2,564 dry t/h
2,549 dry t/h

13.744
19.498

#Pumps

m/km
m/km

Toromocho Tailings Pipelines

1000000
w-dot
w-dot

10000000
61,537 dry t/d
61,170 dry t/d

-dH/dX, NWT
-dH/dX, NWT

12.670
13.644

Speed, %

100%

m/km
m/km

Slide 70

Expansion System 4 Pumps Operating @ 60 %


Diameter

24.000

NPS

Cw

60.00% %

Capacity

36,702 dry t/d

Sfac

1.100

10.000
Toromocho Tailings System Expansion - Sample 2
3500

Contingency
Q 2.4 pumps
62.0%

3000

Design Tonnage

63.0%
Limiting Velocity
61.0%

Throughput, dry t/h

1.000

He = 0

64.0%

2500

65.0%

Nominal Tonnage

66.0%
67.0%

2000

Operating Range

68.0%
69.0%
70.0%
Nominal

1500

Q 4 pumps

Limiting Velocity

Rec

Design Tonnage

0.100

Q 3 pumps

1000
1300

60.0%

1500

1700

2100

1900

2500

2700

m3/h

Flow,

2300

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 1560.0
Q 1560.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Expansion

11/11/2015

1.680
1.680

Cw, %

60.0%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
1,538 dry t/h
1,529 dry t/h

7.272
14.555

#Pumps

m/km
m/km

Toromocho Tailings Pipelines

1000000
w-dot
w-dot

10000000
36,922 dry t/d
36,702 dry t/d

-dH/dX, NWT
-dH/dX, NWT

4.991
5.416

Speed, %

60%

m/km
m/km

Slide 71

Expansion System 4 Pumps Operating @ 60 %


Diameter

24.000

NPS

Cw

64.00% %

Capacity

40,885 dry t/d

Sfac

1.100

10.000
Toromocho Tailings System Expansion - Sample 2
3500

Contingency
Q 2.4 pumps
62.0%

3000

Design Tonnage

63.0%
Limiting Velocity
61.0%

Throughput, dry t/h

1.000

He = 0

64.0%

2500

65.0%

Nominal Tonnage

66.0%
67.0%

2000

Operating Range

68.0%
69.0%
70.0%
Nominal

1500

Q 4 pumps

Limiting Velocity

Rec

Design Tonnage

0.100

Q 3 pumps

1000
1300

60.0%

1500

1700

2100

1900

2500

2700

m3/h

Flow,

2300

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 1560.0
Q 1560.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Expansion

11/11/2015

1.680
1.680

Cw, %

64.0%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
1,715 dry t/h
1,704 dry t/h

12.884
23.753

#Pumps

m/km
m/km

Toromocho Tailings Pipelines

1000000
w-dot
w-dot

10000000
41,159 dry t/d
40,885 dry t/d

-dH/dX, NWT
-dH/dX, NWT

5.442
6.042

Speed, %

60%

m/km
m/km

Slide 72

Expansion System 4 Pumps Operating @ 100 %


Diameter

24.000

NPS

Cw

68.80% %

Capacity

77,370 dry t/d

Sfac

1.100

10.000
Toromocho Tailings System Expansion - Sample 2
3500

Contingency
Q 2.4 pumps
62.0%

3000

Design Tonnage

63.0%
Limiting Velocity
61.0%

Throughput, dry t/h

1.000

He = 0

64.0%

2500

65.0%

Nominal Tonnage

66.0%
67.0%

2000

Operating Range

68.0%
69.0%
70.0%
Nominal

1500

Q 4 pumps

Limiting Velocity

Rec

Design Tonnage

0.100

Q 3 pumps

1000
1300

60.0%

1500

2100

1900

1700

2500

2700

m3/h

Flow,

2300

0.010

0.001
10

100

1000

Sample #
Sample #

1
2

Q 2600.0
Q 2600.0

m3/h
m3/h

Sample #
Sample #

1
2

V
V

m/s
m/s

Expansion

11/11/2015

2.800
2.800

Cw, %

68.8%

Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP

10000

100000
3,248 dry t/h
3,224 dry t/h

34.202
46.561

#Pumps

1000000
w-dot
w-dot

m/km
m/km

Toromocho Tailings Pipelines

10000000
77,959 dry t/d
77,370 dry t/d

-dH/dX, NWT
-dH/dX, NWT

15.713
17.960

Speed, %

100%

m/km
m/km

Slide 73

Operating Ranges:
Initital Toromocho Tailings Systems - Comparison
7000

Design Tonnage
6000

62.0%
63.0%
Limiting Velocity
Q 5.8 pumps

Nominal Tonnage

61.0%

5000

64.0%

Throughput, dry t/h

65.0%
66.0%
67.0%

4000

68.0%

Limiting Velocity

69.0%
70.0%

Operating Range
3000

Nominal
Q 10 pumps

Design Tonnage

Design Tonnage
Q 8 pumps
60.0%

Nominal Tonnage

Limiting Velocity

2000

Nominal
Design Tonnage
Q 4 pumps

Limiting Velocity
1000
1300

1800

2300

2800

3300

3800

4300

4800

5300

5800

Flow, m3/h

11/11/2015

Toromocho Tailings Pipelines

Slide 74

Operating Ranges:
Toromocho Tailings Systems - Complete Operating Range
12000

62.0%
63.0%

10000

Limiting Velocity

Both @ Design Tonnage

Q 5.8 pumps
61.0%
64.0%

8000

65.0%

Both @ Nominal Tonnages

66.0%

Throughput, dry t/h

67.0%
68.0%

Initial Design Tonnage

69.0%

6000

70.0%
Initial Nominal

Initial Nominal Tonnage

Q 10 pumps

Operating Ranges

Initial Limiting Velocity

Initial Design Tonnage


Q 8 pumps

4000

60.0%
Limiting Velocity

Expan Design
Tonnage

Exansion Nominal
Expansion Design

Expan Nominal Tonnage

2000

Q 4 pumps
w-14 pump

Expan Limiting Velocity

Total NominalTonnage
Total Design Tonnage

0
1000

2000

3000

4000

5000

6000

7000

8000

9000

Flow, m3/h

11/11/2015

Toromocho Tailings Pipelines

Slide 75

Expansion System Hydraulics

11/11/2015

Toromocho Tailings Pipelines

Slide 76

Expansion System SS Hydraulics


Conventional Slurry

11/11/2015

Toromocho Tailings Pipelines

Slide 77

Expansion System SS Hydraulics


Bingham Plastic Slurry

Conventional Slurry

11/11/2015

Toromocho Tailings Pipelines

Slide 78

Expansion System Mechanical Design

11/11/2015

Toromocho Tailings Pipelines

Slide 79

Expansion System Mechanical Design

11/11/2015

Toromocho Tailings Pipelines

Slide 80

Expansion System Mechanical Design

11/11/2015

Toromocho Tailings Pipelines

Slide 81

Expansion System Mechanical Design

Available space for the new discharge pipe


11/11/2015

Toromocho Tailings Pipelines

Slide 82

Expansion System Mechanical Design


P/S West Side feed and discharge

P/S West Side feed and discharge

11/11/2015

Toromocho Tailings Pipelines

Slide 83

Expansion System Mechanical Design


P/S West Side feed and discharge

P/S West Side feed and discharge

11/11/2015

Toromocho Tailings Pipelines

Slide 84

Expansion System Mechanical Design


P/S East Side feed and discharge

11/11/2015

Toromocho Tailings Pipelines

Slide 85

Expansion System Mechanical Design


P/S East Side feed and discharge

11/11/2015

Toromocho Tailings Pipelines

Slide 86

Expansion System Pipe Stress Analysis

11/11/2015

Toromocho Tailings Pipelines

Slide 87

Toromocho Tailings Pipelines


Expansion Pipe Stress Analysis
The expansion system pipe stress analysis was more straight forward than
the work done for the original system
4 pumps spaced far apart allow the discharge manifold to be more
flexible
Elevated piping still required to avoid existing piping and structures
under the platform
Only one discharge manifold
More lateral space
Pipe bends used to bring discharge to station floor for East side
pumps increasing piping flexability
11/11/2015

Toromocho Tailings Pipelines

Slide 88

Pipe Stress Analysis


Expansion System, Plant Discharge

11/11/2015

Toromocho Tailings Pipelines

Slide 89

Acknowledgements
Brian Peer:

Brian Peer is a Mechanical Engineer specializing


in mechanical piping design and pipe stress
analysis.
Brian Peer was responsible for the Toromocho
Tailings Pipeline Pump Station Stress and
Flexibility Analysis.
Leroy Worthen:
Mr. Worthen served as commissioning and
start-up engineer for the project.
11/11/2015

Toromocho Tailings Pipelines

Slide 90

Acknowledgements
Dr. George Shou (presentation reviewer):
VP and Chief engineer, BRASS Engineering
International, USA
Dr. Shou has over 30 years experience in slurry
pipeline engineering.
He was the project manager for basic
engineering, detailed engineering, construction
support and commissioning. Wushan Copper
tailings paste pipeline, 6km, 450 and 330mm
OD, in China. The pipeline was successfully
commissioned in September 2009.
11/11/2015

Toromocho Tailings Pipelines

Slide 91

The End
&
Thank you

11/11/2015

Toromocho Tailings Pipelines

Slide 92