Taller GESTIONDECOSTOSENPLANTASPARTEIIDIAP67 100 PDF

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AREA 05-PROCESS LINE “A” AREA 05-PROCESS LINE “A”
AREA: 05-CONCENTRATOR
f) Shut- Down: The motor may be shut-down “normally” EQUIPMENT Nº AND TITLE:05-0205D-SV REGRIND BALL MILL
# 1 PNEUMATIC CLUTCH
operating either the “Local” or “Remote” stop switches
EQUIPMENT LOCATION DRAWING Nº: 05-30-027
(PB1-05-0203-2 or PB2-05-0203-2). In addition, the motor ELEMENTARY AND INTERCONNECTION
will shut down automatically under either of the following DRAWING Nº: 05-0205D
conditions: P&D DRAWING Nº: 00-50-012
1. If oil level in main reservoir drops below a pre- a) Power Source: 460V “Ball Mills “A” MCC-P5C (05-8903).
determined level.
b) Controls: The clutch operating solenoid valve (05-0205D-SV) is
provided with a “Local” Disengage switch (PB1-05-0205D) and a
2. If oil level in either of the bearing inlet reservoirs drops “Remote” control switch is installed in control panel CC-5M which is
below a pre-determined level. located in the control room of the “Concentrator Building”. The “Local”
control switch is located in Vendor furnished control panel (LC-RA-2).
3. If oil level in both bearing inlet reservoirs does not
c) Status Indication: Status indication is provided bye means of a “Red”
reach a pre-determined level within 10 seconds after
engage light and a “Green” disengage light, both of which are integral
initial start – up. to the “Remote” control switch (PB2-05-0205D).
g) Instrumentation: d) Interlocks: The clutch operating solenoid control circuit is interlocked

with the “Regrind Ball Mill” motor (05-0205-M) and the “Regrind Ball
Mill” compressed air system.
e) Start-Up (Engage): Energizing of the clutch operating solenoid may

be initiated by operating the “Remote” engage switch (PB2-05-
0205D). 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 (Disengage): The clutch may be disengaged “normally” by

operating either the “Local” or “Remote” disengage switches (PB1-05-
0205D). In addition, the clutch will disengage 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
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AREA 05-PROCESS LINE “A” AREA 05-PROCESS LINE “A”
AREA: 05-CONCENTRATOR
EQUIPMENT Nº AND TITLE:05-0205D-H1 REGRIND BALL MILL 2. Oil temperature exceeds operating temperature.
# 1 LUBE OIL HEATER
EQUIPMENT LOCATION DRAWING Nº: 05-30-027 3. Heater temperature exceeds operating temperature.
ELEMENTARY AND INTERCONNECTION
DRAWING Nº: 05-0201C
P&D DRAWING Nº: 00-50-012
a) Power Source: 460V “Ball Mills “A” MCC-P5C (05-8903).
b) Controls: The controls for the lube oil heater consists of a low-level lube
oil contact (CR3-05-0205-2), an oil over-temperature switch (TS1-05-
0205-H), all connected in series with the heater contactor coil (42-05-
0205-H)
c) Status Indication: Status indication is provided bye means of a “Red”

operating light at the local control panel LC-RA (light is out when heater
is off).
d) Interlocks: The heater control circuit is interlocked with the “Lube Oil”
system through the low-level switch (LLS-3-05-0205-2) energizing TS1-
05-0205-H and the heater over-temperature switch TS2-05-0205-H.
e) Start-Up: Since the only controls on this heater are the lube oil and
heater temperature switches and the oil level relay (CR3-05-0205-2), the
heater will operate automatically the following conditions are met:
1. Main breaker power is on
2. Oil level in reservoir is above operating level (CR3-05-0205-2

energized).
3. Lube oil temperature is below operating temperature.
4. Heater temperature is below operating temperature.
5. All components are functioning normally
f) Shut-down : The heater may be shut off manually bye means of the
main power circuit breaker only (at the MCC). The heater will shut off
automatically under either of the following conditions:
1. Oil in reservoir drops below operating level (CR3-05-0205-2) de

energized.
INTERCADE www.intercade.org
CONSULTANCY & TRAINING
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12.0 GRINDING AND FLOTATION 12.0 GRINDING AND FLOTATION 69
12.5.1 PRIMARY GRINDING CIRCUITS A&B (cont’d) 12.5.1 PRIMARY GRINDING CIRCUITS A&B (cont’d)
CONSOLE CC-5M/UA – 5000M The belt scale system control the feed rate to ball mill feed belt
Feeder 1A Malf. (motor) alarm 04-0701-M converyors. Both belt scale systems are identical, the first belt scale
Feeder 2A Malf. (motor) alarm 04-0702-M systems are identical, the first belt scale system serves ball mill feed
Feeder 3A Malf. (motor) alarm 04-0703-M belt conveyor 04-0602 for grinding circuit “A”, the other serves ball
Feeder 1B Malf. (motor) alarm 04-0704-M mill feed belt conveyor 04-0603 for grinding circuit “B”. The following
Feeder 2A Malf. (motor) alarm 04-0705-M operation description applies to both feed rate control systems:
Feeder 3A Malf. (motor) alarm 04-0706-M
Feeder 1A Hydr. Malf. alarm 04-0701-M The ore on the ball mill feed conveyor is weighed by an electronic
Feeder 2A Hydr. Malf. alarm 04-0702-M belt scale. The load-cell-type belt scale is equipped with local feed
Feeder 3A Hydr. Malf. alarm 04-0703-M rate indicator, tonnage totalizer and transmission circuits for remote
Feeder 1B Hydr. Malf. alarm 04-0704-M instrumentation.
Feeder 2A Hydr. Malf. alarm 04-0705-M
Feeder 3A Hydr. Malf. alarm 04-0706-M 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
B. BALL MILL FEED BELL CONVEYORS (04-0602&04-0603) recording and control, and one is a digital (pulse) signal for remote
totalization.
1) BELT STOPPED ALARM
If the belt conveyor stops for any reason, including normal Fine ore feed rate is controlled by the feed rate indicating controller
shutdown, the BELT STOPPED ALARM in annunciator UA- which provides a signal to the variable speed drives fo the fine ore
5000M will activate. feeders through bias stations for each feeder unit.
2) EMERGENCY STOP ALARM The signal is also transmitted to a ratio controller. The feed rate
The belt conveyor is equipped with an emergency stop pullcord signal multiplied by the set ratio (solids to liquid) will provide the
located along the path of the belt. The EMERGENCY STOP correct water/ore ratio signal which will control the water flow
ALARM in annunciator UA-5000M will activate if the conveyor (Gallons per minute).
has been stopped by someone pulling the pulicord switches.
2. OPERATING CONTROLS (FOR LOCAL CONTROL BOX)
3) ANNUNCIATOR ALARM NUMBERS
“Power On-Off” switch. Warning: switch to “Power Off” will erase all
CONSOLE CC-5M/UA-5000M “A” CKT “B”CKT belt scale readings.
CONVEYOR CONVEYOR
Belt Stopped Alarm 04-0602M 04-0603M Run, span, zero selector switch
Emergency Stop Alarm 04-0602M 04-0603M
Start test (momentary) pushbutton used to clear the calibration
C. BELT SCALES (04-4501 & 04-4502) counter and to set the test duration counter to zero when running
1) DESCRIPTION OF OPERATION “zero” and “span” calibration test.
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 vendors
instruction for belt scale calibration. INSTRUMENT & CONTROL NUMBERS
“A”CKT “B”CKT
INSTRUMENT & CONTROL NUMBERS BALL MILL BALL MILL
“A” CKT “A” CKT 05-0201 05-0202
CONVEYOR CONVEYOR FIELD
FIELD ELEMENTS 04-0602 04-0603 Flow elemt FE-5002 FE-5102
Weight Element WE-5001 WE-5101 Flow transmiter FT-5002 FT-5102
Speed Sensor WE/ST-5001 WE/ST-5101 Control valve FV-5002 FV-5102
LOCAL CONTROL BOX CONTROL PANEL CP-5M/5F

Feed Rate indicator WI-5001 WI-5101 Ratio station WFI-5001 WFI-5101
Tonnage totalizer WQI-5001B WQI-5101B Flow controller water FIC-5002 FIC-5102
Feed rate signal WT-5001 WT-5101 Flow recorder water FR-5002 FR-5102
Integrator (A/D) WQY-5001 WQY-5101 Flow square root station FY-5002 FY-5102
GRINDING CONTROL PANEL CP-5M/5F 1ST STAGE BALL MILLS (05-0201 & 05-0202)
Tonagge totalizer WQI-5001A WQI-5101A
Feed rate recorder WR-5001 WR-5101 The process control philosophy for both ball mills is identical. The
Feed rate controller WIC-5001 WIC-5101 operation description applies to both Ball Mill circuits.
Ratio station WFI-5001 WFI-5101
Bias station SY-5001 ABC SY-5101 ABC BALL MILL DRIVE MOTOR POWER MONITORING
ORE/WATER RATIO CONTROL SYSTEM (FIC-5002 & FIC-5102) The ball mill power draw is measured and transmitted to the
concentrator controm room for recording and overload alarm
DESCRIPTION OF OPERATION: annunciation on control console CC-5M.
Ore on the ball mill feed conveyor is weighed, speed compensated “A” CKT “B” CKT
and feed rate and tonnage is displayed locally and on control panel BALL MILL BALL MILL
CP-5M/5F. FIELD (MCC) 05-0201 05-0202
The 4-20mA rate signal from the scale is also routed to a ratio Powe primary element JE-5004 JE-5104
controller on CP-5M/5F. The rate signal multiplied by fixed ratio Power trasmitter JT-5004 JE-5104
(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.
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12.0 GRINDING AND FLOTATION
12.5.1 PRIMARY GRINDING CIRCUITS A&B (cont’d)
a. BALL MILL LUBE SYSTEM PACKAGE
“ A” CKT “A” CKT The following alarm windows are activated from the vendor supplied
CONVEYOR CONVEYOR Lube System Package. For vendor supplied Lube System Package,
CONTROL PANEL CP-5M/5F 05-0201 02-0202 se Vendor (MINE & SMELTER CORP). Dwg.Nº. 108479.
Power recorder JR-5004 JR-5101
Overload setpoint switch JSH – 5004 05-0202M CONSOLE CC-5M/UA-5000M “A”CKT “B”CKT
Flow elemt 05-0201 05-0202
Flow transmiter 05-0201 05-0202
2) BALL MILL BEARING TEMPERATURE MONITORING
b. COOLING WATER FLOW SWITCH
The temperature monitoring and alarm system for each ball mill The cooling water flow from each Lube System Package is
continouosly measure and compare the alarm setpoints with actual monitored, and low water flow will activate an alarm on console CC-
bearing and motor temperatures. On deaviation from setpoint, the 5M.
monitor will actuate the annunciator section of the monitor to alert the
operator. FIELD “A” CKT “B” CKT
Cooling water flow switch FSL-5015 FSL-5115
The monitoring and alarm system is equipped with an integral alar
acknowledge and test feature as well as an analog temperature CONSOLE CC-5M/UA-5000M
indicator, and individual selector switches to permit direct readings of Low Cooling water flow alarm FAL-5015 FAL-5115
the equipment temperatures and setpoints.
c. GEAR SPRAY LUBE SYSTEM
The first stage Ball Mill Temperature Monitors are located in control For information on the automatic gear spray system see Vendor
panel CP-5M/5F: (LINCOLN) drawings:
“ A” CKT “A” CKT MSI Nº. 204125 & 204126

CONVEYOR CONVEYOR MSI Nº. 105609 & 105610
CONTROL PANEL CP-5M/5F 05-0201 05-0202
Temperature monitor TI/TAH-5008 TI/TAH-5108 4. BALL MILL AIR CLUTCH SYSTEM
For local instruments seee Vendor (BARBER GREENE CO.)
3) BALL MILL LUBE SYSTEM Dgw. Nº CP-3090
F. 1ST STAGE CYCLONE FEED SUMPS (03-2701 & 03-2702)
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 sump level.
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12.0 GRINDING AND FLOTATION 12.0 GRINDING AND FLOTATION
The sump levels and measured with ultrasonic level detectors and LOCAL (MCC) “A” CKT “B” CKT
are controlled by indicating controllers which regulate the process Pump Nº 2 primary element LE/LT-5006 IE-5111
water control valves. Pump Nº 2 transmitter IT-5011 IT-5111
FIELD ELEMENTS “A” CKT “B” CKT CONTROL PANEL CP-5M/5F

Level sensor/transmiter LE/LT-5006 LE/LT-5106 Pump Nº. 1 current indicator II – 5007 II – 5107
Level indicator/transmiter LIX-5006 LIX-5106 Pump Nº. 2 transmitter II – 5011 II - 5111
Level control valve LV-5006 LV-5106
CONTROL CONSOLE CC-5M/UA-5000M
CONTROL PANEL CP-5M/5F Nº 1 Feed Pump Malf. Alarm 05-1501M 05-1502M
Sump level controller LIC-5006 LIC-5106 Nº 2 Feed Pump Malf. Alarm 05-1561M 05-1562M
2) WATER FLOW RECORDERS H. 1ST STAGE CYCLONE CLUSTER (05-0501 & 05-0502)
The makeup water flow required to maintain sump level, is measured
and recorded at the concentrator control room. The 1st stage cyclone clusters are equipped with the following
pressure gauges:
FIELD “A” CKT “B” CKT
Flow Element FE-5005 FE-5105 FIELD “A” CKT “B” CKT
Flow transmiter FT-5005 FT-5105 Input pressure gauge PI-5009A PI-5109A
Input pressure gauge PI-5009B PI-5109B
CONTROL PANEL CP-5M/5F Input pressure gauge (cluster) PI-5009 PI-5109
Square root extractor FY-5005 FY-5105 Input pressure gauge PI-5009C PI-5109C
Water flow recorder FR-5005 FR-5105 Input pressure gauge PI-5009D PI-5109D
G. 1ST STAGE CYCLONE FEED PUMPS (05-1501 & 05-1561) I. 2ND STAGE BALL MILL WATER CONTROL SYSTEMS (FIC-5027
(05-1502 & 05 - 1562) & FIC-5127)
The following instrumentation is used to measure and display 1. DESCRIPTION OF OPERATION:

cyclone feed pump motor current and pump status.
The second stage ball mill requires dilution water to adjust
LOCAL (MCC) “A” CKT “B” CKT pulp density prior to grinding. The water to adjust pulp density
Pump Nº 1 primary element IE – 5007 IE – 5107 prior to grinding. The water flow rate is measured and
Pump Nº 1 transmitter IT – 5007 IT – 5107 recorded, and the controller maintains a manually set flow rate.
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2) INSTRUMENTS & CONTROL NUMBERS “A” CKT “B” CKT

CONSOLE CC-5M/UA-5000M 05-0203 05-0204
FIELD “A” CKT “B” CKT Overload alarm JAH-5025 JAH-5125
Flow element FE-5027 FE-5127 Flow transmiter 05-0203M 05-0204M
Flow transmiter FT-5027 FT-5127
Control Valve FV-5027 FV-5127 2. BALL MILL TEMPERATURE MONITORING
The temperature monitoring and alarm system for each ball mill will
CONTROL PANEL CP-5M/5F continuosly measure and compare the alarm set-ponts with actual
Flow controller FIC – 5027 FIC-5127 bearing and motor temperatures. On deviation from setpoint, the
Flow recorder FR – 5027 FR-5127 monitor will actuate the annunciator section of the monitor to alert
Flow square root station FY – 5027 FY-5127 the operator to the alarm source.
J. 2ND STAGE BALL MILLS (05-0203 & 05-0204) The temperature monitoring and alarm system is quipped with and
integral alarm acknowledge and test feature, as well as an analog
Both second stage ball wills have indentical process control temperature indicator and individual selector switches to permit
philosophy, and the same operation description applies to both ball direct readings of the equipment temperature.
mill circuits.
The second stage Ball Mill temperature monitors are located in
1) BALL MILL DRIVE MOTOR POWER MONITORING control panel CP-5M/5F:
The ball mill power is measured and converted to standard (4- CONTROL PANEL CP-5M/5F “A” CK “B” CKT
20mA) signal for recording and overload alarm annunciation at Temperature monitor TI/TAH-5026 TI/TAH-5126
concentrator control room.
3. BALL MILL LUBE SYSTEM
FIELD (MCC) “A” CKT “B” CKT
Power primary element JE-5025 JE-5125 a. BALL MILL LUBE SYSTEM PACKAGE
Flow transmiter JT-5025 JT-5125 The following alarm windows are activated from Vendor supplied
Lube System Package. For instrument inside the Lube system
CONTROL PANEL CP-5M/5F Package see Vendor (MINE & SMELTER CORP.) Dwg. Nº
Power recorder JR-5025 JR-5125 108479.
Alarm setpoint switch JSH-5025 JSH-5125
CONSOLE CC-5M/UA-5000M “ A” CK “B” CKT
Lube sys. Filter Dirty-Alarm 05-0203 05-0204
Lube Oil Malf. Alarm 05-0203 05-0204
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b. COOLING WATER FLOW SWITCH The sump levels and measured with ultrasonic level detectors and
The cooling water flow from each Lube System Package is are controlled by indicating controllers which regulate the process
monitored, and low water flow will activate an alarm on console water control valves.
CC-5M.
FIELD “A” CKT “B” CKT Level sensor/transmiter LE/LT-5030 LE/LT-5130
Cooling water flow switch FLS-5040 FLS-5140 Level indicator/transmiter LIX-5030 LIX-5130
Level control valve LV-5030 LV-5130
CONSOLE CC-5M/UA -5000M
Low cooling water flow alarm FAL-5040 FAL-5140 CONTROL PANEL CP-5M/5F
Sump level controller LIC-5030 LIC-5130
c. GEAR SPRAY LUBE SYSTEM
For information on the automaticc gear spray system see Vendor 2) WATER FLOW RECORDERS
(LINCOLN) drawings: The makeup water flow, used to maintain sump level, is continuosly
measured and is recorded at the control room.
MSI Nº. 204125 & 204126
MSI Nº 105609 & 105610 FIELD “A” CKT “B” CKT
Flow Element FE-5029 FE-5129
4. BALL MILL AIR CLUTCH SYSTEM Flow transmiter FT-5029 FT-5129
For local instruments see Vendor (BARBER GREENE CO.)
Dwg. Nº CP—3090. CONTROL PANEL CP-5M/5F
Square root extractor FY-5029 FY-5129
K. 2ND STAGE CYCLONE FEED SUMPS (03-2705 & 03-2706) Water flow recorder FR-5029 FR-5129
1) LEVEL CONTROL L. 1ST STAGE CYCLONE FEED PUMPS (05-1503 & 05-1563)
Makeup water is added to the cyclone feed sumps in order to (05-1504 & 05 - 1564)
maintain the desired feed-pulp density, The controlling parameter
for makeup water addition is sump level. The following instrumentation is used to measure and display
cyclone feed pump motor current and pump status:
The sump levels are measured witch ultrasonic level detectors
and are controlled by indicating controllers which regulate the LOCAL (MCC) “A” CKT “B” CKT
process water control valves. Pump Nº 1 primary element IE – 5007 IE – 5131
Pump Nº 1 field transmitter IT – 5031 IT – 5133
Pump Nº 2 field transmitter IE – 5033 IT – 5133
Pump Nº 2 field transmitter IT – 5033 IT – 5133
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12.0 GRINDING AND FL>OTATION

CONTROL PANEL CP-5M/5F “A” CKT “B” CKT
CONTROL PANEL CP-5M/5F “A” CKT “B” CKT pH probe AE-5035 AE-5135
Pump Nº 1 current indicator II-5031 II-5131 pH transmitter AT-5035 AT-5135
Pump Nº 2 current indicator II-5033 II-5133 Solenoid valve AEV-5035 AEV-5035
Control valve AV-5035 AV-5135
CONTROL CONSOLE CC-5M/UA-5000M
Nº 1 Feed Pump malf. Alarm 05-1503M 05-1504M 2. TANK AGITATOR ALARMS
Nº 2 Feed Pump malf. Alarm 05-1563M 05-1564M
CONSOLE CC-5M/UA-5000M
M. 2ND STAGE CYCLONE CLUSTER (05-0503 & 05-0506) Agitator Malf. Alarm 05-2001M 05-2002M
The second stage cyclone clusters are equipped with the following
pressure gauges: O. ROUGHER FLOTATION FEED SUMP (05-2711 & 05-2712)
Ph INSTRUMENTATION
Input Pressure Gauge PI-5032A PI-5132A The pH measurement signal for each feed sump is transmited to the
Input Pressure Gauge PI-5032B PI-5132B control panel where it is alarmed (high & low pH) and recorded.
Input Pressure Gauge PI-5032C PI-5132C
Input Pressure Gauge PI-5032D PI-5132D FIELD “A” CKT “B” CKT
Input Pressure Gauge (cluster) PI-5032 PI-5132 pH probe AE-5401 AE-5421
Input Pressure Gauge PI-5032E PI-5132E pH transmitter AT-5401 AT-5421
Input Pressure Gauge PI-5032F PI-5132F
Input Pressure Gauge PI-5032G PI-5132G CONTROL PANEL CP-5M/5F
pH recorder AR-5401 AR-5421
N. CONDITIONER TANK (05-1201 & 05-1202) high/low pH setpoint switch ASH/L5401 ASH/L-5421
1. pH CONTROL SYSTEM CONSOLE CC-5F/UA-5400F

High/low pH alarm AAH/L-5401 AAH/L-5421
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 P. FINE ORE STORAGE DUST COLLECTOR (04-0801) (AREA 04)
to a controller and recorder in control panel CP-5M/5F. The
controller operates a solenoid valve, wich in turn actuates the milk of The following instruments are part of the dust collection control
lime control valve. system:
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12.5.2 ROUGHER/SCAVENGER FLOTATION
A. ROUGUER I FLOTATION CELLS
FIELD Rougher I consists of two (2) banks of flotation cells for each circuit.
Slurry tank level sensor FE-5127 The level of each bank is measured by a static pressure type level
Low water flow switch FT-5127 probe. Two dart valves, for level adjustment, are controlled
automatically by the level control signal. The system also has a
CONSOLE CC-5M/UA-5000M manual control option.
Low water flow alarm 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
Q. ANNUNCIATOR/ALARM SYSTEMS Vendor (WEMCO) drawing Nº 8041680-14 for more information.
The alarms for primary grinding circuits are annunciated on UA- FIELD “A” CKT NUMBER NUMBER
5000M. See drawing Nº 05-40-014. level controller 05-2601 LIC-5403
(BANK 1) level control valve thru LV-5403A
level control valve 05-2603 LIC-5403B
level controller 05-2604 LIC-5404

FIELD “B” CKT


B. 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 12.5.2 ROUGHER/SCAVENGER FLOTATION cont`d
A. ROUGUER I FLOTATION CELLS A. ROUGUER I 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 CONTROL PANEL CP-5M/5F
Vendor (WEMCO) drawing Nº 8041680-14. “A” CKT pH recorder AR-5407
“A” CLT pH high/low pH setpoint switch ASH/L-5407
CELL INSTRUMENT “B” CKT pH recorder AR-5427
FIELD “A” CKT NUMBER NUMBER “B” CKT pH high/low pH setpoint switch ASH/L5427
(BANK 1) level control valve thru LV-5405A CONTROL CC-5F/UA-5400F
level control valve 05-2618 LV-5405B “A” CKT high/low pH alarm AAH/L-5407
“B” CKT high/low pH alarm AAH/L-5427
(BANK 2) level control valve thru LV-5406A C. SCAVENGER I FLOTATION CELLS
level control valve 05-2622 LV-5406B 1) LEVEL CONTROL
Scavenger I consist of two (2) banks of flotation cells for each
FIELD “B” CKT circuit… The level of each bank is measured by a static pressure
level controller 05-2623 LIC-5425 type level probe. Dart valves (for level adjustment) are controlled
(BANK 1) level control valve thru LV-5425A automatically by the level control signal. The system also has a
level control valve 05-2609 LV-5423B manual control option.
level controller 05-2610 LIC-5426 The level controller for each bank is mounted locally close to the
(BANK 2) level control valve thru LV-5426A dart valves. All dart valves will fail open upon instrument air
level control valve 05-2612 LV-5426B failure. See Vendor (WEMCO) drawing Nº. 8041680-14.
2) pH INSTRUMENTATION CELL INSTRUMENT

FIELD “A” CKT NUMBER NUMBER
The pH measurement signal for flotation cells is transmitted to the Level controller 05-2633 LIC-5408
control panel where it is alarmed (high/low) and recorded. Level control valve thru LV-5408A
Level control valve 05-2636 LV-5408B
CELL INSTRUMENT
FIELD “A” CKT NUMBER NUMBER Level controller 05-2637 LIC-5409
“A” CKT pH probe 05-2615 thru 2618 AE-5407 Level control valve thru LV-5409A
“A” CKT pH transmitter 05-2615 thru 2618 AE-5407 Level control valve 05-2640 LV-5409B
“B” CKT pH probe 05-2623 thru 2626 AE-5427
“B” CKT pH transmitter 05-2623 thru 2626 AE-5427

12.5.2 ROUGHER/SCAVENGER FLOTATION cont`d 12.5.2 ROUGHER/SCAVENGER FLOTATION (cont’d)
CELL INSTRUMENT D. SCAVENGER II FLOTATION

FIELD “B” CKT NUMBER NUMBER Scavenger II consist of three (3) banks of flotation cells for each
Level Controller 05-2641 LIC-5428 circuit. The level of each bank is measured by a static pressure type
Level Control valve thru LV-5428A level probe. Dart valves (for level adjustment) are controlled
Level Control valve 05-2641 LV-5428B automatically by the level control signal. The system also has a
Level Controller 05-2645 LIC-5429
Level Control valve thru LV-5429A The level controller for each bank is mounted locally close to the
Level Control valve 05-2648 LV-5429B dart valves. All dart valves will fail open upon instrument air failure.
See Vendor (WEMCO) drawing Nº. 8041680 – 14.
2) pH INSTRUMENTATION
CELL INSTRUMENT
The pH measurement signal for flotation cells is transmitted to the FIELD “A” CKT NUMBER NUMBER
control panel where it is alarmed (high/low) and recorded. level controller 05-2649 LIC-5410
CELL INSTRUMENT level control valve 05-2651 LV-5410B
FIELD NUMBER NUMBER
“A” CKT pH probe 05-2637 thru 2640 AE-5413 level controller 05-2652 LIC-5411
“A” CKT pH transmitter 05-2637 thru 2640 AE-5413 (BANK 2) level control valve thru LV-5411A
“B” CKT pH probe 05-2645 thru 2648 AE-5433 level control valve 05-2654 LV-5411B
“B” CKT pH transmitter 05-2645 thru 2648 AE-5433
CONTROL PANEL CP-5M/5F (BANK 3) level control valve thru LV-5412A
“A” CKT pH recorder AE-5413 level control valve 05-2658 LV-5412B
“A” CKT high/low ph setpoint switch ASH/L-5413
“B” CKT high/low ph setpoint switch ASH/L-5433 FIELD “B” CKT
“B” CKT pH recorder AR-5433 level controller 05-2659 LIC-5430
CONSOLE CC-5F/UA-5400F level control valve 05-2661 LIV-5430B
“A” CKT high/low pH alarm AAH/L-5413 level controller 05-2665 LIV-5432

“B” CKT high/low pH aarm AAH/L-5433 (BANK 2) level control valve thru LV-5432A
level control valve 05-2668 LV-5432B
E. ENNUNCIATOR/ALARM SYSTEMS
The alarms for rougher/scavenger flotation are annunciated on

UA-5400F. See drawing Nº. 05-40-015
40
79
12.5.3 CLEANER FLOTATION & REGRIND 12.5.3 CLEANER FLOTATION & REGRIND (cont’d)
A. REGRIND COLLECTION SUMP (05-2722) The feed sump level is maintained by adding fresh water to the
Makeup water is added to the collection sump to maintain the sump. The ultrasonic level sensor measures the sump level and
desired feed-pulp density. The selected flow rate is set from manual supplies level signal to the level controller. The flow of the fresh
controller located on control panel CP-5M/5F. water is also measured and the flow rate 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 SUMP SUMP
concentrator control room. FIELD INSTRUMENTS 05-2713 05-2714
Level sensor/transmitter LE/LT-5212 LE/LT-5222
The status of the three regrind transfer pumps is monitored, and Level indicator/transmitter LIX-5212 LIX-5222
alarm will be annunciated if any one of the three pumps malfunction. Water control valve LV-5212 LV-522
One pump is stand-by. Water flow sensor FE-5213 FE-5223
Water flow transmitter FT-5213 FT-5223
FIELD INSTRUMENTS
Sonic level sensor/transmitter LE/LT-5205
Sump level indicator & transmitter LIX-5205
High setpoint switch LSH-5205 B. REGRIND CYCLONE FEED PUMPS (05-1505 & 05-1565)
Low setpoint switch LSL-5205 (05-1506 & 05-1566)
Water control valve HV-5200
The following instrumentation is used to measure and display
CONSTROL PANEL CP-5M/5F cyclone feed pump motor current and pump status:
Process water controller HIC-5200 SUMP SUMP

FIELD (MCC) 05-2713 05-2714
CONSOLE CC-5M/UA-5000M Pump Nº. 1 prim. element IE-5218 IE-5228
Sump level high alarm LAH-5205 Pump Nº. 1 transmitter IE-5218 IE-5228
Sump level low alarm LAL-5205 Pump Nº. 2 prim. element IE-5219 IE-5229
Transfer pump #1 malf. alarm 05-145OM Pump Nº. 2 transmitter IT-5219 IT-5229
Transfer pump #2 malf. Alarm 05-1541M
Transfer pump #3 malf. Alarm 05-1570M
B. REGRIND CYCLONE FEED SUMPS (05-2713 & 2714)
The two feed sump level control systems are identical and this
operation description applies to both sumps.
80
12.5.3 CLEANER FLOTATION & REGRIND (cont’d) 12.5.3 CLEANER FLOTATION & REGRIND (cont’d)
SUMP SUMP 1) BALL MILL DRIVE MOTOR POWER MONITORING

CONTROL PANEL CP-5M/5F 05-2713 05-2714 The ball mill power is measured and converted to standard (4-20 mA)
Pump Nº. 1 current indicator II - 5218 II - 5228 signal for recording and overload alarm annunciation at control room.
Level indicator/transmitter II - 5219 II - 5229
BALL MILL I BALL MILL II
FIELD (MCC) 05-0205 05-0206
D. REGRIND CYCLONE CLUSTERS (05-0509 & 05-0510) Power primary element JE-5210 JE-5220
Power transmitter JT-5210 JT-5220
The regrind cyclone clusters are equipped with the following
pressure gauges: CONTROL PANEL CP-5M/5F
Power recorder JR-5210 JR-5220
BALL MILL I BALL MILL II Overload setpoint switch JSH-5210 JSH-5220
CLUSTER CLUSTER
FIELD 05-0509 05-0510 CONSOLE CC-5M/UA-5000M
Input pressure gauge PI-5214A PI-5224A Overload alarm JAH-5210 JAH-5220
Input pressure gauge PI-5214B PI-5224B Failure (motor) alarm 05-0205M 05-0206M
Input pressure gauge PI-5214C PI-5224C
Input pressure gauge (cluster) PI-5214 PI-5224
Input pressure gauge PI-5214D PI-5224D 2) BALL MILL TEMPERATURE MONITORING
D. REGRIND CYCLONE MILLS (05-0205 & 05-0206) The temperature monitoring and alarm system for each mill will
continuosly measure and compare the alarm setpoints with actual
The process control philosophy for both ball mills is identical and bearing and motor temperatures. On deviation drom setpoint the
the same operation description applies to both Ball Mill control monitor will actuate the annunciator section of the monitor to alert the
systems. operator to 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:
41
81
12.5.3 CLEANER FLOTATION & REGRIND (cont’d) 12.5.3 CLEANER FLOTATION & REGRIND cont’d
BALL MILL I BALL MILL II 4) BALL MILL AIR CLUTCH SYSTEM

FIELD 05-0205 05-0202 For local instruments see Vendor (BARBER GREENE CO.)
Temperature monitor TI/TAH-5211 TI/TAH-5221 drawing Nº CP-3090.
3) BALL MILL LUBE SYSTEM F. CONCENTRATE SCAVENGER I SUMP (05-2727) LEVEL

CONTROL
a. LUBE OIL SYSTEM PACKAGE The sump level is measured by ultrasonic level detector. This level
The following alarm windows are activated from Vendor supplied signal is used to Start/Stop vertical sump pumps as well as to
Lube System Package. For instruments inside the Lube System generate high level alarm at the control room. One pump is stand-by.
Package see Vendor (MINE & SMELTER CORP) drawing Nº
108479. FIELD
BALL MILL I BALL MILL II Sonic level sensor/transmitter LE/LT-5488
CONSOLE CC-5M-UA-5000M 05-0205 05-0202 Sump level indicator & transmitter LIX-5488
Lube Sys. Filter High/low setpoint switch LSH-L-5488
Dirty-alarm 05-0205 05-0206 High setpoint switch LSH-5488
Lube Oil Malf. alarm 05-0205 05-0206 Pump selector switch HS-5488
COOLING WATER FLOW SWITCH CONSOLE CC-5F/UA-5400F

The cooling water flow from each Lube Oil System Package is Sump level high alarm LAH-5488
monitored by a flow switch. Low water flow will activate an alarm in
the control room. G. 1ST CLEANER FEED SUMP (05-2717)
BALL MILL I BALL MILL II 1) LEVEL CONTROL

FIELD 05-0205 05-0202 The sump level is measured by ultrasonic level detector. This level
Cooling water flow switch FSL-5216 05-5226 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-
CONSOLE CC-5M/UA-5000M by.
Low water flow alarm FAL-5216 FAL-5226
FIELD
C. GEAR SPRAY LUBE SYSTEM Sonic level sensor/transmitter LE/LT-5485
Sump level indicator & transmitter LIX-5485
For information on the automotive gear spray system, see Vendor High/low setpoint switch LSH-L-5485
(LINCOLN) drawing: High setpoint switch LSH-5485
Pump selector switch HS-5485
MSI Nº. 204125 & 204126
MSI Nº. 105609 & 105610 CONSOLE CC-5F/UA-5400F
Sump level high alarm LAH-5485
82
12.5.3 CLEANER FLOTATION & REGRIND (cont’d)

12.5.3 CLEANER FLOTATION & REGRIND (cont’d)
I. 1ST AND 2ND CLEANER FLOTATION CELLS
2) pH INSTRUMENTATION The 1st and 2nd cleaner consist of two (2) banks is measured by
an static pressure type level probe. Dart valves (for level
The pH measurement signal from the sump is transmitted to the adjustment) are controlled automatically by the level control
control room where it is alarmed (high/low) and recorded. signal. The system has a manual control option.
FIELD The level controller for each bank is mounted locally close to the
pH probe AE-5436 dart valves. All dart valves will fail upon instrument air failure.
pH transmiter AT-5436
CELL INSTRUMENT
CONTROL PANEL CP-5M/5F FIELD (1ST CLN) NUMBER NUMBER
pH recorder AR-5436 level controller 05-2672 LIC-5438
high/low pH setpoint switch ASH/L-5436 (BANK 1) level control valve thru LV-5438A
level control valve 05-2675 LV-5438B
H. 2ND AND 3RD CLEANER FEED SUMP (05-2718 & 05-2719)
LEVEL CONTROL level controller 05-2675 LIC-5439
The sump level is measured by ultrasonic level detector. This level (BANK 2) level control valve thru LV-5439A
signal is used to start/stop vertical sump pumps as well as to level control valve 05-2675 LV-5439B
generate high level alarm at the contro room. One pump is stand-
by. FIELD (2ND CLEANER)
2ND CLEANER 3RD CLEANER (BANK 1) level control valve thru LV-5441A
(05-2718) (05-2719) level control valve 05-2685 LIV-5441B
FIELD SUMP SUMP
Sonic level sensor/trans LE/LT-5486 LE-LT-5487 level controller 05-2686 LIV-5442
Sump level indicator & trans LIX – 5486 LIX-5487 (BANK 2) level control valve thru LV-5442A
High/low setpoint switch LSH/L-5486 LSH/L-5487 level control valve 05-2688 LV-5442B
Pump selector switch HS-5486 HS-5487
J. 3RD CLEANER FLOTATION CELLS (05-2692 through 05-2695)
CONSOLE CC-4F/UA – 5400F
1) LEVEL CONTROL
Sump level high alarm LAH-5486 LAH-5487
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
42
12.5.3 CLEANER FLOTATION & REGRIND cont`d

12.5.4 THICKENING AND FILTERING
The level controller for the bank is mounted locally close to the dart
valves. All dart valves will fail open upon instrument air failure. A. CONCENTRATE THICKENER (05-1203)
Thickener instrumentation includes overtorque alarms, safety
INSTRUMENT shutdown switches, and a torque recorder.
FIELD “B” CKT NUMBER
Level Controller LIC-5447 The concentrate a thickener discharge rate is controlled manually by
Level Control valve LV-5447A the setting of the underflow discharge valve. Thickener dirve motor
Level Control valve LV-5447B and the two underflow pumps are alarmed for motor malfunction-
2) pH INSTRUMENTATION 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
The pH measurement signal from the flotation cells is transmitted to
level alarm at the control room. One pump is stand-by.
the control panel where it is alarmed (high/low pH) and recorded.
FIELD INSTRUMENTS
FIELD Rake torque sensor OE-5450
pH probe AE-5445 Rake torque indicator and transmitter OIT-5450
pH transmitter AT-5445 High-High torque switch OSHH-5451
High torque switch OSH-5453
PANEL CP-5M/5F Motor torque indicator OI-5452
pH recorder AR-5445
high/low ph setpoint switch ASH/L-5445 CONTROL PANEL CP-5M/5F
Rake torque recorder OR-5450
CONSOLE CC-5F/UA-5400F High torque a setpoint switch OSH-5450
High/low pH alarm AH/L-5445
CONSOLE CC-5F/UA – 5400F
High torque alarm OAH-5450
K. ANNUNCIATOR/ALARM SYSTEMS Drive motor malf. Alarm 05-2101M
U’flow pump #1 malf. alarm 05-1521M
The alarms for Regrind area are annunciated on UA-5000M. See U’flow pump #2 malf. Alarm 05-1522M
drawing Nº 05-40-014.
FIELD
Alarms for Cleaner Flotation area are displayed on UA-5400F. See Capacitance level probe LE/5456
drawing Nº 05-40-015 High/ow setpoint switch LSH/L-5456
CONTROL CONSOLE CC-5F/UA-5400F

Low level alarm LAL-5456
High level alarm LAH-5456
84
12.5.4 THICKENING AND FILTERING (cont’d) 12.5.4 THICKENING AND FILTERING (cont’d)
C. CONCENTRATE FILTERS (05-2301 & 05-2302) PUMP #1 PUMP #2

The filter feed Distributor gravity feeds the two concentrate drum FIELD (COMPRESSOR ROOM) 05-1536 05-1537
filters, the feed rate to each drum filters is manually adjusted. If Seal water pres. switch (alarm) PSL-5464 PSL-5474
one of the filters is shutdown, an air actuated shut-off valve will Seal water pres. switch (shutdown) PSL-5465 PSL-5475
close off the corresponding drum filter feed line. Seal water solenoid valve EV-5470A EV-5480A
Seal water solenoid valve EV-5470B EV-5480B
The liquid level of each filter is measured by a capacitance type
level switch wich will transmit high and low level alarms to E. VACUUM RECEIVERS (05-1401 & 05-1402)
console CC-5F. Both vacum receivers are equipped with pressure gauges and
pressure transmitters. The receiver vacuum is displayed on control
A high filter cake storage level will be detected by a tilt switch, panel CP-5M/5F.
wich will then activate corresponding alarm on console CC-5F.
Filter failure alarms are also displayed on the annunciator. RECEIVER RECEIVER
FIELD (COMPRESSOR ROOM) PT-1401 PT-1408
FILTER #1 FILTER #2 Pressure transmitter PT-5468 PT-5478
FIELD INSTRUMENT 05-2301 05-2302
Shut-off valve HV-5457 HV-5459 CONTROL PANEL CP-5M/5F
Shut-down hand switch HS-5457 HS-5459 Vacuum receiver pres. indicator PI-5468 PI-5478
Capacitance level probe LE-5458 LE-5460
High/low setpoint switch LSH/L-5458 LSH/L-5460 F. ANNUNCIATOR / ALARM SYSTEMS
Tilt switch LSH-5481 LSH-5482
The alarms for Thickening and Filtering are annunciated on UA-
CONTROL CONSOLE CC-5F/UA-5400F 5400F. See drawing Nº- 05-40-015
Low level alarm LAL-5458 LAL-5460
High level alarm LAH-5458 LAH-5460
High storage level alarm LAH-5481 LAH-5482
Filter failure alarm 05-2301M 05-2302M
D. VACUUM PUMPS (05-1536 & 05-1537)

The filtration vacuum pumps, together with the drum filter blower
and air compressors, are located in the compressor room.
The vacuum pumps are equipped with local protective

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.
43
12.5.5 TAILINGS AND WATER TANKS 12.5.5 TAILINGS AND WATER TANKS cont’d
A. TAILINGS THICKENER (06-1201)
Tailings thickener instrumentation includes overtorque alarms, safety C.RECLAIM WATER PUMPS (06-1501, 1502, 1503 & 1504)
shutdown switches, and torque recorder. The four reclain water pumps, which deliver water to the
Process Water Tank (00-1202), are controlled by level
The tailings thickener discharge rate is controlled by manual setting signals from the process water tank. A sequential controller,
of the U’flow discharge valve. located in MCC Room #6, controls the start/stop sequence of
each pump. All pumps will shutdown on low level in settling
Remote recording and control instrumentation for the tailings pond or no high-high level in Process Water Tank (00-1202).
thickener are located in the concentrator control room. An alarm
condition will be signaled on control console CC-5F if the thickener FIELD INSTRUMENTS (AT SETTLING POND)
drive motor malfunctions.
Level sensor element LE-6016
FIELD INSTRUMENTS
Rake torque sensor OE-6001 Low level switch LSL-6016
Rake torque transmiter OY-6001
High torque switch (normal overload) OSH-6002
High-high torque switch (motor shutdown) OSHH-6003 LOCAL INSTRUMENTS (MCC ROOM #6)
Horn silence pushbotton HS-6004 Sequential controller for pumps
Stalled overload indicating ligth and horn (06-1501, 02, 03 & 04)
normal overload indicating light
High torque switch (overload shutdown) OSH-6001A Control Philosophy:
Low level: start one pump
CONTROL PANEL CP-5M/5F High level: stop one pump
Thickener torque recorder OR-6001 High – high level: stop all pumps
High torque setpoint switch OSH-6001
D. PROCESS WATER TANK (00-1202)
CONTROL CONSOLE CC-5F/UA-5400F
High torque alarm OAH-6001 The process water tank is equipped with a level gauge board
Drive motor malf. Alarm 06-2101M and a differential pressure-type level transmitter. The 4-20mA
tank level signal is transmitted to concentrator control room
B. RECLAIM WATER SETTLING POND (00-2101) where it is recorded and annunciated for high and low alarm
Makeup water is added to settling pond in order to replenish water lost to conditions.
process. The makeup water flow is controlled by a local level controller
actuating the electrically operated makeup water control valve. In addition, the level signal is routed from the concentrator
control room to MCC Room #6 (reclain water settling pond),
FIELD INSTRUMENTS where it is displayed and used to generate the sognal for the
Level sensor element LE-6010 reclaim water pump sequential control.
Level transmitter LT-6010
Level controller LC-6010
Level control valve LV-6010
86
12.5.5 TAILINGS AND WATER TANKS cont’d 12.5.5 TAILINGS AND WATER TANKS cont’d
FIELD INSTRUMENTS (AT TANK) FIELD INSTRUMENTS (AT TANK)

Level gauge board LI-0003 Level gauge board LI-0001
Tank level inidicator & transmitter LIT-0004 Tank level inidicator & transmitter LIT-0002
High/low level switch LSH-L0005
LOCAL INSTRUMENTS (AT MCC #6) Level control valve LV-0005
Tank level indicator LI-0004 Flow switch FSH-0006
Low level switch (starts one pump) LSL-0004
High level switch (stops one pump) LSH-0004 CONTROL PANEL CP-5M/5F
High-high level switch (stops all pumps) LSHH-0004 Tank level recorder LAH-0002
Tank at low level – light; semi-graphic
CONTROL PANEL CP-5M/5F Tank at high level – ligth; semi -graphic
Tank level recorder LR-0004 High/low level setpoint switch LSHH-0002
High/low level setpoint switch LSH/L-0004
Tank at low level – ligth; semi-graphic CONTROLE CONSOLE CC-5M/UA-5000M
Tank at high level – ligth; semi-graphic High level alarm LAH-0002
Low level alarm LAL-0002
CONTROL CONSOLE CC-5M/UA-5000M High water flow alarm FAH-0006
High level alarm LAH-0004
Low level alarm LAL-0004 F. POTABLE WATER TANK (00-1203 & 00-1204)
Each Potable Water Tank is eqquiped with a level gauge board and
E. FIRE PROTECTION (AND FRESH WATER) TANK (00-1201) an altitude type level control valve.
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 TANK TANK
transmitted to concentrator control room where the tank level is recorded FIELD 00-1203 00-1204
and annunciated for high and low level alarm conditions. Level gauge boad LI-0017 LI-0019
Pilot valve LV-0016 LV-0018
In addition, a conductivity type level switch is used to sense the tank Level control valve LCV-0016 LCV-0018
level to control (open/ close) motorized valve for adding river water. An
electrically controlled valve is provided on the supply line to the fire G. ANNUNCIATOR/ALARM SYSTEMS
protection tank as no instrument air is available.
The alarms for Tailings Thickener area are annunciated on UA-
The eight inch diameter fire protection water linea leaving the tank is 5400F. See drawing Nº 05-40-015.
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 Alarms for Water Tanks are annunciated on UA-5000M. See drawing
alarm. Nº 05-40-015.
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, Electrical interlocks for each item of equipment are described in
substations, switchgear and motor control centers are provided Section 12.5, ELECTRICAL CONTROLS.
with protective devices to ensure against damage to equipment
and materials in the event of electrical overload or fault Electrical interlocks are normally provided to prevent start-up or
conditions. to cause shutdown of a particular piece of equipment.
Motor control centers are provided with thermal overload relays Start-up prevented due one more start-up conditions not being
to protect their associated motors. satisfied (permissive start).
For description of transformers, substation, switchgear and Shut-down is initiated by an interlock when the “operating”
motor control centers, refer to Section 8.0, titled “Plant status of that interlock has changed either by deliberate intent
Electrical Power System” or by reason of mal-function in the system.
88
12.0 GRINDING, FLOTATION, THICKENING AND 12.0 GRINDING, FLOTATION, THICKENING AND
FILTERING FILTERING
12.9 EQUIPMENT TRIAL RUNS (No Load)

12.8 PRE-STARTUP EQUIPMENT AND SYSTEM CHECKS
On completion of all necesary checks, the Plant may be released sor
On termination of erection and before starting up a machine, a the trial runs. The idle run of the machines should be carried out in
careful check should be carried out to make sure the machine has accordance with (including period of time) manufacturers’ installation,
been properly installed, adjusted and serviced and that the servicing and aoperating instructions. The starting procedure is
machine and operating area are free of remnants of construction supervised on the spot. In the event deficiences become evident during
materials. 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
A complete record should be made of this work. All deficiences bearings are adequately lubricated, taht all oil and grease pumps are
should be recorded, including a full description of the problem properly working and that the control devices, especially for oil, grease,
and action required. Upon completation of the remedial action, a cooling water, etc, respond properly.
second check should be made to insure the deficiency has been
corrected and the machine or system is in satisfactory working Checks during these trial runs that the electrical interlocking system has
condition. been executed in accordance with the plans. Check in particular wheter
or not the control devices are included in the interlocking system and all
Prior to starting any machine or system, the operator should equipment protection and personnel safety devices function properly.
become fully familiar with the manufacturers’ installation,
servicing and operating instructions. 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 conjuction 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 machine or system, become fully familiar with the
manufacturers`installation, servicing and operating instructions.
45
89
FILTERING FILTERING
12.9 EQUIPMENT TRIAL RUNS (No Load) (cont’d) 12.9 EQUIPMENT TRIAL RUNS (No Load) (cont’d)
The following are for specific reference: After the break-in run is completed, fill the grinding mill with water and
check for and stop all leakage from liner bolts.
A. Grinding Mills
The mill should the be charged with grinding media, graded in size.
Some local heat may occur on the grinding mill trunnion bearings Initial charge should be approximately 65 percent of total charge. A
until they seat themselves. This heating will be observed to be cushion charge of material should be placed in the liners before
confined to narrow bands on the trunnion surfaces and may charging the grinding media.
wander back and forth over the width of the trunnions. As the
surfaces “seat”, a uniform heat will develop over the trunnion Mills should not be operated without a continuous and uniform rate of
surfaces and then will gradually decrease. new feed.
Observe the contact pattern formed on the grease coated mill
B. Slurry Pumps
gear and pinion. A uniform contact pattern should be developing.
Do not attempt to start a pump until drive rotation has been verified.
If the temperature of the trunnion should exceed vendor’s
recommended maximum stop the mill and allow it to cool before
restarting. Operation with seal water, either low in quantity or pressure can cause
serious damage. Seal water requirements, including quatinty and
The mill Power Recorder and Temperature Monitor should be pressure are defined in the manufacturers’ installation, operation and
closely observed during the break-in period. It will be noted that maintenance data.
each rise in temperature of main bearings will be accompanied
by an increase in mill power. Complete break-in will be indicated Do not operate pump if solids hace settled and pump cannot be turned
by a bottoming of power consumption. 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 12.0 GRINDING, FLOTATION, THICKENING AND 90
FILTERING FILTERING
12.10 PLANT START-UP, OPERATION AND SHUTDOWN 12.10 PLANT START-UP, OPERATION AND SHUTDOWN
12.10.1 GENERAL 12.10. PLANT START-UP, OPERATION AND SHUTDOWN (cont’d)
Upon satisfactory completion of the trial runs, commissioning of this B. Control Stations
portion of the plan may commence. The control and monitoring of the operation of first and second
stage grinding, including the individual ítems of equipment are
The following start-up procedures assume that start-up occurs performed from control panel CP-5M/5F and Control Console CC-
immediately or very shortly after completion of the test runs. If this 5M installed in the control room of the Concentrator.
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 In addition, local control panels are provided for each:
required to insure the system or item of equipment is ready for
operation. 1. Mill bearing lubrication system
2. Mill gear lubrication system
Normal start-up involves making the prerequisite field checks and 3. Mill air clutch system
then starting the equipment according to a systematic procedure.
The entire concentrator, first stage grinding through and including Each system is furnished as a package unit, complete with required
concentrate loadout and tails disposal, must be considered as an controls and instrumentation.
operating unit for start-up. There us no appreciable storage
throughout. Therefore, before starting any specific section the next C. Start-Up
section or section must be prepared to receive the process flow.
1. Determine that the plant communication system is in satisfactory
Initial start-up procedures as defined are with the automatic working condition, that each area of operation is properly staffed
sampling system not in operation. When the sampling system is to and prepared for start-up, equipment and system checks are
be brought on line and the procedures for initial sampling shall be complete and the system is ready for operation.
established by the Plant Superintendent, in conjuntion with the Plant
Metallurgist. 2. Review the status of the Fine Ore Stockpile and Fine Crushing
and Screening System. Is there sufficient ore reserve in the
12.10.2 FIRST AND SECOND STAGE GRINDING stockpile and sufficient ore supply to complete the scheduled
run.
A. General
Start-up, operation and shutdown procedures are for that portion of 3. Review status of the flotation system. Is it prepared to receive
the plant extending from reclaiming of ore from Fine Ore Storage process flow.
04-6001 to and including the Conditioner Tanks 05-1201, 05-2001,
05-1202 and 05-2002. 4. Contact operating personnel at location to establish;
First and second stage grinding consists of two independent lines. a) System properly staffed.
To afford better control, specially for initial start-up, only one line b) Electrical power is available to all motor startes and
should be started at a time. As the operation of that line stabilized, control panels and that other utilities; ie: water and
the other line can then be started. The following procedures are compressed air are available to equipment as required.
applicable for either circuit.
46
91
FILTERING FILTERING
12.10. PLANT START-UP, OPERATION AND SHUTDOWN (cont’d) 12.10. PLANT START-UP, OPERATION AND SHUTDOWN (cont’d)
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.
e) Pump sumps have adequate head of water.
16. Start the first stage bal mill motor. Observe mill power recorder
f) Mills are clear of personnel and obstructions. and temperature monitor for abnormal readings.
g) Reagent are or will be available at the various points of use 17. Check all annunciators to ensure that all systems are clear to
and controls are set for stablished flow rate. engage the mill clutches.
5. Turn “Remote-Local” selector switches to Local for the Reclain Belt 18. Set Feed Rate Controller (5001 or 50101) to approximately 60
Feeders and Ball Mill Feed Conveyor. Advise local operator, under percent of circuit rated capacity.
local control, to start the feeders and conveyor and load the mill
feed system to approximately normal load, then stop the feed 19. Engage the first stage ball mill air clutch. Observemill power
system. recorder and temperature monitor for abnormal readings.
6. Return “Remote/Local” selector switches for this mill feed system 20. Start the Ball Mil Feed Belt conveyor.
to remote.
21. Start the appropiate number of reclain Belt Feeders. Use manual
7. Contact the operator in the Fine Crushing and Screening Control speed control. Observe feed rate recorder.
Room and determine status of the Fine Ore Storage Dust,
Collecting System. If not already in operation, advise the operator 22. Monitor the First Stage Cyclone Feed Sump Level Indicating
at that location to start the dust collecting system. Controller (LIC5006 or LIC5106). When the level starts to rise,
indicating discharge of pulp from the mill, start the Cyclone Feed
8. Advise the local operator to activate the Belt Scales (04-4501 and Pump, and observe pump current.
04-4502).
23. Engage the second stage ball mill air clutch. Observe mill power
9. Set the setpoints of all flow controllers and othe control devices to recorder and temperature monitor for abnormal readings.
the initial established values and start all process recorders.
24. Monitor the Second Stage Cyclone Feed Sump Level Indicating
10. Advise the grinding mill operator(s) to start the lubrication systems Controller (LIC5030 or LIC5130). When the level starts to rise,
for the first and second stage grinding mills. It is preferable after a indicating discharge of pulp from the mill, start the Second Stage
prolonged shut-down to start these systems locally and observe Cyclone Feed Pump.
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.
92
FILTERING FILTERING
12.10 PLANT START-UP, OPERATION AND SHUTDOWN (cont’d) 12.10 PLANT START-UP, OPERATION AND SHUTDOWN (cont’d)
One of the first and second stage grinding circuits is now in operation. c. A large return of oversize from the classifier,
The same producers should be followed for the other circuit. accompanied by a reduction in rate of classifier product.
D. Operation Good Operation
1. Switch belt feeders to “Auto” mode and after operations a. A continuous regular dull mill noise without any
have been stabilized, gradually increase the feed rate by distinguishing noise from balls hitting the shell-a rumble.
aproxymately 15 percent increments at first and then less as b. Uniformity of mill discharge as to consistency and sizing.
the rated capacity is approached. c. Uniformity of classifier oversize returns.
As the rate is increased, monitor the power draw of motors 4. For initial start-up, the mills should be operated for 48 hours with
to see that none of them are operating under an overload. the 65 percent of total grinding media charge to furter allow
bearings and drive to “work-in” and during which time preliminary
2. Rates and equipment settings specified are optimim for adjustments can be made. The charge should then be gradually
start-up. Conditions will change with ore charactetistics. brought up to the rated charge.
Operatings rates and settings must be established through
experience and testing. It is recommended that the first few weeks of operation be with up
to approximately 80 percent of the total recommended charge.
3. If the load in the circuit (solids to classifier) is maintained at
a fairly constant level an the mill power maintained at the The experience obtained from this might indicate a change in the
proper level, the product rate and size will normally be top size of media or in the make-up of the charge. The last 20
satisfactory. percent of the charge can then be added to bring about the
desired changes. Another reason for recommending that the mill
4. Conditions of the grinding mill are indicated by: initially operate with about 80 percent charge is to watch the mill
horsepower and if the mill power indicates that teh desired power
An Underloaded Mill will be drawn with a slightly lees charge than originally
recommended, this can be taken into account in the addition of
a. High level of noise resulting from the balls pounding the last 20 percent.
the lining.
b. An excessive amount of fines in the mill discharge. E. Shutdown
c. Very little oversize being returned from the classifier.
1. Normal or scheduled Shutdown
An Overloaded Mill
Normal or scheduled shutdown sequence is generally in the
a. Mill discharging at a high rate and the discharge same order as the startup sequence. The following
containing a high proportion of material of new feed important points or exception must be considered.
size.
b. An appreciable drop in power below that indicated for
normal operation or an underloaded mill.
47
FILTERING FILTERING
a. The cyclone feed sumps and pumps must be clear of all The following important point or exception must be considered.
solids before shutdown. This can be accomplished by
flushing the system with clear water before system a. Do not start a cyclone feed pump if solids have settled and
shutdown or draining the sumps. the pump cannot be turned by hand. It is then necessary to
drain the sump and flush out the pump.
b. The conditioner tank agitator must remain in operation as
long as there is a slurry in the tank. For shurdown the tank 12.10.3 FLOTATION
(and system) must be flushed out with clear water or the
tank drained. A. General
c. Length of down-time will determine operation or non- Start-up, operation and shutdown procedures are for that portion
operation of the grinding mill main trunnion bearing and of the plant extending from the Rougher Feed Pump receiving
pinion bearing lubrication systems should be kept slurry from the Conditioner Tanks to the Final Tailings Sump 05-
operating. If the shutdown time is to be of long duration, 2721 and Final Concentrate Sump 05-2726.
the lubrication unit may be shutdown if it is so desired.
Regardless, allow the trunnion bearing lubrication system Rougher, Rougher I, Rougher II, Scavenger I and Scavenger II
to operate for several minutes after the mill is shut down. flotation consist of two indeoendent circuits A and B . Each of
these lines receive feed from the corresponding grinding circuit A
d. If the mill is to be down for anu appreciable time, turn on and B. The grinding circuit started will then dictate the flotation
the lubricating oil heaters. It is to be noted that prior to circuit to be started. The following procedures are applicable to
starting a mill, the lubricating oil temperature for both either circuit.
systems should be at least 32 degrees C for satisfactory
operation. B. Control stations
2. Un planned (Emergency) Shutdown The control and monitorng of the operation of this section of the
plant are performed from Control Panel CP-5MFand Control
Abnormal situation such as: low speed stop, emergency stop Console CC-5F, installed in the control room in the Concentrator
switch actuation, crusher lube system malfunction, plugged chute Building.
etc, that will, if operation continues, cause immediate damage to
equipment or affect the flow of material are interlocked with the C. Start – Up
specific item of equipment or affect the flow of material are
interlocked with the specific item of equipment or affect the flow 1. For initial start-up, it is assumed that the regrind system
of material are interlocked with the specific item of equipment and will not be started and be by-passed until the flotation,
all critical upstream equipment for inmediate shutdown. After dewatering and siltration systems are started and
having checked the cause of the shutdown and ascertained that operation stabilized.
the cause of the shutdown has been corrected, the stopped
equipment can be re-started, generally in the order of previously 2. In defining start-up procedures, ir must be assumed that
defined start-up procedures. 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.
FILTERING FILTERING
This preparation shall include: l. Check and ensure that mechanism air intakes are at proper
setting. Generally, these are 100 percent open for roughers
a. Ensure that the system is properly staffed for start-up. and 30 to 40 percent open for cleaners.
b. Establish electrical power is available to all motor starters m. Ensure correct dart valve positions in flotations feed.
and control panels and that other utilities; ie : water and n. All pump sumps have adequate head of water.
plant and instrument compressed air, are available to
equipment as required. 3. 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 for stablished flow rate. a. Start all flotation machine motors in predetermined
sequence.
d. The dewatering, filtering and tailings disposal sections will
be prepared to receive the flotation concentrate and tails. b. Set “Local/Remote” selector switch 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. The remaining start-up operations are performed by the
local operators.
g. Ensure all “Auto/Manual” selector switches on automatic
pulp level controllers are in the “auto” position and all 4. Upon flow of pulp from the conditioner tank, start the rougher
pneumatically actuated dart valves are operable and in flotation feed pump.
“Auto” position.
5. When the pulp reaches a specific bank of cells, start required flow of
h. Establish that all flotation machines are filled with water to reagents, flow of froth and launder spray water.
the required operating depth. Mechanisms should not be
started until the cell liquid level is above the top row of 6. As the tails and concentrate from a specific line of cells discharges
holes in the disperser. to a sump, start the transfer pump serving that sump.
i. Ensure that froth sprays and launder sprays are operable. 7. When pump flow approaches normal rates, open all manually
operated dart valves in flotation machines and lock actuating levers
j. Check and ensure all froth bars are set at normal levels. in predetermined position.
k. Check and ensure flotation cell weirs are set to a level 8. Adjust reagents and air to provide the desired froth characteristics
below froth lip level. and overflow rate,
9. Adjust level control sensors to provide the optium operating froth

depth.
48
95
FILTERING FILTERING
Should xtreme surging of flotation feed slurry be experienced during Normal or scheduled shutdown is generally in the same order as
start-up, it is recommended that weir bars in the connection and for start-up. The following important points must be considered.
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 a. Allow time for all flotation cell activity to cease and for all
will then pass over the weir and will not cause flooding of the froth flotation cell activity to cease and for pulp in flotation
launders. It is not recommended that the controller settings be machines to be reduced to the desired degree of dilution.
changed to provide fast surge relief. This will result in very poor control
for nomal operation long after the feed surge problem is solved. b. Pulps in sumps and pumps must be purged of solids to
degree that they will not be “sanded-up” upon shutdown.
D. Operation Otherwise, sumps and pumps must be drained and
flushed put with water.
1. Metallurgical variations incurred in start-up are usually confined
to two items; variation in recovery or variation in grade of c. Thorouhly purge with water the final concentrate pumping
concentrate from that anticipated. Prior to start-up, the decision line.
should be made on wheter grade of concentrate or recovery is of
prime importance. The operator may then concentrate more on 2. Unplanned (Emergency Shutdown)
one if necessary to get the plant in operation.
There are no shutdown interlocks between equippment in the
2. Under normal operations, actual values will change. Factors such flotation system. All transfer pumps are provided with spare.
as characteristics or ore, degree of grinding and amount of Therefore, except for some sanding which may generally be
reagents used will alter results. A table convering variables of cleared without shutdown, no malfunction of any piece of
flotation is entered at the end of this section. equipment would seriously impede the flow of pulp and thereby
require emergency shutdown.
3. A target operation should be developed, then conditions adjusted
through experience and metallurgical controls to attempt to meet Should a spontaneous shutdown of the entire flotation system be
this target. required, the system including cells, sumps and pumps should
be drained and flushed out with water prior to restart.
The operator has the responsability for setting control parameters
with automatic control of some primary variable after that. 12.10.3 REGRIND
4. After operation is stabilized, motor amp readings, pulp specific A. General
gravity and approximate air intake setting should be recorded for
base line data. The regrind section consists of two independent circuits. To
afford better control, especially for initial start-up, only one circuit
E. Shutdown
should be started at a time. As the operation of that line is
stabilized, the other line can then be started. The following
1. Normal or Scheduled Shutdown
procedures are applicable to either line.
FILTERING FILTERING
3. Set the setpoints of all flow controllers and other control

B. Control Stations
devices to the initial established values and start all process
recorders.
The control and monitoring of the regrind section, including
the individual items of equipment, are performed from 4. Set the “Remote/Local” selector switches to “Local” for the
Control Panel CP-5M/5F and Control Consoles CC-5M & 5F, mill lubrication system pumps (low and high pressure).
installed in the Control room in the Concentrator Building.
5. Advise the grinding mill operator to start the bearing and
In addition, local control panels are provided for each: gear lubrication system for the regrind mill. It is preferable
after a prolonged shutdown to start these systems locally
1. Mill bearing lubrication system. and observe that the system are functioning properly. For
2. Mill gear lubrication system. short duration shutdowns, the systems should be left
3. Mill air clutch system running. The bearing lube system may also be started at
central control console CC-5F.
Each system is furnished as package unit, complete with The lubrication systems should be started from the local
required controls and instrumentation. control panels in the following order.
C. Start - Up a. If not already on, turn on the main bering and pinion
bering lubrication system oil heater. (Oil heater would
1. Determine that the plant communication system is in normally br turned on a day in advance of start-up,
satisfactory working condition, that each area of depending on the ambient temperature).
operation is properly staffed and prepared for start-up, The heater is primarily provided to maintain an oil
equipment and system checks are complete and the temperature of 32 degress C when the mill is
system is ready for operation. shutdown. After the mill is started, except for
exceptionally cold climates, the heater should be
turned off.
2. Contact operating personnel at location to establish:
b) Depress the “Start” lube pump push-button starting
the low pressure trunnion bearing lube oil system
a. System properly staffed. pump.
b. Electrical power is avalaible to all motor startes
and control panels and that other utilities; ie: water c) Depress the “Start” lube jacking pumo push-button,
and compressed air are available to equipment as starting the main bearing high pressure jacking
required. pump. The jacking pump is interlocked with the low
c. All grinding mills are filled to overflow with water. pressure trunnion bearing lube system to insure that
d. All automatic process samplers are off and the system is in operation before starting the high
cutters are out of the path of material flow. pressure system.
e. All pump sumo have adequate head of water.
d) Start the gear spray lubrication system.
f. All mills are clear of personnel and obstructions.
49
97
FILTERING FILTERING
6. Turn the “Remote/Local” selector switch for the Normal or scheduled shutdown sequence is generally the reverse
appropriate Regrind Transfer Pump to “Local” Verify that of the start-up sequence. The following important points ir
an operator is positioned at this sumo and pump. exceptions must be considered.
7. Advise the local operators that the system is to be started. a. Sumps and pumps handling pulp must be clear of all solids
Sound the “Start” warning alarm. before shutdown. This can be accomplished by flushing the
system with clear water before system shutdown or draining
8. Start the regrind ball mill motor. Check that the graphic the sumps.
display running ligth is on and check all annunciators to
ensure that all systems are clear to engage the mill clutch. b. Length of down-time will determine operation or non-operation
Observe mill power recorder. of the grinding mill main trunnion bearing lubrication systems
after shutdown. If the shutdown time is to be of short duration,
9. Advise the flotation operator to divert feed to the regrind the lubrication systems should be kept operating. If the
section. shutdown time is to be of long duration, the lubricantion system
to operate for several minutes after the mill is shutdown.
10. Local operator is to start the regrind transfer pump as pulp
begins to discharge to the regrind collection sump. 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
11. When the regrind transfer pump graphic display running mill, the lubricating oil temperature for both systems should be
light comes on, engage the regrind ball mill air clutch. at least 32 degrees C for satisfactory operation.
Observe mill power recorder and temperature monitor for
abnormal readings- 2. Unplaned (Emergency) Shut-Down
12. Monitor the regrind cyclone feed sump level indicator (LIC Abnormal situations such as: low speed stop, emergency stop
5212 or LIC 5222). When the level starts to rise, indicating switch actuation, crusher lube system malfunction, plugged
discharge of pulp from the mill, start the regrind cyclone chute, etc. That will. If operation continues, cause inmediate
feed pump. Observe feed pump motor corrent. damage to equipment or affect the flow of material, are
interlocked with the specific item of equipment or affect the flow
The regrind section is now in operation- of material, are interlocked with the specific item of equipment
and all critical upstream equipment for inmediate shutdown. After
The same procedures should be followed for Circuit Nº2. having checked the cause of the shutdown and ascertained that
the cause of the shutdown has been corrected, the stopped
D. Operation equipment can be restarted, generally in the order of previously
defined start-up procedures.
Basic operating parameters are as specified for First and Second
Stage Grinding. The following important point or exception must be considered.
E. Shut Down
1. Normal or Scheduled Shutdown
98
FILTERING FILTERING
a. Do not start a pump handling pulp if solids have settled c. Establish that flocculant is or will be available at the Final
and the pump cannot be turned by hand. It is the Concentrate Sump 05-2726 and filter aid available at the
necessary to drain the sump and flush out the pump. Filter Feed Distributor 05-1601.
12.10.4 CONCENTRATE THICKENING AND FILTERING d. Advise the thickener operator to check that:
A. General 1. The thickener is clear of any objects that would

Start-up, operation and shutdown procedures are for that portion of bind the rakes.
the plant extending from the Final Concentrate Sump 05-2726 to 2. The rake drive has been operated for a short
and including Final Concentrate Storage. time. That the rakes are not bound and there was
no high torque condition.
B. Control Stations 3. There is some clear water in the bottom of the
The control and monitoring of the operation of this section of the tank, preferably enough to fill the cone bottom.
plant is performed from Control Panel CP-5M/5Fand Control
Console CC-5F, installed in the control room of the Concentrator e. Check with filtering system operator that all equipment is
Building. prepared for operation.
In addition, local control panels are provided for the Concentrate
Thickener and the Concentrate Filtering Systems. f. Determine that seal water is available at all pumps,
including the vacuum pump.
C. Start-Up
g. Determine that fresh water supply is available at correct
1. In defining start-up procedures, it must be assumed that the pressure.
thickening-filtering operator(s) has been advised of the
planned startup of the grinding and flotation sections, with h. Advise the filter operator to set dart valves in the Static
sufficient lead time for preparation of this section to receive Distributor 05-1601 so that the outlets to the filters are
the feed. closed and the overflow return line to the Final Concentrate
Sump is open.
This preparation shall include:
The following start-up procedures are for temporally recycling the
a. Determine that the plant communication system is in thickener underflow back to the thickener feed. Otherwise, it will
satisfactory working condition, that each area of operation is be necessary to dispose of the underflow until it is of suitable
properly staffed and prepared for start-up, equipment and density for filtering.
system checks are complete and the system is ready for
operation. i. Set the setpoints of all flow controllers and other control
devices to initial estimated valves Start thickener torque
b. Check with the appropriate foreman to determine that recording.
electrical power is available to all motor starters and control
panels and that other utilities; ie: water and compressed air, j. Establish that reclain water system is prepared to receive
are available to equipment as required. the thickener overflow,
50
99
FILTERING FILTERING
k. Turn the “Remote/Local” selector switch for the Final b. Check the interface of the slugde level. It should be down
Concentrate Pump 05-1519 to “Local”. This pump is to be at approximately the rake level. If it should rise above this
started locally.. level, add more flocculant to improve the thickening. It is
important to keep the interface down from the start.
2. When the system is ready, advise the flotation operator that the c. The underflow pump must be operated at sufficient
thickening and filtering section is prepared for start-up. capacity to prevent deposition of the coarse material in the
underflow line.
3. Upon notification that the flotation section is to be started, start
the thickener rake mechanism. Observe torque recorder. As the density of the solids reach normal operating conditions,
the underflow is ready for filtering.
4. Locally start the Final Concentrate Pump as the slurry starts to
discharge to the Final Concentrate sump. 7. Start the filter agitator.
5. Monitor the final Concentrate Pump “Running” Light. When it 8. Start the filter drum.
comes on, start the Concentrate Thickener Underflow Pump 05- The filter agitator and drum should be started before any feed is
1521. sent to the filter.
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
The Concentrate Thickener is now in operation, with the underflow prevent introducing slurry underneath the cloth on the filter
recycling back to the Final concentrate Sump by way of the Filter Feed drum. Check cloth tracking and also observe vacuum receiver
Static Distributor Overflow. pressure.
The objetive is to get the thickener “in balance” as soon as possible. 10. Start Drum Filter Blower.
“In balance” means the screen analysis and tonnage of the underflow
are the same as the feed. 11. Start Filtrate Pump.
As the thickener is being filled: 12. Balance the flow into the filter tank with the filtration rate of the
filter. In normal operation, avoid excessive overflow of the filter
a. Watch the underflow density and torque on the thickener tank.
rakes. On initital start-up there are no settled fines and
whatever coarse material is present in the feed rapidily D. Operation
settles and can sand out on the thickener bottom. This General
coarse material, with no fines for lubrication, does not flow. The operating goal is to produce the maximum amount of filter cake
It is difficult to rake and can cause excessively high with minimum moisture content.
torques initially until fines have a chance to settle and mix
with the coarse material. Thickener
Control of the thickener operation is done primarily by control of the
thickener underflow concentration.
FILTERING FILTERING
The rate of underflow withdrawal should the be adjusted according to If the underflow is too thin:
the underflow concentration.
1. The slugde is being withdrawn too fast. Decrease the discharge
It is important that the underflow withdrawal rate is high enough to rate.
remove settled solids at a tonnage equal to the feed solids tonnage.
2. An island or ring of non-fluid solids may have formed near the
What goes in must come out. If sufficient solids are not removed from center of the machine. This ring rotates with the rake. Solids that
the thickener underflow, they will build up in the machine and settle outside of this ring are no transported to the underflow and
eventually overflow. eventually this situation will result in an overloaded thickener. If the
ring cannot be dislodged by high pressure water hoses – applied
If flocculants are used to increase thickener capacity, the thickener beneath the surface – or air lines, the unit must be drained and
pulp level can be monitored and the amount of flocculant used cleaned out. Island formation is usually caused by the use of an
adjusted accordingly. This reduces flocculant consumption to a excessively high flocculant dosage or inadequate flocculant
minimum. preparation and addition.
If flocculants are used to improve overflow clarity, overflow turbidity 3. If the underflow pumping rate is too high, it is possible to pull thin
measurements may be used to indicate flocculant dosage slurry out of the center of the machine so fast that other settled
requeriments. 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
The rake mechanism is normally kept in continuous operation. If for lower underflow trech. This action is commonly called rat holing. It
saome reason the rakes are to be shut off for an hour or more, the can be eliminated by using a lower underflow discharge rate. If the
settled solids should first be pumped out of the machine. underflow line plugs with thick sludge, close the line with high
pressure water. When the line is free, resume underflow pumping at
If the thickener overflow turbidity is higher than anticipated: an increased rate until the inventory of thick solids has been
removed.
1. Satisfactory flocculation may not have been obtained. The
flocculation system should be checked. If the unit cuts out on overload:
2. The underflow rate may be too low and a large amount of solids 1. Check general mechanical condition of mechanism. Check
may have accumulated in the tank. The underflow rate must be lubricating oil level in mechanism.
increased.
2. The solids may be overthickening because they have remained in
3. The feed rate to the thickener may be too high, exceding the the tank too long. Too much water has been eliminated and the
capacity of the thickener. Either the feed rate must be cut back or underflow is no longer fluid. Consequently, the rake mechanism is
the flocculation system improved to increase the capacity of the encountering a large load. The underflow rate is too low and it
thickener. should be increased.
4. Splashing of the feed over the feedwell skirt or excess turbulence in 3. Solids are being fed to the thickener faster than they are being
the feedwell may be causing short circuiting. Check drawings to removed. As a result, the rake enconters a larger and larger load.
determine if feedwell and feed launder are properly installed. The discharge rate should be increased.

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34

g) Instrumentation: d) Interlocks: The clutch operating solenoid control circuit is interlocked

e) Start-Up (Engage): Energizing of the clutch operating solenoid may

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 (Disengage): The clutch may be disengaged “normally” by

1. If the “Regrind Ball Mil #1” : motor is stopped.

Mgtr. Amador Soto Gallufe – Consultor Intercade

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

c) Status Indication: Status indication is provided bye means of a “Red”

1. Main breaker power is on

2. Oil level in reservoir is above operating level (CR3-05-0205-2

3. Lube oil temperature is below operating temperature.

4. Heater temperature is below operating temperature.

5. All components are functioning normally

1. Oil in reservoir drops below operating level (CR3-05-0205-2) de

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12.0 GRINDING AND FLOTATION 12.0 GRINDING AND FLOTATION 70

LOCAL CONTROL BOX CONTROL PANEL CP-5M/5F

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“ A” CKT “A” CKT MSI Nº. 204125 & 204126

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

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FIELD ELEMENTS “A” CKT “B” CKT CONTROL PANEL CP-5M/5F

The following instrumentation is used to measure and display 1. DESCRIPTION OF OPERATION:

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2) INSTRUMENTS & CONTROL NUMBERS “A” CKT “B” CKT

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12.0 GRINDING AND FL>OTATION

1. pH CONTROL SYSTEM CONSOLE CC-5F/UA-5400F

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level controller 05-2604 LIC-5404

FIELD “B” CKT

level controller 05-2610 LIC-5424

B. ROUGHER II FLOTATION CELLS

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A. ROUGUER I FLOTATION CELLS A. ROUGUER I FLOTATION CELLS

2) pH INSTRUMENTATION CELL INSTRUMENT

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12.0 GRINDING AND FLOTATION 12.0 GRINDING AND FLOTATION 78

CELL INSTRUMENT D. SCAVENGER II FLOTATION

“A” CKT high/low pH alarm AAH/L-5413 level controller 05-2665 LIV-5432

The alarms for rougher/scavenger flotation are annunciated on

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Process water controller HIC-5200 SUMP SUMP

B. REGRIND CYCLONE FEED SUMPS (05-2713 & 2714)

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SUMP SUMP 1) BALL MILL DRIVE MOTOR POWER MONITORING

The monitoring and alarm system us equipped with an integral alarm

The regrind Ball Mill Temperatures Monitors are located in control

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BALL MILL I BALL MILL II 4) BALL MILL AIR CLUTCH SYSTEM

3) BALL MILL LUBE SYSTEM F. CONCENTRATE SCAVENGER I SUMP (05-2727) LEVEL

COOLING WATER FLOW SWITCH CONSOLE CC-5F/UA-5400F

BALL MILL I BALL MILL II 1) LEVEL CONTROL

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12.5.3 CLEANER FLOTATION & REGRIND (cont’d)

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12.5.3 CLEANER FLOTATION & REGRIND cont`d

2) pH INSTRUMENTATION F. CONCENTRATE SCAVENGER I SUMP (05-2727) LEVEL CONTROL