Operating and Maintenance Manual

Pipeline Systems Incorporated
COMPAÑÍA MINERA ANTAMINA S.A.
ANTAMINA PROJECT
COPPER & ZINC CONCENTRATES PIPELINE
OPERATING AND MAINTENANCE MANUAL
DOCUMENT NO. 777-G-G-002
0 Use
A 6/30/00 Client Review WJN ---- ---- ---- WJN RHD ---- ----
REV. DATE ISSUED FOR BY CHK DISC AREA PE PM BECH CMA
TABLE OF CONTENTS
1.0 INTRODUCTION............................................................................................................... 1
1.1 Purpose.................................................................................................................... 1
1.2 Project Background................................................................................................. 1
2.0 REFERENCES ................................................................................................................... 2
2.1 Process Design Reference Documents.................................................................... 2
2.2 System Control Philosophy Reference Documents ................................................ 2
2.3 Other Reference Documents ................................................................................... 3
2.4 Vendor Reference Documents ................................................................................ 3
3.0 BASIC OPERATING GUIDELINES................................................................................. 4
3.1 Definitions............................................................................................................... 4
3.1.1 Pipeline Stations ...................................................................................... 4
3.1.2 Terminology............................................................................................. 4
3.1.3 Units......................................................................................................... 6
3.2 System Description ................................................................................................. 6
3.2.1 General ..................................................................................................... 6
3.2.2 Pump Station............................................................................................ 7
3.2.3 Pipeline .................................................................................................... 8
3.2.4 Pressure Monitoring Stations................................................................... 8
3.2.5 Valve Stations .......................................................................................... 9
3.2.6 Terminal Station....................................................................................... 9
3.3 Process Design ...................................................................................................... 10
3.3.1 Background ............................................................................................ 10
3.3.2 Design Slurry Characteristics................................................................. 10
3.3.2.1 Particle Size Distribution ........................................................ 10
3.3.2.2 Concentration.......................................................................... 11
3.3.2.3 Rheology ................................................................................. 11
3.3.2.4 pH............................................................................................ 11
3.3.2.5 Temperature ............................................................................ 11
3.3.2.6 Specific Gravity of Solids ....................................................... 11
3.4 Operating Range Limits ........................................................................................ 11
3.4.1 Throughput Limits ................................................................................. 11
3.4.2 Choke Station Design ............................................................................ 12
3.5 Pressure Rating Limits .......................................................................................... 13
3.6 Product Segregation .............................................................................................. 13
3.6.1 General ................................................................................................... 13
3.6.2 SCADA Interlocks ................................................................................. 15
3.6.3 Pipeline AdvisorTM (Batch Tracking) .................................................... 16
3.6.4 Conductivity Pulse ................................................................................. 17
3.7 General Operating Philosophies............................................................................ 17
3.7.1 High Pressure Slurry .............................................................................. 17
3.7.2 Wear....................................................................................................... 18
3.7.2.1 Mechanical Equipment ........................................................... 18
777-G-G-002, Rev. 0 i September 2000

3.7.2.2 Mainline Pipe .......................................................................... 19
3.7.2.3 Station Piping.......................................................................... 19
3.7.2.4 Station Valves ......................................................................... 19
3.7.2.5 Ceramic Chokes ...................................................................... 20
3.7.3 Protect Mainline Pumps......................................................................... 20
3.7.4 Vibration ................................................................................................ 20
3.8 Operating Strategies.............................................................................................. 20
3.8.1 Pump Station Storage Tanks.................................................................. 20
3.8.1.1 Concentrate Production versus Pipeline Capacity .................. 20
3.8.1.2 Zinc Storage Tanks ................................................................. 21
3.8.1.3 Copper Storage Tanks............................................................. 21
3.8.1.4 Maximizing Available Storage ............................................... 22
3.8.2 Automatic Sequences............................................................................. 23
3.8.3 Choke Changing..................................................................................... 23
3.8.4 Batch monitoring ................................................................................... 25
3.8.5 Pipeline AdvisorTM/ Pipeline Simulator ................................................ 26
3.8.6 Correcting Off-Specification Concentrate ............................................. 26
3.8.7 Locked Valves........................................................................................ 27
4.0 OPERATING PROCEDURES ......................................................................................... 29
4.1 Pipeline System Operations .................................................................................. 29
4.1.1 Pipeline Start.......................................................................................... 29
4.1.1.1 Automatic Sequence ............................................................... 29
4.1.1.2 Manual Remote Sequence....................................................... 32
4.1.1.3 Local Sequence ....................................................................... 37
4.1.1.4 Conductivity Pulse .................................................................. 38
4.1.2 Pipeline Shutdown ................................................................................. 38
4.1.2.3 Local Sequence ....................................................................... 42
4.1.2.4 Emergency Stop ...................................................................... 42
4.1.2.4.1 HMI-Initiated Emergency Stop.......................... 42
4.1.2.4.2 Mainline Pump Initiated Emergency Stop ......... 43
4.1.3 Choke Changing..................................................................................... 44
4.1.3.2.1 VS1 Sequence .................................................... 45
4.1.3.2.2 VS3 Sequence .................................................... 45
4.1.3.2.3 TS1 Sequence..................................................... 46
4.1.3.3 Local Sequence ....................................................................... 46
4.1.4 Pipeline Filling and Draining................................................................. 46
4.1.4.1 Pipeline Filling........................................................................ 47
4.1.4.1.1 Entire Pipeline.................................................... 47
4.1.4.1.2 Pipeline Section ................................................. 51
4.1.4.2 Pipeline Draining .................................................................... 51
777-G-G-002, Rev. 0 ii September 2000

4.1.4.2.1 Entire Pipeline.................................................... 51
4.1.4.2.2 Pipeline Section ................................................. 52
4.1.5 Pipeline Pigging ..................................................................................... 52
4.1.5.1 Pigging PS1 to VS1 ................................................................ 53
4.1.5.2 Pigging VS1 to VS3................................................................ 55
4.1.5.3 Pigging VS3 to TS1 ................................................................ 57
4.2 Sub-System Operations......................................................................................... 59
4.2.1 Tank Operations..................................................................................... 59
4.2.1.1 Copper Storage Tank Filling................................................... 59
4.2.1.1.1 Automatic Sequence .......................................... 59
4.2.1.1.2 Manual Remote Sequence.................................. 59
4.2.1.1.3 Local Sequence .................................................. 60
4.2.1.2 Zinc Tank Filling .................................................................... 60
4.2.1.2.3 Local Sequence .................................................. 61
4.2.1.3 Copper Tank Switching (While Pumping) ............................. 61
4.2.1.3.3 Local Sequence .................................................. 63
4.2.1.4 Zinc Tank Switching (While Pumping) .................................. 63
4.2.1.4.3 Local Sequence .................................................. 64
4.2.2 Product Switching (While Pumping) ..................................................... 64
4.2.2.3 Local Sequence ....................................................................... 68
4.2.3 Tank Draining Operation ....................................................................... 68
4.2.3.3 Local Sequence ....................................................................... 68
4.2.4 Tank Re-circulation Operation............................................................... 69
4.2.4.1 Copper Tank Re-circulation.................................................... 69
4.2.4.1.3 Local Sequence .................................................. 70
4.2.4.2 Zinc Tank Re-circulation ........................................................ 71
4.2.4.2.3 Local Sequence .................................................. 71
4.2.4.3 Swing Tank Re-circulation ..................................................... 72
4.2.4.3.3 Local Sequence .................................................. 73
777-G-G-002, Rev. 0 iii September 2000

4.2.5 Test Loop Operation .............................................................................. 74
4.2.5.1 Copper Concentrate Testing.................................................... 74
4.2.5.2 Zinc Concentrate Testing ........................................................ 75
4.2.6 Sump Product Recirculation .................................................................. 76
4.2.6.1 Copper Area Sump.................................................................. 77
4.2.6.1.1 Normal Operation .............................................. 77
4.2.6.1.2 Recycle to Storage Tanks................................... 77
4.2.6.1.3 Recycle to Regrind Circuit................................. 78
4.2.6.1.4 Pump to Tailings ................................................ 78
4.2.6.2 Zinc Area Sump ...................................................................... 79
4.2.6.2.2 Recycle to Storage Tanks................................... 79
4.2.6.2.3 Recycle to Regrind Circuit................................. 80
4.2.6.2.4 Pump to Tailings ................................................ 80
4.2.6.3 Mainline Pump Building Sump .............................................. 81
4.2.6.3.2 Recycle to Copper Area Sump........................... 81
4.2.6.3.3 Recycle to Zinc Area Sump ............................... 82
4.2.7 Charge Pump Switching Operation........................................................ 82
4.2.7.1 Copper Charge Pumps ............................................................ 82
4.2.7.1.3 Local Sequence .................................................. 84
4.2.7.2 Zinc Charge Pumps................................................................. 84
4.2.7.2.3 Local Sequence .................................................. 85
4.2.8 Charge Pump Flushing........................................................................... 85
4.2.9 Mainline Pump Switching...................................................................... 86
4.2.9.3 Local Sequence ....................................................................... 88
4.2.10 Mainline Pump Flushing........................................................................ 88
4.2.10.3 Local Sequence ....................................................................... 89
4.3 Emergency Operations .......................................................................................... 89
4.3.1 Charge Pump Failure ............................................................................. 89
4.3.2 Mainline Pump Failure .......................................................................... 90
4.3.2.1 Automatic Mode ..................................................................... 90
4.3.2.2 Manual Mode .......................................................................... 91
4.3.3 Power Failure ......................................................................................... 91
4.3.3.1 PS1 .......................................................................................... 91
4.3.3.2 Intermediate Stations............................................................... 92
4.3.3.3 TS1.......................................................................................... 92
777-G-G-002, Rev. 0 iv September 2000

4.3.4 Extended Shutdown ............................................................................... 92
4.3.5 Communications Failure........................................................................ 93
4.3.5.1 Fiber Optic Cable Cut ............................................................. 93
4.3.5.2 Station Failure......................................................................... 94
4.3.6 PLC Failure ............................................................................................ 95
4.3.7 Mainline Valve Failure .......................................................................... 95
4.3.8 Rupture Disc Failure .............................................................................. 96
4.3.8.1 VS1 Rupture Disc Failure....................................................... 96
4.3.8.4 VS4 Rupture Disc Failure..................................................... 100
4.3.8.5 TS1 Rupture Disc Failure ..................................................... 101
4.3.8.6 Recovery of Spilled Concentrate .......................................... 102
4.3.9 Pipeline Leak........................................................................................ 102
4.3.9.1 PS1 – Suction of Mainline Pumps ........................................ 102
4.3.9.2 PS1 – Discharge of Mainline Pumps .................................... 103
4.3.9.3 Mainline Pipe and Intermediate Stations .............................. 103
4.3.9.4 TS1........................................................................................ 104
4.3.10 Pipeline Plug ........................................................................................ 104
4.3.10.1 Pump Station Plug ................................................................ 105
4.3.10.2 Valve/Terminal Station Plug................................................. 105
4.3.10.3 Mainline Pipe Plug................................................................ 105
4.3.11 Mainline Pump Overpressure .............................................................. 106
4.3.11.1 Discharge Pressure Ramp Down........................................... 106
4.3.11.2 Wirth-Installed Protection..................................................... 106
4.3.11.3 Pump Discharge Relief Valves ............................................. 106
4.4 Individual Equipment Procedures....................................................................... 107
4.4.1 Linear Screens...................................................................................... 107
4.4.2 Samplers............................................................................................... 107
4.4.3 Agitators............................................................................................... 107
4.4.4 Centrifugal Pumps ............................................................................... 107
4.4.5 Mainline, Positive Displacement Pumps ............................................. 107
4.4.6 Vertical Sump Pump ............................................................................ 107
4.4.7 Automatic Valves................................................................................. 107
4.4.7.1 Knife Gate Valves................................................................. 107
4.4.7.2 Ball Valves............................................................................ 107
4.4.8 Salt Water Injection Skid ..................................................................... 107
4.4.9 Concentrator Emergency Power Supply .............................................. 108
5.0 MAINTENANCE PROCEDURES ................................................................................ 109

5.1 Linear Screens..................................................................................................... 109
5.2 Storage Tanks...................................................................................................... 109
5.3 Agitators.............................................................................................................. 110
5.4 Pumps.................................................................................................................. 110
777-G-G-002, Rev. 0 v September 2000

5.4.1 Mainline Positive Displacement Pumps .............................................. 110
5.4.1.1 Fluid End............................................................................... 111
5.4.1.1.1 Pistons and Liners ............................................ 111
5.4.1.1.2 Valves .............................................................. 112
5.4.1.2 Power End............................................................................. 113
5.4.1.3 Drive ..................................................................................... 114
5.4.2 Horizontal, Centrifugal Pumps ............................................................ 115
5.4.2.1 Charge Pumps ....................................................................... 115
5.4.2.2 Area Sump Pumps................................................................. 115
5.4.3 Vertical, Centrifugal Pump .................................................................. 116
5.5 Pipeline and Components ................................................................................... 116
5.5.1 Unlined station piping.......................................................................... 116
5.5.2 Lined station piping ............................................................................. 116
5.5.3 Mainline pipe and liner ........................................................................ 116
5.5.4 Knife gate valves.................................................................................. 117
5.5.5 Ball Valves........................................................................................... 117
5.5.6 Ceramic Chokes ................................................................................... 118
5.5.6.1 General .................................................................................. 118
5.5.6.2 Choke Wear .......................................................................... 118
5.5.6.3 Cavitation.............................................................................. 119
5.5.7 Rupture Discs....................................................................................... 119
5.6 Pipeline right of way........................................................................................... 119
6.0 SUBSYSTEM OPERATING AND MAINTENANCE PROCEDURES....................... 121
6.1 SCADA System .................................................................................................. 121
6.1.1 Control Room ...................................................................................... 121
6.1.2 Intermediate Sites................................................................................. 121
6.2 Telecommunications Systems............................................................................. 121
6.2.1 Fiber Optics.......................................................................................... 121
6.2.2 Radio .................................................................................................... 122
6.2.3 Video.................................................................................................... 122
6.3 Cathodic Protection System ................................................................................ 122
6.4 Remote Power Systems....................................................................................... 123
777-G-G-002, Rev. 0 vi September 2000

APPENDICES
Appendix A: Pipeline Corridor Route Map, 775-D-C-001
Appendix B: System Block Diagram, Drawing No. 0000-F-110
Appendix C: Process Flow Diagrams
Appendix D: Piping and Instrumentation Diagrams
Appendix E: Operating Range Diagram
Appendix F: Profile and Hydraulic Gradient
Appendix G: Fiber Optic Channel Diagram
777-G-G-002, Rev. 0 vii September 2000

1.0 INTRODUCTION
1.1 Purpose
This document provides general technical information as well as specific instruction

in the function, operation and maintenance of the pipeline and facilities for the
Antamina Concentrates Slurry Pipeline Project.
1.2 Project Background
Compañía Minera Antamina (CMA) plans to develop a copper and zinc mine
complex in the central region of Peru. The mineral ore will be ground to produce
separate chalcopyrite (copper) ore, sphalerite (zinc) ore, and bornite (copper) ore
concentrates which shall be transported via a 300-km pipeline to a ship loading
facility located approximately at Puerto Huarmey. The pipeline shall be designed to
transport a total concentrate production at a design throughput of 300 dry metric tons
per hour.
777-G-G-002, Rev. 0 1 September 2000

2.0 REFERENCES
This operating and maintenance manual was developed from numerous reference
documents that provide the background information on the design of the pipeline.
This information, coupled with vendor-supplied data, was used to prepare the
procedures contained herein. A summary of these reference documents is provided
2.1 Process Design Reference Documents
The following reference documents were used to develop the process design of the
Antamina concentrates pipeline. Additional information or more detailed
descriptions may be found in these documents.
Document Number Title

777-LR-134 Laboratory Report (PSI)
777-G-H-003 Evaluation of Laboratory Test Results Report (PSI)
777-G-H-001 Design Basis (PSI)
777-G-H-005 Hydraulic Design Report (PSI)
24097-DF-001 Process Design Criteria (Bechtel)
B019A Mine to Port, Dynamic Simulation Study (Simons)
2.2 System Control Philosophy Reference Documents
The following reference documents, in addition to those listed above, were used to
develop the control strategies for the Antamina concentrates pipeline. Additional
information or more detailed descriptions may be found in these documents.

777-S-G-001 Operating and Control Philosophy (PSI)
0360-J-220 to 226 Sequence of Operations Tables (PSI)
777-G-H-005 Pipeline AdvisorTM (PSI)
777-G-H-006 Transient Analysis Report (PSI)
777-S-P-003 Conceptual Study for Conductivity Pulse System for Zinc
Slurry Batch Tracking (PSI)
777-G-H-009 Pipeline Pigging Philosophy
777-G-G-002, Rev. 0 2 September 2000

2.3 Other Reference Documents
The following reference documents are available to supplement the operating and
maintenance procedures contained in this manual. Additional information or more
detailed descriptions may be found in these documents.

775-G-P-009 Operation and Maintenance Manual for Cathodic
Protection System (PSI)
777.01-S-I-009 Pipeline Supervisory Control and Data Acquisition
(SCADA) Operating and Maintenance Manual (PSI)
24097-G-xxx Radio System Operating and Maintenance Manual
(Bechtel)
831-S-T-001 Fiber Optic Telecommunication System – Operating and
Maintenance Manual (PSI)
24097-x-xxx Emergency Power System Manual
24097-x-xxx Concentrator Uninterruptible Power Supply
788-G-001 Pipeline Simulator User’s Manual
857-G-707 Standard Job Procedures
2.4 Vendor Reference Documents
The following vendor-supplied documents are available to supplement the operating

and maintenance procedures contained in this manual. Additional information or
more detailed descriptions may be found in these documents.

_________ Mainline Pump Manual (Wirth)
_________ Agitator Manual (Hayward Gordon)
_________ Linear Screen Manual (Delkor)
777-G-G-002, Rev. 0 3 September 2000

3.0 BASIC OPERATING GUIDELINES
3.1 Definitions
3.1.1 Pipeline Stations
Station Title Kilometer Facility Abbreviation

Post Code
Pump Station 0 0360 PS1
Pressure Monitoring Station 1 13.76 0371 PMS1
Valve Station 1 125.30 0372 VS1
Cathodic Protection Station 1 234.42 0371 CPS1
Terminal Station 301.86 0510 TS1
3.1.2 Terminology
Term Definition
SCADA Supervisory control and data acquisition

SCADA system The entire system of PLC’s, HMI’s, and supporting
software used by the operator to operate the pipeline
Pipeline AdvisorTM Proprietary software supplied as part of the pipeline
SCADA system that provides operator advice, tracks slurry
batches, and detects pipeline leaks
PLC Programmable logic controller
HMI Human-machine interface (also called MMI – man-
machine interface) – this is the console through which the
operator receives information and executes pipeline
functions
on slurry Infers that the operation occurs while operating with slurry
in the pipeline.
on water Infers that the operation occurs while operating with water
in the pipeline.
777-G-G-002, Rev. 0 4 September 2000

Term Definition
head Hydraulic energy expressed in an equivalent column of the

fluid being discussed
choking The use of ceramic chokes installed in the pipeline to
increase flow resistance, back-pressure, and head reduction.
fixed choke The fixed choke includes the chokes in the legs at each
station that are engaged when opening the wear and seal
valves at the station – fixed choke is always engaged when
there is flow in the station.
choke leg/choke loop The variable chokes include the choke legs/choke loops at
the entrance to a station that is engaged by closing the valve
at the base of the loop – variable choke loops may or may
not be engaged when there is flow in the station.
automatic A one-button, preprogrammed sequence installed in the
pipeline SCADA system that fully completes a task with a
single operator command.
prompted automatic A preprogrammed sequence installed in the pipeline
SCADA system that is initiated by the operator and has
intermediate hold points requiring operator
action/confirmation prior to advancing the sequence.
manual remote An action or sequence that is completed step-by-step by the
pipeline operator through the pipeline SCADA system
local An action or sequence that is completed by the operator(s)
via local control panels without the use of the SCADA
system.
hard-wired The device is connected directly to the equipment meaning
it is not reliant on the SCADA system for information
transfer – the device/equipment connection works when the
equipment is operated in local mode
ethernet A data highway through which information is passed from
a device to the equipment (and SCADA system) – the
device/equipment connection requires the ethernet to be
operating and will not work if the equipment is operated in
local mode
777-G-G-002, Rev. 0 5 September 2000

3.1.3 Units
The table below summarizes the units and abbreviations that will be found in this
manual.
Abbreviation Unit
AC alternating current
AFD adjustable frequency drive
DC direct current
HDPE high density polyethylene
km kilometer
KP kilometer post
m meter
m3/h cubic meters per hour
mm millimeter
NPS nominal pipe size
ppm parts per million
o
C degrees Celsius
spm strokes per minute
t/h dry metric tonnes per hour
UPS un-interruptible power supply
wt% percent concentration by weight
3.2 System Description
3.2.1 General
The following drawings provide a simple (system block diagram – see Appendix B),
medium (process flow diagram – see Appendix C) and detailed (piping and
instrument drawing – see Appendix D) overview of the slurry pipeline system.
Drawing Number Title

0000-F-110 Pipeline System Block Diagram
0300-F-120 PFD – PS1 – Copper Concentrate
0300-F-121 PFD – PS1 – Zinc Concentrate
0300-F-122 PFD – PS1 – Zinc/Copper Concentrate
0300-F-123 PFD – Intermediate Facilities – Zinc/Copper Concentrate
0300-F-124 PFD – TS1 – Zinc/Copper Concentrate
0000-M-115 P&ID – Typical Valve Operator Details
0360-M-110 P&ID – PS1 – Zinc Concentrate Storage Tanks
0360-M-111 P&ID – PS1 – Copper Concentrate Storage Tanks
777-G-G-002, Rev. 0 6 September 2000

Drawing Number Title
0360-M-112 P&ID – PS1 – Copper Concentrate Charge Pumps
0360-M-113 P&ID – PS1 – Zinc Concentrate Charge Pumps
0360-M-114 P&ID – PS1 – Safety Loop
0360-M-115 P&ID – PS1 – Mainline Pumps, Sheet 1 of 2
0360-M-116 P&ID – PS1 – Mainline Pumps, Sheet 2 of 2
0360-M-117 P&ID – PS1 – Potable Water
0360-M-118 P&ID – PS1 – Seal Water
0360-M-119 P&ID – PS1 – Plant and Instrument Air
0371-M-110 P&ID – PMS1 to PMS4 and CPS1
0372-M-110 P&ID – VS1
0373-M-110 P&ID – VS2
0374-M-110 P&ID – VS3
0375-M-110 P&ID – VS4
0510-M-110 P&ID – TS1 – Terminal Choke Station
0510-M-111 P&ID – TS1 – Copper Concentrate Storage Tanks
0510-M-112 P&ID – TS1 – Zinc Concentrate Storage Tank
The following sections provide a simple overview of the facilities along the pipeline
including the basic operating concept. Full details of the overall system, principle
equipment, and supplemental equipment can be found in Section 4 of this manual.
3.2.2 Pump Station
The pump station is located at the Antamina concentrator at the start of the transport
pipeline. Slurry is fed from the concentrator thickeners into agitated storage tanks –
two for zinc and three for copper. The two zinc tanks (0360-TKF-400 and 0360-
TKF-401) are interchangeable while the copper tanks have been preliminarily
designated as low-bismuth copper (0360-TKF-405), high-bismuth copper (0360-TKF-
406), and a swing tank (0360-TKF-407). Swing tank operation is discussed in section
4.2.1 below.
Either zinc or copper concentrate is fed to the pipeline via a designated pair of
centrifugal charge pumps (0360-PPS-410 and 0360-PPS-411 for copper and 0360-
PPS-412 and 0360-PPS-413 for zinc) which provide the suction pressure required by
the mainline pumps. One charge pump is operating at any time with the other on
standby as an installed spare.
Three of four mainline slurry pumps (0360-PPP-416, 0360-PPP-417, 0360-PPP-418,

and 0360-PPP-419) provide the high pressure required to pump the concentrate slurry
through the pipeline. The fourth pump is an installed spare. Operation with only two
mainline pumps is possible during emergencies and is discussed in section 4.3.2
below.
777-G-G-002, Rev. 0 7 September 2000

Process water supplied from the storage tanks at the concentrator is used to dilute
slurry (if required) to the desired pipeline concentration. Additionally, process water
is used for water batches between slurry batches or to displace slurry from the
pipeline for long term shutdowns.
3.2.3 Pipeline
The pipeline starts at the pump station mine site and ends at the terminal at Huarmey.
The pipeline is a high strength steel pipeline with an inner high-density polyethylene
(HDPE) liner to protect the pipe against corrosion. In general, velocities in the
pipeline are low enough that wear of the liner is not expected to be significant. A
thicker HDPE liner has been installed in areas that may be exposed to conditions
causing wear (see section 5.5.3)
The hydraulic design of the pipeline is such that pumping is required from PS1 to
VS1 while gravity flow provides adequate driving force from VS1 to the terminal.
Therefore, a 10NPS (standard 10” pipe with a 10.75” outside diameter) was installed
between PS1 and VS1 while a mix of 8NPS (8.625” outside diameter), 9NPS (9.625”
outside diameter) and 10NPS pipe was installed between VS1 and TS1 to control the
gravity flow rate. The table below summarizes the installed mainline piping (not
including the station piping discussed below).
Section Pipe size

PS1 to VS1 10NPS
VS1 to VS4 8NPS
VS4 to PMS4 9NPS
PMS4 to TS1 10NPS
3.2.4 Pressure Monitoring Stations
Pressure monitoring stations have been installed along the pipeline at key locations.
Four stations (PMS1, PMS2, PMS3, and PMS4) were installed to monitor
intermediate conditions in the pipeline. This data supplements pressure data available
at the intermediate valve stations and provides information that supports operator
decision-making (see section 4.4 below).
Additionally, the pressure monitoring station data (along with pump station, valve
station and terminal data) provide the necessary input into the pipeline leak detection
system found in the Pipeline AdvisorTM.
777-G-G-002, Rev. 0 8 September 2000

3.2.5 Valve Stations
There are four intermediate valve stations (VS1, VS2, VS3, and VS4) as well as a valve
station at the terminal (TS1). These valve stations have two primary functions – dividing
static head during pipeline shutdowns and removing excess head during operation.
During pipeline shutdowns on slurry, the valve stations divide the static shutdown
head such that the mainline pipe is not over-pressured. Valves are closed in a
prescribed sequence (see section 4.1.2) that keeps the pipeline full while avoiding
pressures above the pipeline design. Valves at all five locations (VS1, VS2, VS3,
VS4, and TS1) are required to safely shutdown the pipeline. Refer to section 3.5 for
additional information on pipeline pressure limits.
Ceramic chokes have been installed at VS1, VS3 and TS1 to permit stable pipeline
operation within the operating range of the pipeline. During operation at maximum
design throughput with the pipeline full of slurry, friction losses in the pipeline consume
the available head from VS1 to the terminal. As such, very little choking is required.
As the flow rate is reduced or the pipeline is operating with water batches, friction
losses in the pipe are lower. Additional choking is required to maintain a full pipe,
balanced flow condition. Choke facilities at VS1, VS3, and TS1 have been designed to
provide the required choking to cover all operating scenarios. Sections 3.3 and 3.4
provide additional information on the design of the pipeline choke stations.
3.2.6 Terminal Station
In addition to the choke station at TS1 (see discussion above), concentrate receiving
facilities are located at the terminal station. Concentrate from the pipeline is routed to
a concentrate distributor (0510-STP-500), which diverts flow to either the copper or
zinc distributor. The pipeline operator, who is following the concentrate batches
through the pipeline, is responsible for and has control of the valves from this
distribution box.
The zinc concentrate distributor (0510-STP-501) is controlled by the terminal

operator. Flow from the distributor can be directed to the zinc storage tank (0510-
TKF-500), zinc clarifier, or treated water pond. Additionally, it is possible to split
concentrate flow to the clarifier and the storage tank.
The copper concentrate distributor (0510-STP-502) is also controlled by the terminal

operator. Flow from the distributor can be directed to the low bismuth copper storage
tank (0510-TKF-501), high bismuth copper storage tank (0510-TKF-502), copper
clarifier, or treated water pond. Likewise, it is possible to split concentrate flow to the
clarifier and one storage tank.
While the terminal operator controls the individual concentrate distributors, close
communication is required between the pipeline and terminal operators to ensure
777-G-G-002, Rev. 0 9 September 2000

proper response to batch arrivals. The pipeline operator work station includes a
console through which all terminal information is available. This permits the pipeline
operator to monitor the setting of these valves.
3.3 Process Design
3.3.1 Background
The Antamina concentrates pipeline was designed to safely transport copper and zinc
concentrates from the mine site concentrator to the filter plant at the terminal. The
sizing and selection of pipeline components was based on an extensive review of
concentrate properties, production rates, and the actual route of the pipeline. A
complete summary of the documents used to develop the process design of the
pipeline can be found in Section 2.1 above.
The design parameters for the pipeline were selected to provide flexibility during
operation. However, there are limitations as to what can be safely transported. The
pipeline operator must monitor concentrate slurry properties to ensure safe operation
– or to adjust pipeline operations to handle a particular slurry.
The following sections summarize the limits of the Antamina pipeline.
3.3.2 Design Slurry Characteristics
The Antamina pipeline has been designed to transport concentrates within the ranges
summarized below. These ranges are expected to cover all normal concentrator
operating conditions (i.e., normal concentrate production). It may be possible to
transport concentrate with properties outside these limits. However, this should only
be done with the approval of the pipeline process engineer.
3.3.2.1 Particle Size Distribution
The following table summarizes the particle size distribution range for the Antamina
pipeline. The table presents cumulative percent passing versus particle size.
Size Fine Coarse Notes

149 µm (100 mesh) 99.9% 99.9% Minimum 99% passing 150 µm
105 µm (150 mesh) -- 95.0%
88 µm (170 mesh) -- 88.3%
53 µm (270 mesh) 99.7% 78.4% Minimum 80% passing 55 µm
37 µm (400 mesh) 98.4% 64.6%
25 µm (500 mesh) 91.5% 48.0%
20 µm (N/A mesh) 80.0% -- Maximum 80% passing 20 µm
777-G-G-002, Rev. 0 10 September 2000

3.3.2.2 Concentration
The minimum concentration for transport is 55 wt%.
The maximum concentration for transport is 65 wt% (except bornite – see Section
3.3.2.6).
3.3.2.3 Rheology
The maximum reduced viscosity for transport is 12.64
The minimum reduced viscosity for transport is 3.52
The maximum yield stress for transport is 2.78 dynes/cm2
The minimum yield stress for transport is 64.82 dynes/cm2
3.3.2.4 pH
The minimum pH for transport is 10.0.
The maximum pH for transport is 11.5.
3.3.2.5 Temperature
The minimum temperature for transport is 10o C.
The maximum temperature for transport is 15o C.
3.3.2.6 Specific Gravity of Solids
The design range for the specific gravity of solids is 4.0 to 4.2.
For bornite concentrate, the estimated specific gravity of solids is 4.4. For bornite
concentrate, transportation must be limited to 60 wt%.
3.4 Operating Range Limits
The selected pipe diameter(s), mainline pump and choke quantities produces a
transport system with an “as-built” capacity that provides some operating flexibility
outside the design point. The operating range diagram for the system (see Appendix
E) summarizes the operating capabilities of the Antamina pipeline transport system.
3.4.1 Throughput Limits
The pipeline design throughput is 300 t/h at 57 wt%. This represents the contract
throughput (i.e., the throughput for which a performance guarantee has been
provided) of 283.5 t/h plus a 6 percent safety factor. The system selected to meet that
777-G-G-002, Rev. 0 11 September 2000

design point has the capacity as shown on the operating range diagram in Appendix E
(0371-H-111).
The operating range diagram is a graphical interpretation of pipeline capacity. The

upper and lower limits of the range are bounded by the minimum and maximum
concentrations. The left boundary is set at the minimum safe operating velocity of the
pipeline. Operating at lower velocities could cause solid particles to settle in the
pipeline reducing throughput capacity. The right boundary is set at the installed
system capacity (i.e., pump horsepower, pipeline pressure rating, and choking
capacity). Operating at higher capacities could result in overpressure of and/or
damage to system components.
Note that these limits will be tested during the commissioning and actual operation of
the pipeline to determine if greater flexibility can be achieved. However, operation
outside the approved operating range should not be attempted unless specific
procedures are developed by the pipeline process engineer.
Note that the Antamina concentrator normally produces less than 283.5 t/h (often less
than 250 t/h) of concentrate. This means that the pipeline will often be operating near
the minimum throughput with process water batches in between batches of
concentrate to maintain the minimum operating velocity. A start/stop operation
should not be employed to match pipeline throughput to concentrate production.
The concentrator has the design capacity to produce up to 248.5 t/h of copper
concentrate and 204 t/h of zinc. During high grade ore campaigns, the production of
concentrate exceeds the capacity of the pipeline. The pipeline is then operated at
maximum throughput capacity while the surplus production is accumulated in the
pump station storage tanks. At the beginning of the campaign, planning is required to
ensure that the pump station storage tanks are empty. At the conclusion of the
campaign, the surplus pipeline capacity (versus concentrate production) is used to
pump the stored concentrate to the terminal.
The filter plant is basically sized to process concentrates at the same rate as they are
delivered to the terminal. Some storage is provided at the terminal for operating
flexibility and to contain delivered concentrate during upset conditions (problems at
the filter plant).
3.4.2 Choke Station Design
The pipeline is basically made up of two operating sections – a pumped section from
PS1 to VS1 and a gravity section from VS1 to TS1. In the first section, the mainline
pumps provide the motive force to overcome friction losses in the pipeline. In the
second section, the elevation difference between VS1 and TS1 provides the energy
required to overcome the friction losses.
777-G-G-002, Rev. 0 12 September 2000

The entire pipeline is designed to operate under packed flow (full pipe) conditions.
Operation in an open channel flow regime (i.e., a part full pipe or slack flow
condition) results in high operating velocity that could wear out the bottom of the
line. Choke stations are installed at VS1, VS3 and TS1 to provide back-pressure on
the pipeline and prevent this condition from occurring.
The hydraulic gradient for the pipeline design condition is shown on the profile and
hydraulic gradient drawing (see Appendix F). A more complete review of the design
of the choke stations can also be found in PSI document 777-G-H-005, “Hydraulic
Design Report”.
3.5 Pressure Rating Limits
The profile and hydraulic gradient drawing (0371-H-110) found in Appendix F also
provides a summary of the pressure limits for the pipeline. The pipe wall thickness is
selected to match the required design pressure in the line. As illustrated on the
drawing, pressures are considered for static (pipeline is shutdown on slurry) and
operating conditions. The resulting pressures are additionally calculated versus the
pipeline profile to select the required pipe wall thickness.
The table across the top of the drawing indicates the pipe wall thickness at points
along the pipeline. The pipe is telescoped (i.e., pipe wall thickness changes at many
points along the pipeline) such that the wall thickness matches the pressure
requirements taking into account the elevation of the profile at that point.
Rupture discs are provided at the valve stations to protect against overpressure of the
pipeline. Pipeline pressure just upstream of the valve stations will increase
significantly when the pipeline is shutdown. Although valve closures are timed to
prevent overpressure of the pipeline, the station valves are the most likely source of
an “overpressure” event. Thus, the rupture discs are located upstream of each station.
The rupture discs can not protect against all possible over pressure events. If flow is
blocked or partially blocked (perhaps during a pipeline restart) at a point between
stations, pressures upstream of the blockage could exceed the pipeline design
pressure. Pressure monitoring stations have been provided along the pipeline to
provide intermediate readings of pipeline pressure. The pipeline operator must
monitor these readings – particularly during startups on slurry – to ensure that
allowable pipeline pressures are not exceeded.
3.6 Product Segregation
3.6.1 General
The concentrate pipeline is expected to transport at least four distinct products during
operations. They are listed in the table below.
777-G-G-002, Rev. 0 13 September 2000

Product Characteristics
Low bismuth copper concentrate Chalcopyrite copper concentrate containing
less than 220 ppm bismuth
High bismuth copper concentrate Chalcopyrite copper concentrate containing
220 ppm or more bismuth
Bornite copper concentrate Bornite copper concentrate (contains several
thousand ppm bismuth)
Zinc concentrate Sphalerite zinc concentrate
Product segregation begins at the mine site storage tanks. As product is pumped from
the thickeners, the operator must identify the product and determine which tank will
be used. It is expected that all zinc concentrate will not require segregation by grade
and can be sent to either of the two storage tanks (0360-TKF-400 or 0360-TKF-401)
at any time.
Three copper tanks have been provided for storage of copper. Although any of the
tanks can be used to store any copper concentrate, they have been assigned a
preliminary service designation per the table below.
Tank Number Service

0360-TKF-405 Low bismuth copper concentrate
0360-TKF-406 High bismuth copper concentrate
0360-TKF-407 Swing tank – either low or high bismuth copper
concentrate (possible future bornite tank)
In general, a minimum of one hour of water pumping must occur between dissimilar
batches of concentrate. It is recommended that the water batch be at least two hours
to facilitate product segregation upon arrival at the terminal.
As discussed below, the SCADA system prevents switches between copper and zinc
unless the one hour minimum water batch has been put into the pipeline. However,
there is no interlock for the copper tanks. To provide operating flexibility (i.e., use
any copper tank for any product), no interlocks between tanks were programmed into
the SCADA system.
To avoid confusion, it is recommended that the copper storage tanks be utilized in

accordance with their established service designation. The swing tank should only be
used during periods of high production when containment in a single copper storage
tank is a problem. At the conclusion of a high grade/high concentrate production
campaign, the swing tank should be pumped to a minimum level to either the low or
high bismuth copper tank (matching the material in the swing tank).
777-G-G-002, Rev. 0 14 September 2000

When bornite mining is started in earnest (estimated to be production year 5), a
review of swing tank utilization will indicate if additional storage is required or if the
swing tank can be converted to a designated bornite tank.
Once in the pipeline, the Pipeline AdvisorTM (see Section 3.6.3) using SCADA input
tracks the concentrate batches. Additionally, a conductivity pulse system has been
installed to provide a backup to the Pipeline AdvisorTM (see Section 3.6.4).
At the terminal, there are three receiving tanks likewise with designated concentrate
service per the table below.
Tank Number Service

0510-TKF-500 Zinc concentrate
0510-TKF-501 Low bismuth copper concentrate
0510-TKF-502 High bismuth copper concentrate
The pipeline operator only makes the split between copper and zinc at the terminal
concentrate distributor (0510-STP-500). The tank to be used is selected by the port
operators who are also scheduling operations at the filter plant. Close coordination is
required between the pipeline and port operators to ensure the concentrates are
correctly routed at the terminal.
The terminal tanks drain by gravity to the filter plant. Additionally, the tanks have
sloped bottoms to facilitate flow out of the tank. It is expected that the quantity of
material remaining in a tank at the conclusion of a batch (i.e., received and filtered)
will be very small.
3.6.2 SCADA Interlocks
The principal SCADA interlock at the mine site protects from cross contamination
between copper and zinc concentrates. Valves HV-8629 (zinc) and HV-8630 (copper)
isolate the mainline pump suction header from the concentrate charge pumps. The
mainline pump suction header is the first common carrier point in the plant.
When pumping one concentrate, the valve for the opposite concentrate can not be
opened. The permissive to open the valve is one hour of water pumping through the
pipeline. The water pumping is achieved by opening the flush water line (and closing
the storage tank draw down valve) and pumping water through the charge pump into
the pipeline. The flow meter, density meter, and total pump strokes are monitored to
confirm the water pumping (i.e., the clock stops if water stops flowing for any
reason).
At the terminal concentrate distributor, there are two outlet valves (copper and zinc).
One valve must be opened at all times. Therefore, when switching from one
777-G-G-002, Rev. 0 15 September 2000

concentrate to the other, the “new” valve must be opened prior to shutting the
currently open valve.
At the terminal there are no product interlocks. The Pipeline AdvisorTM (see Section
3.6.3) and the pipeline operator must monitor concentrate batches in the pipeline to
ensure proper routing in the terminal. The SCADA system provides the primary
information to the operator. However, a local chart recorder (UR-8636) is also
available (shows HV-8629 and HV-8630 position versus time) such that, even if the
SCADA system is lost, the pipeline operator can calculate batch position based on
start time and pumping duration.
Likewise, a chart recorder (UR-9358) has been installed in the terminal. It records
flow, density and valve positions for the concentrate distributor. This provides a hard
record of pipeline flows in the event the SCADA system is lost.
3.6.3 Pipeline AdvisorTM (Batch Tracking)
The Pipeline AdvisorTM is a SCADA supplement that assists the pipeline operators in
monitoring operations and making the necessary changes during batch pumping. A
feature installed in the Pipeline AdvisorTM software is batch tracking.
The batch tracking starts when concentrate is delivered to the storage tank. Whenever
pumping is started into a tank (tank inlet valve is opened below the moving screen),
the SCADA system will query the operator as to the product quality. Note that this is
for copper only as the zinc concentrate quality is expected to be consistent during all
phases of operation.
Default values for each copper tank have been established per the table in Section
3.6.1 above. For the swing tank, the previous operator selection is deemed to be the
default value (i.e., pumping of the same product is continuing). The Pipeline
AdvisorTM then tags the tank based on the operator selection.
If there is material in the tank that does not match the operator selection, the Pipeline
AdvisorTM will re-query the operator as to the selection to ensure it is not a mistake.
If the new concentrate selection is affirmed, the entire tank will be designated as the
new concentrate.
Note that it is extremely important to minimize the mixing of copper concentrate

grades in the pump station tanks as this practice could compromise dry product
blending at the terminal.
Whenever concentrate pumping is initiated from the tank (SCADA signal when the
draw down valve is opened), the Pipeline AdvisorTM will reconfirm the type of
concentrate being pumped (operator query). This batch will then be tagged and
tracked through the pipeline by monitoring flow and counting pump strokes.
777-G-G-002, Rev. 0 16 September 2000

The Pipeline AdvisorTM will provide the operator with estimated time of arrival for
each batch interface (concentrate/water or water/concentrate). Using input from the
SCADA system the Pipeline AdvisorTM will also monitor valve position in the
terminal. If the concentrate distributor is incorrectly set up for an arriving batch of
concentrate, significant alarms will be sounded alerting the pipeline operator of a
problem.
3.6.4 Conductivity Pulse
A conductivity pulse system has been installed as a backup to the Pipeline AdvisorTM
batch tracking discussed above. In order to ensure segregation of copper and zinc
concentrates, a short batch of high conductivity water will be pumped in front of each
zinc batch.
The conductivity pulse is accomplished by injecting saturated salt water into the
process water immediately in front of the zinc batch. Salt water from 0360-ZMZ-400
is injected for 5 minutes upstream of the zinc charge pumps. This cycle is initiated by
an operator request to open a zinc tank valve. The conductivity of the water is
measured downstream of the charge pumps (CIT-8607) to confirm the strength and
duration of the pulse.
At the terminal, the pulse is measured downstream of the terminal choke station (CIT-
9359) indicating the imminent arrival of a zinc batch. Alarms similar to those for
Pipeline AdvisorTM batch tracking (see Section 3.6.3) will sound if the concentrate
distributor is not set to receive zinc.
Note that the signal from both conductivity indicators is blocked if the density meter
reads more than 1.20, in other words when slurry is in the line. If the density meter at
the terminal (DIT-9362) goes from 1.0 (water) to a higher level (above 1.20) without
a conductivity pulse, the SCADA system will assume the arriving batch is copper.
Like zinc, alarms will sound if the concentrate distributor is not set to receive copper.
3.7 General Operating Philosophies
3.7.1 High Pressure Slurry
Any fluid under high pressure is potentially dangerous, and slurry is particularly
dangerous because the solids suspended in the liquid produce an effect similar to
sandblasting. Maintenance, construction and operating personnel should be made
aware of the dangers of high-pressure slurry. Any slurry leak under high pressure can
begin as a minor drip and rapidly advance to a dangerous fluid cutting hazard in
minutes. Anything in its path is potentially at risk of being cut. Always be on guard
for this potential occurrence when in the vicinity of high pressure piping.
Observe the following precautions at all times:
777-G-G-002, Rev. 0 17 September 2000

• Do not open valves unless absolutely necessary.
• Be sure that new personnel are cautioned about the dangers of high-
pressure slurry.
• Personnel should use caution around leaks. Any observed leak requires
that the section be immediately shut down or switched to water, and that
the leak, or leaks, be repaired.
• Equipment and piping are provided with vents, drains and/or flushing
connections which allow the release of entrapped pressure. Make certain
there is no pressure on equipment and that the pressure gauges read zero
before opening equipment. Caution must be used because pressure
gauges, vents, and drains may plug. Be absolutely sure there is no
trapped pressure before opening the equipment.
• Before working on the equipment, be sure that all isolation valves are
closed, then open vents and drains, being extremely careful that no one
is near a discharge point.
• The pulsation dampeners cannot be open to line pressure if the
diaphragm has ruptured. Never work on a pulsation dampener unless the
pump is shut down and all piping isolated from pressurized lines.
Always open the drain on slurry side piping to release stored dampener
pressure. Proceed with any work on the dampeners in the manner
specified for the equipment.
• Do not attempt to find the cause of a leak while the line is under
pressure.
• Isolate piping or equipment to repair a leak; if necessary, shut the
pipeline down.
3.7.2 Wear
3.7.2.1 Mechanical Equipment
Concentrate slurry is abrasive by nature. Mechanical equipment such as the agitators,

charge pumps and mainline pumps have been designed and selected to meet operating
conditions with minimum wear. However, wear will occur and routine maintenance
will be required on virtually all pipeline components. This is discussed further in
Section 5 of this manual.
To prevent excessive wear or premature failure of equipment, it must be operated

within the design range specified. Operations should be monitored for compliance
with the system limits.
777-G-G-002, Rev. 0 18 September 2000

3.7.2.2 Mainline Pipe
Although concentrate slurry is abrasive, commercial experience has demonstrated that

controlling pipeline operating velocity is an effective means to control wear. The
Antamina pipeline is designed to operate in a range whereby the expected wear rate is
low. The HDPE liner was installed to mitigate internal corrosion of steel pipe.
Some sections of the pipeline are susceptible to higher operating velocities for short
periods of operation. This includes possible slack flow areas (after pipeline high
points and downstream of valve stations). In these areas, a thicker internal liner (12
mm instead of 6 to 7 mm) has been installed to provide a wear allowance.
Additionally, the operating velocities in the 8 NPS section between VS1 and VS4 are
near the maximum recommended operating velocities. As such, a slightly thicker
liner (9 mm instead of 6 mm) was installed to provide additional protection against
erosion.
3.7.2.3 Station Piping
All high-pressure station piping (ANSI 1500 class) has been lined with polyurethane.
The polyurethane provides a dual function – corrosion and erosion protection.
As with the mainline pipe, station piping is subjected to corrosion from the
concentrate slurry and process water. Additionally, flow in the station is very
turbulent due to the short radius elbows, tees, chokes and valves in the station piping.
The high turbulence creates localized high velocities, which in turn can create high
erosion rates. The polyurethane has been commercially proven to resist this erosion.
3.7.2.4 Station Valves

The high pressure valves at the intermediate valve stations and terminal are metal-
seated ball valves designed to resist erosion. However, the primary valves that open
and close against flowing concentrate slurry (wear valves) will experience very high
flow velocities due to the high pressure drop across the valves. In time (depending on
the number of valve cycles), the wear valves will start to leak.
For this reason, two valves have been provided in each spot that primary opening or
closing of the station will occur – a wear valve and a seal valve. The wear valve
(downstream valve) is opened second and closed first. As a result, it experiences the
most wear due to high flow velocities and, possibly, cavitation. The seal valve is
closed second and opened first. Its primary function is to provide a positive shutdown
of the station if a small leak develops in the wear valve. To avoid accelerated damage
to the wear valve, always close the seal valve after the wear valve has been closed (all
automated sequences contain this feature).
See section 5.5.5 for additional information regarding the metal-seated ball valves.
777-G-G-002, Rev. 0 19 September 2000

3.7.2.5 Ceramic Chokes
Ceramic chokes are provided in VS1, VS3 and TS1 to dissipate excess head in the
transport pipeline. Although they are fabricated from ceramic to resist erosion, the
chokes will necessitate routing replacement.
See Section 5.5.6 for additional information regarding the ceramic chokes.
3.7.3 Protect Mainline Pumps

The mainline pumps are a primary component of the transport pipeline and an
expensive repair item. As such, operating procedures and equipment interlocks have
been developed to protect the mainline pumps. As an example, the copper and zinc
concentrate charge pumps may run dry or without seal water but will not shut down if
the mainline pumps are running (the SCADA system will alarm the operator but not
shutdown the charge pump).
This philosophy was adopted for two main reasons. First, all pump station equipment
except the mainline pumps has at least a full size spare. Thus, it can be sacrificed to
protect the mainline pumps. Second, the cost of repair to other station equipment is
small in comparison to the cost of a significant mainline pump repair.
It is imperative to follow the procedures in this manual and keep the SCADA
interlocks in place to protect the mainline pumps as a system priority.
3.7.4 Vibration
The mainline pumps are reciprocating machines and will introduce vibration into the
attached piping and equipment. Pulsation dampeners are provided on the suction and
discharge piping to moderate the induced vibrations. The piping design is expected to
provide adequate rigidity to resist vibration. However, it is expected that constant
vibration could shake loose bolts or wiring connections – particularly the suction and
discharge valve actuators. Routine inspections must be made of all equipment
mounted on or connected to the mainline pumps to ensure connections remain tight.
3.8 Operating Strategies
3.8.1 Pump Station Storage Tanks
3.8.1.1 Concentrate Production versus Pipeline Capacity

The design throughput of the concentrate pipeline is 300 t/h even though the peak
concentrate production rate is expected to be as high as 450 t/h. The minimum
pipeline continuous throughput is 264 t/h even though concentrate production is
below 250 t/h for as much as 90 percent of the year. A minimum of four grades of
concentrate will be transported through the pipeline. All of these factors were used to
size the mine site storage tanks.
777-G-G-002, Rev. 0 20 September 2000

It is well documented elsewhere that advance planning is required for the pipeline to
successfully transport full concentrator production without curtailing operations. For
most ore grades, the pipeline transport capacity exceeds concentrate production
capacity. However, there are some ore grades that will produce more than 300 t/h of
concentrate. These mining campaigns should be fairly well defined and known up to
several months in advance of putting the ore into the concentrator. In general,
pipeline operations must be scheduled to pump down PS1 storage tanks to minimum
levels in preparation for high-grade operations at the concentrator.
The PSI Pipeline Simulator can be used to assist the pipeline operators in managing
high-grade campaigns. Current tank levels and expected concentrate production rates
can be entered into the Simulator. The operator can then simulate concentrate batches
to ensure pipeline and storage tank operations result in smooth transport of the
concentrator production. With experience, set pipeline schedules can be developed
for certain concentrator production rates (ore quality).
3.8.1.2 Zinc Storage Tanks
Current mining plans indicate that the Antamina concentrator will produce only one
grade of zinc concentrate. As such, the two zinc storage tanks can be operated as a
single large tank. Under normal circumstances, one tank should be filled or pumped
at a time rather than both concurrently. However, switches between tanks can be
made as required by the operator without fear of mixing concentrates.
3.8.1.3 Copper Storage Tanks

Currently, it is expected that the Antamina concentrator will produce three basic
copper concentrates – low bismuth, high bismuth, and bornite. A storage tank has
been provided for low and high bismuth grades. At this point, there is no designated
bornite tank at the pump station.
A third copper concentrate has been installed and designated as the swing tank. It is
expected that this tank will be used during high-grade campaigns to contain either low
or high bismuth copper concentrate production. As such the service will switch
between the grades – inventory control will be required in the swing tank to minimize
cross contamination.
If the swing tank is filled with concentrate, the operator should attempt to pump it into
the pipeline before the corresponding low (or high) bismuth tank. When the swing
tank has reached the minimum safe level for direct feed to the mainline pumps
(approximately 2 meters level), pumping should be switched to the primary low (or
high) bismuth concentrate tank. Then, the remaining contents in the swing tank can
be pumped to the primary tank in accordance with Section 3.8.1.4 below.
It may be possible, through careful scheduling, to avoid using the swing tank for low
or high bismuth copper storage. If this operation is successful for the first few years
777-G-G-002, Rev. 0 21 September 2000

of production, the swing tank could be designated as the bornite tank when production
begins.
Note that it is also possible to use all three copper tanks to contain one production.
However, the pipeline operator must carefully monitor tank levels, stored concentrate
quality and current production quality to minimize mixing of the concentrates.
3.8.1.4 Maximizing Available Storage
There are several circumstances under which it is desirable to remove as much

concentrate from a storage tank as possible. It is estimated that the minimum safe
tank level for direct feed to the mainline pumps is about 2 m of slurry. At lower
levels the mainline pump suction pressure may become unstable. However it is
possible to pump the residual slurry from one tank to another to minimize the retained
volume. This operation could occur for the following reasons:
• Tank is coming out of service for maintenance

• Swing tank is being drained down for a service switch
• Tanks are being drained as much as possible to prepare for a high grade
ore campaign
• Tanks are being drained to permit agitator shutdown
When taking a tank out of service, recovering the concentrate is a priority. The tank
heel (remaining slurry below the 2 m level) can be pumped from one storage tank to
another using the charge pumps. As the tank level drops, the agitator must be shut off
and the charge pump speed reduced to avoid mechanical problems. Operating
experience will dictate how low each tank can be pumped – the actual level may vary
for each tank as the suction piping lengths vary.
When pumping out a tank, the receiving tank should be at least 50 percent full. This
will permit blending of the incoming concentrate. The density of this concentrate
may vary after the agitator is stopped. When the minimum pumping level is reached,
the remaining concentrate is dumped to the area sump pump which recovers the
concentrate back to the thickener.
At the completion of a particular copper batch, the swing tank can be similarly
pumped down. Piping has been installed to permit this operation concurrent to
pumping copper concentrate through the pipeline. Flush water piping has been
connected to the swing tank to facilitate water washing of the tank (if desired by the
operator).
In anticipation of a high-grade campaign, zinc and copper tanks could be pumped to a

minimum. While one tank for each concentrate will never be pumped below the 2 m
level required to feed the mainline pumps, the other tanks can be pumped down to
777-G-G-002, Rev. 0 22 September 2000

maximize the available storage. Operating experience will determine if this activity is
justified to contain concentrate production.
Finally, for most of the year (more than 90% of the operating days), the concentrator
and pipeline can be operated using only one copper and one zinc tank as concentrate
production is below the maximum pipeline throughput. Under this circumstance the
pipeline can transport concentrate as it is produced. To save on power consumption,
it may be possible to shut down the agitators in the unused tanks. As discussed
above, the unused tank can be pumped down to a minimum level and “shut down”
until concentrate production rates require use of the tank.
3.8.2 Automatic Sequences
In general, automated sequences have been provided to simplify common and

repetitive operator functions. Additionally, “intelligent” software has been provided
to assist the operator decision making (see Section 3.8.5). However, the pipeline
operator is the primary control point for the pipeline.
As such, most automated sequences have stop/hold points requiring operator input to
continue. In this manner, the pipeline operator can confirm the conditions are safe for
the sequence to proceed. This manual and the SCADA sequence tables provide a
detailed description of sequences and must be understood by the pipeline operator.
When the pipeline is in operation, all automated sequences should be engaged. This
will permit the SCADA system to maximize an independent response to an
emergency situation. This is particularly critical if the pipeline operator is otherwise
involved in addressing the emergency conditions. This SCADA system provides both
automatic and one-button emergency shutdown sequences that can safely shutdown
the entire pipeline with no operator input. Disengaging these sequences can lead to
difficult, operator intensive emergency shutdowns and increased risk to damage to the
pipeline or related equipment.
3.8.3 Choke Changing
Choke changing is required at VS1, VS3, and TS1 as slurry and water batches transit
the pipeline to maintain full pipe conditions. The chokes are used to dissipate surplus
head in the downhill section of the line (from roughly VS1 to the terminal).
If the pipeline is full of concentrate slurry from PS1 to TS1 (no water batches), a
steady state operating condition can be established. Steady state means that the
pipeline can operate safely and continuously without changes to the pump speed or
choke settings at VS1, VS3, and TS1. If there are slurry and water batches in the line,
choke settings will require change as the slurry water interface moves through the
pipeline. The Antamina pipeline will normally operate in the batch mode.
777-G-G-002, Rev. 0 23 September 2000

The Pipeline AdvisorTM monitors on-line SCADA data and uses it to establish a
pipeline hydraulic gradient. Based on this information, the Advisor will recommend
choke increases or decreases at VS1, VS3, or TS1 with the objective of maintaining
full pipe conditions.
In general, choking must be increased when:

• The pipeline flow rate is reduced
• Slurry is pushing water down the hill (between VS1 and VS4)
• Water replaces slurry flowing through chokes at VS1, VS3, or TS1
In general, choking must be decreased when:

• The pipeline flow rate is increased
• Water is pushing slurry down the hill (between VS1 and VS4)
• Slurry replaces water flowing through chokes at VS1, VS3, or TS1
Changing chokes at a station can affect operating conditions along the entire pipeline.
For example, adding a choke at TS1 will increase the pressure upstream of TS1 by
adding resistance to flow in the station (a higher inlet pressure is required to achieve
the same flow through the station). Over time, the pressure increase will move back
through the pipeline, through all the intermediate stations, and be noticed at the
mainline pump discharge (assuming steady state operations). Chokes at VS1 or VS3
may have to be opened to maintain the desired pressure levels at the upstream
stations.
Note that the PSI Pipeline Simulator is also a useful tool in setting chokes at the
stations. Actual operating conditions (batch interfaces, slurry concentrations, choke
settings, and pipeline flow rate) can be entered into the model. The desired choke
change can be made in the Simulator and the model run to illustrate the impact of the
change. The Simulator can assist the operator in developing strategies to control
pipeline pressure using the chokes at VS1, VS3, and TS1.
Chokes are head dissipation devices and have been sized to remove nominally 50 m
of head. However, pressure drop across the choke is dependent on the fluid flowing
through the chokes – a higher SG results in a higher pressure drop. When water is
flowing through a choke station, the pressure drop across the chokes is about half the
pressure drop for slurry.
During most operating conditions, the slurry chokes are adequate to control pipeline
pressures. However, during some low concentrate production periods, operating
scenarios may exist where additional choking is required. The condition will occur
when the pipeline is operating at minimum flow and slurry is pushing a long water
batch down the hill and into the terminal. Engaging all the slurry chokes does not
777-G-G-002, Rev. 0 24 September 2000

provide enough back-pressure to keep the line in full flow conditions so some
specially designed water chokes have been provided at VS3 and TS1. The table
below identifies the water chokes.
Engage water chokes at by closing valve

FO-9270A and FO-9270B VS3 HV-9262
FO-9271A and FO-9271B VS3 HV-9263
FO-9368A and FO-9368B TS1 HV-9367
FO-9371A and FO-9371B TS1 HV-9370
Water chokes are sized to remove 175 m of liquid head. Thus, each loop with two
chokes removes 350 m of head – equal to seven slurry chokes. Use of the water
chokes permits the operator to establish a full pipe pressure gradient under the
operating condition discussed above.
Note that the water chokes are ceramic and thus, resistant to wear. However, they
should not be used in slurry service. The high pressure drop creates high turbulence
on slurry and will prematurely wear both the choke and the downstream piping. Flow
should be switched out of the water choke loop just prior to arrival of the slurry batch
at the station.
3.8.4 Batch monitoring
Batch monitoring is perhaps the most important function in the operation of the
Antamina concentrates pipeline. As the pipeline transports two products that can not
be re-segregated after they are mixed, avoiding cross-contamination is critical.
The installed system provides 3 methods to identify and calculate batches in the
pipeline and upon arrival at the terminal. They are:
• Batch tracking by the Pipeline AdvisorTM
• Conductivity pulse for tagging zinc
• Chart recorder at the pump station and terminal station for backup
The batch tracking module in the Pipeline AdvisorTM provides the primary batch
tracking feature for the pipeline. The Advisor electronically tags the concentrate
when entering the storage tank and follows it into the pipeline based on valve
positions in PS1. Once the concentrate enters the pipeline, the Advisor tracks the
position of the batch by monitoring flow and counting pump strokes. It is expected
that the arrival of a batch can be predicted within less than 2 minutes of actual arrival
(subject to final testing during commissioning).
The second system for tracking concentrate batches and avoiding cross-contamination
is a conductivity pulse system (see Section 4.1.1.4 for details of this system). The
777-G-G-002, Rev. 0 25 September 2000

conductivity pulse tags the water with elevated conductivity (accomplished by salt
water injection at the pump station) in front of zinc batches. When the conductivity
pulse is measured at TS1, the SCADA system will alarm the operator of an
impending arrival of zinc concentrate. The SCADA system (and operator) will check
the TS1 distribution valves for proper position and alarm if incorrect.
Likewise, if a concentrate batch arrives at the terminal without an advance

conductivity pulse (determined by density increase), the SCADA system will alert the
operator that a copper batch has arrived. Again, the TS1 distribution valves will be
checked for proper position and alarmed if incorrect.
The third system is a backup to the automatic systems. A chart recorder has been
provided at PS1 and TS1 that tracks key product segregation information. The
recorder at PS1 charts flow, density, and isolation valve position (HV-8629 for zinc
and HV-8630 for copper) versus time. This allows the pipeline operator to calculate
when the batch entered the pipeline and, based on total flow over time, where the
batch is located.
The recorder at TS1 charts density, flow and conductivity. Like the PS1 chart, the
information will permit the operators to manually calculate batch arrivals and, using
the conductivity reading, determine the batch type. This method could be used if the
Pipeline AdvisorTM should become disabled.
3.8.5 Pipeline AdvisorTM/ Pipeline Simulator
HOLD FOR PIPELINE ADVISOR MANUAL
HOLD FOR PIPELINE SIMULATOR MANUAL
3.8.6 Correcting Off-Specification Concentrate
It is possible the concentrate slurry arriving at the storage tanks does not meet the
design conditions (see Section 3.3) for pipeline transport. This is a particular concern
during concentrator startups where operation may not be stable.
Under normal circumstances, the thickener underflow density is maximized and may
exceed the transport concentrate limits. The benefit of the high density is maximizing
storage capacity (in tonnes) of the fixed volume tanks. A density control loop is
included as part of the feed to the mainline pumps. This control allows the pipeline
operator to modulate density within the pipeline operating range. As such, high
density concentrate delivered to the storage tanks does not constitute off-specification
concentrate.
It is also likely that any deviations in concentrate quality will be of a short duration.
Natural mixing in the storage tank will temper the impact of the deviation possibly
eliminating any problems with transport of the material. Alternately, the operator can
777-G-G-002, Rev. 0 26 September 2000

undertake concentrate mixing to mitigate quality problems. The table below
summarizes possible concentrate quality problems and operator actions that can
correct the problem.
Concentrate quality problems Possible operator actions to correct

Overly coarse concentrate • Blend with finer material in another tank
(see Section 4.2.4)
• Recycle to regrind circuit via area sump
(see Sections 4.2.6.1.3 and 4.2.6.2.3)
• Drain to impoundment, dry, mechanically
recover, and transport (see Section 4.2.3)
Overly fine concentrate • Blend with finer material in another tank
(see Section 4.2.4)
• Drain to impoundment, dry, mechanically
recover, and transport (see Section 4.2.3)
Overly concentrated concentrate • This is not a problem as discussed above
Overly dilute concentrate • Blend with higher concentration material in
another tank (see Section 4.2.4)
• Recycle to concentrate thickeners via area
sump (see Sections 4.2.6.1.1 and 4.2.6.2.1)
High viscosity/yield concentrate • Blend with lower viscosity/yield material in
• Leave in agitated storage tank for a day and
retest (possibly need to break down
flocculant from thickeners)
• Transport at a lower concentration (lower
density with more dilution water)
Low viscosity/yield concentrate • Blend with lower viscosity/yield material in
• Recycle to concentrate thickeners via area
sump (see Sections 4.2.6.1.1 and 4.2.6.2.1)
and transport at a higher density
If other test results are outside the design range for transport, consult the pipeline
engineer for appropriate actions.
3.8.7 Locked Valves
Throughout the pipeline system, there are numerous valves that are locked open or
closed. As an example, manual station isolation valves are locked open. Pump
777-G-G-002, Rev. 0 27 September 2000

station sump outlet valves to the tailings pond are locked closed. The primary
purpose of the locks is to prevent accidental or incorrect operation of the valves.
In all cases, it is fully understood that the locked valves will require operation at some
point during the operation of the pipeline. However, these instances are expected to
be very rare and require special operator attention. Close control of the locks and
keys must be maintained to ensure maximum pipeline reliability.
777-G-G-002, Rev. 0 28 September 2000

4.0 OPERATING PROCEDURES
The sections below summarize pipeline operating procedures.
4.1 Pipeline System Operations
4.1.1 Pipeline Start
Pipeline start assumes the line is full of slurry and/or water and pumping is initiated.
If the line is empty, see Section 4.1.4.
Additionally, initiation of a pipeline start assumes that all equipment (or its spare) is
available and ready for use, and that any problem that initiated a pipeline shutdown
has been resolved.
4.1.1.1 Automatic Sequence
The automatic sequence for pipeline startup is incomplete in that it prepares the
pipeline for operation, but the pipeline operator must initiate flow in the line.
Pipeline restart conditions will vary depending on the duration of the shutdown and
the batches of concentrate and water (length and position) in the line. Thus, a fully
automated sequence can not be developed for startups.
To initiate a pipeline startup, the pipeline operator must complete the following steps
from the main control page of the HMI:
• Operator selects copper or zinc pumping and designates charge pump

• Operator selects 3 (of 4) mainline pumps
• Operator selects quantity of chokes at VS1, VS3 and TS1 (normally
there is no change from conditions at system shutdown)
• Operator selects prestart the mainline pumps
• Operator selects start of the selected charge pump
• Operator selects open station seal valves
• Operator selects open zinc/copper isolation valve at pump station (HV-
8629 or HV-8630)
Note that a one hour water batch is required between batches of different
concentrates. If the water batch was not pumped prior to shutdown and the operator
selects a concentrate change, the SCADA system will alarm.
777-G-G-002, Rev. 0 29 September 2000

Having completed the above steps, the pipeline operator has identified the target
condition of the pipeline after restart. The SCADA system will then complete the
following steps:
• SCADA system opens selected 3 mainline pump suction and discharge

valves
• SCADA system pre-starts selected 3 mainline pumps (starts auxiliaries)
• SCADA system sets station choke valves, opens seal valve on the fixed
choke leg to be used (VS1, VS3, TS1), and opens seal valves (VS2,
VS4)
• SCADA system opens suction valve on selected charge pump, opens
flush water valve(s), and starts charge pump
• SCADA system confirms adequate pump discharge pressure, opens
pump discharge valve, and main isolation valve to mainline pump
suction header
• SCADA system opens HV-8629 or HV-8630
The pipeline pre-start is now complete. At this point, the pipeline operator will
initiate flow in the line following a manual remote sequence (identical to portion of
the full manual remote sequence in Section 4.1.1.2). The steps are summarized in the
table below.
Operator Action Station Item number
Open wear valve in selected fixed HV-9356 or HV-9376

TS1
choke leg at terminal station
ALWAYS INITIATE OPENING/STARTUP OF THE PIPELINE FROM
THE TERMINAL AND WORK UP TOWARD THE PUMP STATION TO
AVOID OVER-PRESSURING THE LINE
Confirm pressure drop upstream of PIT-9388 and PIT-9351
TS1
terminal wear valve
Confirm flow into terminal TS1 FIT-9361
Confirm pressure drop at pressure PIT-9345
PMS4
monitoring station 4
Confirm pressure drop downstream PIT-9305
VS4
of valve station number 4
Open wear valve at valve station HV-9303
VS4
number 4
777-G-G-002, Rev. 0 30 September 2000

Confirm pressure drop upstream of PIT-9301

VS4
valve station number 4
Confirm flow at valve station FIT-9304
VS4
number 4
VS3
Note that it is possible that PIT-9280 will read 0 kPa prior to pipeline startup. If so,
wait approximately 15 seconds after wear valve at VS4 is open and proceed to the
next step.
VS3
choke leg at valve station number 3
VS3
VS2
next step.
VS2
number 2
VS2
VS1
next step.
VS1
VS1
VS1
number 1
Ramp up selected three mainline Hold for 15 seconds
PS1
pumps to 5% of speed
777-G-G-002, Rev. 0 31 September 2000


PMS3
monitoring station number 3
PS1
PMS2
PS1
Ramp up selected three mainline FIT-8623
PS1
pumps to desired speed or flow rate
Under normal circumstances, once the pipeline is open and flowing with the
mainline pumps operating smoothly, slurry pumping can be initiated. If the
pipeline has been down for an extended period (longer than 4 hours), an extended
water batch may be required. See Section 4.3.4.
Open the selected tank valve for 0360-TKF-400 (HV-8503)
concentrate pumping 0360-TKF-401 (HV-8504)
PS1 0360-TKF-405 (HV-8523)
0360-TKF-406 (HV-8524)
0360-TKF-407 (HV-8535)
Note that if a new zinc batch is being started following a prior copper batch, the
SCADA system will inject a 5 minute conductivity pulse prior to allowing the tank
valve to open.
Close flush water valve PS1 HV-8543
At the completion of this sequence, the pipeline should be placed in automatic mode
to engage the emergency shutdown sequence. Depending on the position of batches
in the line and the duration of the shutdown, the hydraulic gradient should reach
normal, full pipe conditions within about 20 to 30 minutes.
4.1.1.2 Manual Remote Sequence
Opening the pipeline from the terminal to the pump station completes a pipeline start.
Flow is confirmed in each section to ensure the pipe is not over-pressured if there is a
problem.
The first step in a pipeline start is to determine the desired operating conditions. The
operator must select a product being pumped (though the pipeline restart is normally
completed with water), a charge pump, three mainline pumps, the choke leg to be
777-G-G-002, Rev. 0 32 September 2000

used at VS1, VS1, and TS1, and the product destination at the terminal. Normally,
the target operation (pumping rate, setting of valves, number of chokes, etc.) will
match the conditions when the pipeline was shut down.
The table below summarizes the steps to be taken to execute a pipeline start. Note
that the sequence assumes that all systems perform properly and that an orderly
startup can be achieved. It is expected that the operator will stop and address system
problems if they are identified during the sequence.
Check current or next concentrate Open HV-9365 for copper

batch arriving at terminal and set
TS1 Open HV-9366 for zinc
concentrate distributor (0510-STP-
500) valves
Advise port operators pumping is 0510-STP-502 for copper
about to start and to set up copper or TS1 0510-STP-501 for zinc
zinc distributor
Select quantity of chokes for See Section 4.1.3
TS1
terminal choke station
Set choke loop valves per Section Set position of HV-9367,
4.1.3 TS1 HV-9370, HV-9352, HV-9353,
and HV-9354
Confirm isolation valve open in the HV-9357 or HV-9377
TS1
selected fixed choke leg
Select quantity of chokes for valve See Section 4.1.3
VS3
station number 3
4.1.3 VS3 HV-9263, HV-9264, HV-9265,
and HV-9266
VS3
Select quantity of chokes for valve See Section 4.1.3
VS1
station number 1
VS1
4.1.3 HV-9204, and HV-9205
VS1
Open flush water supply valve PS1 HV-8543
777-G-G-002, Rev. 0 33 September 2000

Select tank from which pumping 0360-TKF-400 (HV-8514)

will occur and open water valve 0360-TKF-401 (HV-8514)
PS1 0360-TKF-405 (HV-8540)
0360-TKF-406 (HV-8540)
0360-TKF-407 (HV-8537)
Note that the SCADA system will block pumping of a different type of concentrate
than was being pumped prior to the pipeline shutdown unless a minimum one hour
water batch has been introduced. Under normal circumstances, startup should be
completed with the same concentrate type as was being pumped prior to shutdown.
Select charge pump and open seal 0360-PPS-410 (HS-8701)
water valve 0360-PPS-411 (HS-8702)
PS1
0360-PPS-412 (HS-8704)
0360-PPS-413 (HS-8705)
Open suction valve of selected 0360-PPS-410 (HV-8583)
charge pump 0360-PPS-411 (HV-8584)
0360-PPS-412 (HV-8545)
PS1 (or HV-8546 if 0360-TKF-407)
0360-PPS-413 (HV-8548)
(or HV-8547 if 0360-TKF-407)
Select three mainline pumps and 0360-PPP-416 (HV-8665)
open discharge valves 0360-PPP-417 (HV-8675)
PS1
0360-PPP-418 (HV-8685)
0360-PPP-419 (HV-8695)
Open suction valves of selected 0360-PPP-416 (HV-8663)
three mainline pumps 0360-PPP-417 (HV-8673)
PS1
0360-PPP-418 (HV-8683)
0360-PPP-419 (HV-8693)
Open seal valve in selected fixed HV-9355 or HV-9375
TS1
Open seal valve at valve station HV-9302
VS4
number 4
VS3
Open seal valve at valve station HV-9242
VS2
number 2
VS1
777-G-G-002, Rev. 0 34 September 2000

Pre-start selected three mainline 0360-PPP-416

pumps 0360-PPP-417
PS1
0360-PPP-418
0360-PPP-419
Once the pre-start of the mainline pumps is completed, the pipeline is ready to start
operations. The operator should alert all relevant personnel – particularly the port
operators – that start up is imminent. When all is confirmed okay, the pipeline
startup can continue.
Start selected charge pump 0360-PPS-410
0360-PPS-411
PS1
0360-PPS-412
0360-PPS-413
Open discharge valve of selected 0360-PPS-410 (HV-8596)
charge pump 0360-PPS-411 (HV-8595)
PS1
0360-PPS-412 (HV-8556)
0360-PPS-413 (HV-8555)
Open selected concentrate valve to PS1 HV-8630 (copper)
the mainline pump suction line HV-8629 (zinc)
Again, the SCADA system will block a concentrate pumping change unless a
minimum 1 hour water batch has been introduced into the pipeline.
TS1
ALWAYS INITIATE OPENING/STARTUP OF THE PIPELINE FROM
THE TERMINAL AND WORK UP TOWARD THE PUMP STATION TO
AVOID OVER-PRESSURING THE LINE
TS1
terminal wear valve
Confirm flow into terminal TS1 FIT-9361
PMS4
monitoring station 4
VS4
VS4
number 4
Confirm pressure drop upstream of VS4 PIT-9301
777-G-G-002, Rev. 0 35 September 2000

VS4
number 4
VS3
Note that it is possible that PIT-9280 will read 0 kPa prior to pipeline startup. If
so, wait approximately 15 seconds after wear valve at VS4 is open and proceed to
the next step.
VS3
VS3
VS2
the next step.
VS2
number 2
VS2
VS1
the next step.
VS1
VS1
VS1
number 1
PS1
Confirm pressure drop at pressure PMS3 PIT-9340
777-G-G-002, Rev. 0 36 September 2000

PS1
PMS2
PS1
Ramp up selected three mainline FIT-8623
PS1
pumps to desired speed or flow rate
Under normal circumstances, once the pipeline is open and flowing with the
mainline pumps operating smoothly, slurry pumping can be initiated. If the
pipeline has been down for an extended period (longer than 4 hours), an extended
water batch may be required. See Section 4.3.4.
Open the selected tank valve for 0360-TKF-400 (HV-8503)
concentrate pumping 0360-TKF-401 (HV-8504)
PS1 0360-TKF-405 (HV-8523)
0360-TKF-406 (HV-8524)
0360-TKF-407 (HV-8535)
Note that if a new zinc batch is being started following a prior copper batch, the
SCADA system will inject a 5 minute conductivity pulse prior to allowing the tank
valve to open.
Close flush water valve PS1 HV-8543
At the completion of this sequence, the pipeline should be placed in automatic mode
to engage the emergency shutdown sequence. Depending on the position of batches
in the line and the duration of the shutdown, the hydraulic gradient should reach
normal, full pipe conditions within about 20 to 30 minutes.
4.1.1.3 Local Sequence
The above sequence can be completed locally. However, an operator would be

required at each intermediate valve station to open valves and monitor pressures and
flows. The startup must be coordinated via radio following the steps in the sequence
above. Personnel will likely not be available at the pressure monitoring stations
necessitating that those steps be skipped.
The requirement for a local startup would imply that both the primary (fiber optic
cable) and secondary (radio link) communication systems were not functioning
777-G-G-002, Rev. 0 37 September 2000

properly. It is not recommended that the pipeline be operated for an extended period
without this communication system (see Section 4.3.5).
4.1.1.4 Conductivity Pulse
As discussed above, a conductivity pulse is injected before each zinc batch to

facilitate product segregation.
The conductivity pulse system has been programmed into the SCADA system and is
tied to the zinc valve to the mainline pump suction header (HV-8629) and the zinc
tank valves (HV-8503 and HV-8504). When HV-8629 is open (the system is
pumping from the zinc side) and the operator selects a tank valve to open, the valve
action is delayed 5 minutes for injection of a conductivity pulse.
The SCADA system completes the injection of the salt water conductivity pulse
automatically. The injection pump is started, the pulse confirmed and the pump
stopped without operator action. The salt water tank level is recharged with process
water automatically.
The conductivity pulse is a short process water batch with salt water injected into it.
The salt water raises the conductivity of the process water. The higher conductivity is
measured at the discharge of the zinc charge pumps (CIT-8607) and the 5 minute
duration is confirmed by pump station flow (FIT-8623). After confirmation of the
pulse, the SCADA system will indicate the salt water sequence is completed and
permit opening of the selected zinc tank valve.
The conductivity pulse is detected upon arrival at the terminal (CIT-9359). The
SCADA system will alarm if terminal distribution valves are not properly set to
receive zinc concentrate.
4.1.2 Pipeline Shutdown
A pipeline shutdown comprises a planned shutdown of the system rather than an

emergency stop or other upset condition.
Prior to initiating a pipeline shutdown, it is recommended that, at minimum, a one

hour water batch is pumped into the pipeline. This will facilitate re-start of the line as
the product segregation interlocks will be cleared. Additionally, all of the pump
station equipment will be fully flushed prior to shutdown eliminating the need to flush
each piece of equipment individually.
If pumping of a one hour water batch is not feasible, water pumping should be
initiated prior to shutdown to flush all pump station equipment. Five minutes of
water pumping should be adequate to flush through the mainline pumps.
777-G-G-002, Rev. 0 38 September 2000

If five minutes of water pumping is not possible, the shutdown should be treated as an
emergency stop per Section 4.1.2.4.
The preferred normal shutdown method for the pipeline is the use of a pre-
programmed automatic sequence. This ensures the pipeline is safely shut down with
minimum risk of over-pressuring the line while minimizing the chance for slack
conditions. Significant slack conditions at the pipeline high points and downstream
of valve stations can result in damage to the pipeline or chokes during restart. Using
the automated sequence will provide the best shutdown results.
After completing the desired water pumping (one hour minimum is recommended),
the operator can initiate the automatic shutdown sequence via the HMI.
• Operator initiates the automatic shutdown sequence by stopping the
mainline pumps
• Operator completes the sequence by closing the pipeline
Following the operator initiation, the SCADA system will shut down all pipeline
facilities using a pre-programmed sequence. The automatic shutdown will shut down
and isolate the operating mainline pumps, close the wear and seal valve at all stations,
and shut down the operating charge pumps. The SCADA system provides a one-
button stop command for the entire system.
As discussed above, the preferred shutdown method is using the automatic sequence
to protect the pipeline. If for some reason the automatic sequence is not available
(PLC problems), the following sequence can be followed. This sequence is more
conservative than the automatic sequence and will result in lower pipeline shutdown
pressures (larger slack zones).
After completing the desired water pumping (one hour minimum is recommended),
the operator can complete the pipeline shutdown by completing the following
sequence.

Advise port operators pumping is N/A
TS1
about to stop
Ramp operating mainline pumps FIT-8623
PS1
down to zero speed
Stop operating mainline pumps 0360-PPP-416
PS1
0360-PPP-417
777-G-G-002, Rev. 0 39 September 2000

0360-PPP-418
0360-PPP-419
After 15 seconds, confirm upstream PIT-9201
pressure at VS1 is less than or equal
VS1
to 12,500 kPa – if not, wait until
pressure is below 12,500 kPa
Close wear valve at VS1 VS1 HV-9207 or HV-9217
10 seconds after initiating VS1 valve PIT-9248
closure confirm VS2 upstream
pressure is less than or equal to VS2
13,000 kPa – or wait until pressure
is below 13,000 kPa
Make sure selected valve at VS1 is closing before initiating closure of the wear
valve at VS2
Close wear valve at VS2 VS2 HV-9242
is below 17,000 kPa
valve at VS3
Close wear valve at VS3 VS3 HV-9268 or HV-9278
is below 14,000 kPa
valve at VS4
Close wear valve at VS4 VS4 HV-9303
closure, confirm pressure upstream
of TS1 is less than or equal to TS1
is below 11,000 kPa
valve at the terminal
777-G-G-002, Rev. 0 40 September 2000

Close wear valve at TS1 TS1 HV-9356 or HV-9376

Close seal valve at VS1 VS1 HV-9206 or HV-9216
Close seal valve at VS2 VS2 HV-9242
Close seal valve at VS3 VS3 HV-9267 or HV-9277
Close seal valve at VS4 VS4 HV-9302
Close seal valve at TS1 TS1 HV-9355 or HV-9375
Shutdown auxiliaries for the 0360-PPP-416
previously operating three mainline 0360-PPP-417
PS1
pumps 0360-PPP-418
0360-PPP-419
Close operating charge pump 0360-PPS-410 (HV-8596)
discharge valve 0360-PPS-411 (HV-8595)
PS1
0360-PPS-412 (HV-8556)
0360-PPS-413 (HV-8555)
Stop operating charge pump 0360-PPS-410
0360-PPS-411
PS1
0360-PPS-412
0360-PPS-413
Close suction valve of previously 0360-PPS-410 (HV-8583)
operating charge pump 0360-PPS-411 (HV-8584)
0360-PPS-412 (HV-8545)
PS1
(or HV-8546)
0360-PPS-413 (HV-8548)
(or HV-8547)
Close selected concentrate valve to PS1 HV-8630 (copper)
the mainline pump suction line HV-8629 (zinc)
Close flush water supply valve PS1 HV-8543
Close discharge valves of previously 0360-PPP-416 (HV-8665)
operating mainline pumps 0360-PPP-417 (HV-8675)
PS1
0360-PPP-418 (HV-8685)
0360-PPP-419 (HV-8695)
Close suction valves of previously 0360-PPP-416 (HV-8663)
operating mainline pumps 0360-PPP-417 (HV-8673)
PS1
0360-PPP-418 (HV-8683)
0360-PPP-419 (HV-8693)
At the completion of this sequence, the pipeline is shutdown and ready for re-start.
Pressures along the pipeline must be monitored to ensure they hold steady. Drops or
increases in observed pressure could indicate leaking valves.
777-G-G-002, Rev. 0 41 September 2000

The above sequence can be completed locally. However, an operator would be

required at each intermediate valve station to close valves and monitor pressures and
flows. The pipeline shutdown must be coordinated via radio following the steps in
the sequence above.
The requirement for a local shutdown would imply that both the primary (fiber optic
cable) and secondary (radio link) communication systems were not functioning
properly. It is not recommended that the pipeline be operated for an extended period
without this communication system (see Section 4.3.5).
If pressure data is not available or reliable, the following sequence should be followed
to shutdown the pipeline in local mode. In each case, it is assumed that the local
operator will first shut the wear valve then the seal valve.
• Shut down the mainline pumps (start timing)

• After 120 seconds, close VS1
• After 200 seconds, close TS1
4.1.2.4 Emergency Stop
Emergency shutdown of the pipeline can be initiated from two locations – through the
HMI by the pipeline operator and at the mainline pumps. These two emergency stops
are discussed in the following sections.
4.1.2.4.1 HMI-Initiated Emergency Stop
If the pipeline operator initiates an emergency shutdown, the SCADA system will
immediately ramp down all operating mainline pumps. The SCADA system will then
shut down all pipeline facilities using a pre-programmed sequence (basically identical
to the automated shutdown discussed in Section 4.1.2.1). The automatic shutdown
will shut down and isolate the operating mainline pumps, close the wear and seal
valve at all stations, and shut down the operating charge pumps. Effectively, the
emergency shutdown follows the same sequence as the planned shutdown to protect
the pipeline.
For normal shutdowns, the shutdown sequence is initiated after water pumping. After
an emergency shutdown, all pump station piping and equipment may be full of slurry
(depending on status when the shutdown was initiated). If slurry is present, the
777-G-G-002, Rev. 0 42 September 2000

charge pump and mainline pumps should be flushed (see Sections 4.2.8 and 4.2.10
respectively) prior to restart.
4.1.2.4.2 Mainline Pump Initiated Emergency Stop
An emergency stop for the pipeline can be initiated from the mainline pumps in two
ways – if all pumps go offline (low suction pressure shutdown, power failure, etc.) or
manually at the local pump control panels by the station operator.
If the mainline pumps trip (shutdown), the charge pumps and mainline pump
auxiliaries may or may not be running and the pipeline will remain open. As some
mainline pump trips can be very short in nature (high voltage power dip to the pump
AFD’s), the pipeline operator may want to immediately restart the pumps. Therefore,
mainline pump trips will not automatically shutdown the charge pumps and close the
pipeline valves.
If the mainline pumps trip, the SCADA system should remain operational in all cases
(the SCADA system is connected to the concentrator UPS). The SCADA system will
query the pipeline operator if a system shutdown is required. If the operator elects to
shutdown the entire system, the preprogrammed shutdown sequence (see Section
4.1.2.1) will be completed by the SCADA system.
If the pipeline operator plans a quick restart, the system shutdown would be rejected.
If there is no response to the query, the SCADA system will initiate the sequence after
5 minutes. This function has been installed in the event the pipeline operator is
addressing other emergency conditions at the time of the mainline pump trip. A timer
is installed on the main pipeline control page to alert the operator of an impending
automatic shutdown.
A mainline pump initiated shutdown can also be initiated from any local mainline
pump panel. Each panel has been equipped with an emergency “all-stop” button. If
pushed by the station operator, all operating mainline pumps will automatically shut
down as well as all mainline pump auxiliaries. However, like the mainline pump trip,
other system components (charge pumps and station valves) will not be automatically
shut down. Again, the SCADA system will query the pipeline operator as to whether
a complete system shutdown will be required and follow the same protocol for
delaying or initiating a shutdown.
Similar to the emergency shutdown discussed in Section 4.1.2.4.1, a mainline pump

initiated shutdown may occur while pumping concentrate. If so, the charge pump and
mainline pumps should be flushed following the shutdown (see Section 4.2.8 and
4.2.10).
777-G-G-002, Rev. 0 43 September 2000

4.1.3 Choke Changing
As slurry and water batches transit the pipeline and throughput varies, the number of
chokes required for head dissipation will change. This section summarizes the
sequences to change the number of chokes at VS1, VS3, and TS1.
VS1, VS3 and TS1 are all equipped with automatic choke changing sequences. In
each station, the operator can select a number of chokes to engage. The SCADA
system will automatically open and close valves to move from the current condition to
the operator set point. To complete the change, the following steps are taken:
• Operator selects station (VS1, VS3 or TS1)
• Operator selects choke changing
The SCADA system will display a dialog box showing the current conditions
(number of chokes engaged).
• Operator enters the new number of chokes to be engaged
Following the operator entry, the SCADA system will automatically adjust the valves
in the selected station to meet the operator specified condition.
Note that water chokes are installed at VS3 and TS1 (FO-9270A&B, FO-9271A&B,
FO-9368A&B, and FO-9371A&B). During some operations (low throughput rate and
slurry pushing a water batch) significant head dissipation may be required to maintain
full pipe conditions. These chokes are designed to provide extra head dissipation
when water is passing through the station.
As the use of these chokes will be infrequent and occurs during unique operating
conditions, the water chokes are not part of the automated choke changing sequence.
The pipeline operator will engage and disengage these chokes as required by the
pipeline operation.
The sections below provide the valve settings required at each choke station. When
making the switch manually, the following procedures should apply to transition from
the existing setup to the desired setup.
• When switching from one fixed choke leg to the other, always open the
new leg prior to closing the currently flowing leg
777-G-G-002, Rev. 0 44 September 2000

• When switching from one fixed choke leg to the other, always verify flow
through the new leg after closing the wear valve in the previously flowing
leg before closing the seal valve
• When switching choke loops, always open the new loop prior to closing
the currently flowing loop
• In general, the isolation valves on the fixed choke legs (downstream of the
chokes) should remain open unless the wear/seal valve combination is
leaking or the leg is being isolated for maintenance.
4.1.3.2.1 VS1 Sequence
The table below summarizes the valve positions at VS1 to achieve the desired number
of chokes at the station.
Number of chokes 2 3 4 5 6 7 8 9 10 11 12 13
HV-9203 O O O O C C O O O O C C
HV-9204 O O C C C C O O C C C C
HV-9205 O C O C O C O C O C O C
HV-9206/9207 O O O O O O C C C C C C
HV-9216/9217 C C C C C C O O O O O O
O = open, C = closed
4.1.3.2.2 VS3 Sequence
The table below summarizes the valve positions at VS3 to achieve the desired number
Number of chokes 3 4 5 6 7 8 9 10 11 12 13 14
HV-9267/9268 O O O O O O C C C C C C
HV-9277/9278 C C C C C C O O O O O O
The above table does not include the water chokes at VS3 that are engaged by closing
HV-9262 and/or HV-9263.
777-G-G-002, Rev. 0 45 September 2000

4.1.3.2.3 TS1 Sequence
The table below summarizes the valve positions at TS1 to achieve the desired number
Number of chokes 4 5 6 7 8 9 11 12 13 14 15 16
HV-9355/9356 O O O O O O C C C C C C
HV-9375/9376 C C C C C C O O O O O O
Note that to avoid cavitation, the last chokes in each fixed choke leg are larger in
diameter (less pressure drop) than the others along the pipeline. Due to this feature,
there is no 10 choke option as the transition from 9 to 11 is smaller than it would be at
the other stations.
The above table does not include the water chokes at TS1 that are engaged by closing
HV-9367 and/or HV-9370.
Choke changing at VS1, VS3, and TS1 can be accomplished using the operator
interface at each station. The valve actuators are equipped with a lockout feature that
does not permit local operation of the station valves. This feature is designed to
protect against accidental or purposeful closure of an incorrect valve that could
overpressure the pipeline.
In order to operate the station valves to change chokes from the local panel, the
following steps must be taken:
• HOLD FOR DETAILS FROM SCADA MANUAL
4.1.4 Pipeline Filling and Draining
The following sequences provide normal pipeline filling and draining procedures.
Under normal operating conditions, the pipeline should be filled or drained on water
(i.e., the pipeline or section contains or will contain process water). Filling or draining
the pipeline or a section on/with slurry should be avoided. This operation may be
required in certain emergency situations as discussed in Section 4.3.9.
777-G-G-002, Rev. 0 46 September 2000

4.1.4.1 Pipeline Filling
There is no automatic sequence for pipeline filling. This operation is expected to be

infrequent and therefore will be done manually. As numerous valves for this process
are manual valves that can not be actuated remotely, this operation will be completed
by a coordinated effort between the pump station and outside operator(s) positioned at
the intermediate valve stations.
4.1.4.1.1 Entire Pipeline
When filling the entire pipeline, process water is introduced at the mainline pumps
and delivered to the pipeline. As there is no back pressure on the pumps (the pipeline
is empty), the discharge pressure of the pumps will be very low. Thus, the discharge
dampener pre-charge should set at not more than 2,000 kPa to permit safe, smooth
operation of the pumps.
The table below provides a sequence for filling the mainline pipe. It is assumed that
the pipe is filled using the flush water connections at the mainline pump suction.

Select three mainline pumps for 0360-PPP-416
filling the line 0360-PPP-417
PS1
0360-PPP-418
0360-PPP-419
Open flush water valves on mainline 0360-PPP-416 (HV-8664)
pump suction 0360-PPP-417 (HV-8674)
PS1
0360-PPP-418 (HV-8684)
0360-PPP-419 (HV-8694)
Open discharge valves on mainline 0360-PPP-416 (HV-8665)
pumps 0360-PPP-417 (HV-8675)
PS1
0360-PPP-418 (HV-8685)
0360-PPP-419 (HV-8695)
Pre-start three mainline pumps 0360-PPP-416
0360-PPP-417
PS1
0360-PPP-418
0360-PPP-419
Ensure both wear and seal valves are HV-9206 and HV-9207
VS1
closed at VS1 HV-9216 and HV-9217
Open vent/drain valve at VS1 VS1 2” vent valve near FE-9202
Start pumping water Set pump speed at 10 spm – ramp
PS1 up to 70 spm as back pressure
builds in the line
777-G-G-002, Rev. 0 47 September 2000

Note that even with the low dampener charge pressure, it will be necessary to
operate the pumps at a slow speed until some back pressure is built up in the
pipeline. Ramp up of the pumps should proceed slowly to ensure safe operation.
When water starts coming out of the vent valve near FE-9202
VS1
vent valve at VS1, close it
Continue pumping until upstream PIT-9201
VS1
pressure at VS1 reaches 6000 kPa
At this point, pumping can be paused to prepare the next section of line to be filled
up to VS2. It is not required to pause water pumping but pipeline pressures must
be monitored carefully.
Close variable choke valves at VS1 HV-9203
VS1 HV-9204
HV-9205
Make sure both the wear and seal HV-9242 and HV-9243
VS2
valves are closed at VS2
Open vent/drain valve at VS2 VS2 vent valve upstream of HV-9242
Open wear and seal valves at VS1 to HV-9216 and HV-9217
VS1
allow flow to VS2
Resume pumping if paused 0360-PPP-416
0360-PPP-417
PS1
0360-PPP-418
0360-PPP-419
When water starts coming out of vent valve upstream of HV-9242
VS2
VS2
Close wear and seal valves at VS1 VS1 HV-9216 and HV-9217
VS1
Make sure both wear and seal valves HV-9267 and HV-9268
VS3
are closed at VS3 HV-9277 and HV-9278
Open vent/drain valve at VS3 VS3 vent valve near HV-9282
Open wear and seal valves at VS2 VS2 HV-9242 and HV-9243
PS1
0360-PPP-417
777-G-G-002, Rev. 0 48 September 2000

0360-PPP-418
0360-PPP-419
When water starts coming out of vent valve near HV-9282
VS3
VS3
Close wear and seal valve at VS2 VS2 HV-9242 and HV-9243
VS2
VS1
Close variable choke loops at VS3 HV-9264
VS3 HV-9265
HV-9266
Note that water choke loops HV-9262 and HV-9263 are not expected to be needed
for this operation. These loops are needed when slurry is pushing water in the
pipeline.
Ensure wear and seal valves are HV-9302 and HV-9303
VS4
closed at VS4
Open vent/drain valve at VS4 VS4 vent valve near FE-9304
0360-PPP-417
PS1
0360-PPP-418
0360-PPP-419
When water starts coming out of vent valve near FE-9304
VS4
Continue pumping until pressure PIT-9301
VS4
upstream of VS4 reaches 8000 kPa
VS3
777-G-G-002, Rev. 0 49 September 2000

Close wear and seal valve at VS2 VS2 HV-9242 and HV-9243
VS2
VS1
up to TS1. It is not required to pause water pumping but pipeline pressures must
Ensure both wear and seal valves are HV-9355 and HV-9366
TS1
closed at TS1 HV-9375 and HV-9376
Open vent/drain valve at TS1 TS1 vent valve near HV-9389
0360-PPP-417
PS1
0360-PPP-418
0360-PPP-419
When water starts coming out of vent valve near HV-9389
TS1
vent valve at TS1, close it
TS1
pressure at TS1 reaches 4000 kPa
Continue pumping until pressure PIT-9301
VS4
upstream of VS4 reaches 8000 kPa
VS3
VS2
VS1
Shut down mainline pumps PS1 0360-PPP-416
777-G-G-002, Rev. 0 50 September 2000

0360-PPP-417
0360-PPP-418
0360-PPP-419
At this point, the pipeline is pressurized and nearly filled with water. It is likely that
air pockets will exist at local high points along the pipeline. It is recommended that
the pipeline be operated at steady state on water to move the air out the end of the
line.
Note also that the water supply for pipeline filling can also be delivered to the
mainline pumps through the copper or zinc charge pumps using the flush water valve
(HV-8543).
4.1.4.1.2 Pipeline Section

Filling of a section of the pipeline (assumed to be a complete section between major
stations) is accomplished by following the applicable steps in the procedure above.
The basic steps to be followed are:
• Open a vent valve at the bottom of the section to be filled
• Release water into the section from the section above and start pumps
• Close vent valve when water arrives at the station
• Pressurize the line above the section being filled
Specific valve locations and sequences can be pulled from the overall sequence above
to fill a given section.
Note that it is possible that short sections of the line are drained within a complete
station-to-station section. However, this is a unique event and special procedures
must be developed for filling the line.
4.1.4.2 Pipeline Draining
There is no automatic sequence for pipeline draining. This operation is expected to

be infrequent and therefore will be done manually. As numerous valves for this
process are manual valves that can not be actuated remotely, this operation will be
completed by a coordinated effort between the pump station and outside operator(s)
positioned at the intermediate valve stations.
4.1.4.2.1 Entire Pipeline
When draining the entire pipeline, process water is drained at PS1 and TS1. The
pipeline high point is at PMS2. Water will directionally drain from this point back to
777-G-G-002, Rev. 0 51 September 2000

PS1 and toward TS1. However, due to localized low points, a significant volume of
water will remain in the line.
If the entire pipeline is to be drained, it is recommended that the water is pushed out
of the line using compressed air to push the pig through the line. The procedures for
pigging can be found in Section 4.1.5.
4.1.4.2.2 Pipeline Section
Some sections of the pipeline can be drained fairly well by gravity due to the general
down slope between stations. Draining of these sections can be accomplished by
opening a vent/drain valve at the down hill station to drain the water into the
emergency pond where it can be recovered. A vent/drain valve at the up hill station is
also opened to permit air entrance to the line speeding the drain down process. The
table below summarizes the principle pipeline sections and the actions that should be
taken to drain them:
Pipeline Section Actions to Drain

PS1 to VS1 Drain with air driven pipeline pig
VS1 to VS2 Drain by gravity to VS2 pond
VS4 to TS1 Drain with air driven pipeline pig
As with pipeline filling, short sections of pipe may be drained for specific repairs.
Special procedures are required to complete these activities. The ability to drain a
particular section will depend on the final pipeline profile.
4.1.5 Pipeline Pigging
As established in PSI document 777-G-H-009, the pipeline is broken into 3 sections

for pigging – PS1 to VS1, VS1 to VS3, and VS3 to the terminal. Piping connections
have been provided at the outlets of PS1, VS1 and VS3 to permit insertion of the
pig(s) into the line without special equipment. Additionally, piping connections have
been provided at the inlets to VS1, VS3 and TS1 to install pig receivers.
When pigging the line, it is recommended that only one section of the line is pigged at
a time. If problems develop during pigging (stuck pig, debris in the line, etc.), the
operator has only one problem area. Additionally, pigs should be kept moving in the
line. If a problem develops with one pig, all the others in the line must be stopped. It
is possible to use multiple pigs in the same section if required for cleanings or
inspection.
Pipeline pigging should always be done with water. If the line is being pigged due to
a build-up in pressure drop along the line (possibly caused by settled solids in the
777-G-G-002, Rev. 0 52 September 2000

line), the line should be filled with water prior to pigging. Pigs should never be
pushed through the line with slurry.
4.1.5.1 Pigging PS1 to VS1
The table below summarizes the steps required to pig the pipeline from PS1 to VS1.
This procedure assumes that the pipeline is full of water and shut down.

Note line pressure at the station PIT-8690
PS1
outlet
Close the manual station isolation HV-8692
PS1
valve at PS1
Open vent/drain valve to bleed off vent valve near HV-8692
PS1
water pressure in the line
Confirm pressure in the line has PIT-8690
PS1
dropped to zero
Open 12” blind flange on station blind flange at HV-8692
PS1
outlet piping
Install pig into the line PS1 blind flange at HV-8692
Note that the pig should be pushed as far as possible into the pipeline. It is very
important to push the pig past the tee connection to ensure it is pushed into the line
rather than back up against the blind flange.
Close the blind flange after the pig is blind flange at HV-8692
PS1
installed
Open the flush water valve at the 0360-PPP-416 (HV-8664)
suction of one mainline pump 0360-PPP-417 (HV-8674)
PS1
0360-PPP-418 (HV-8684)
0360-PPP-419 (HV-8694)
Open the discharge valve of the 0360-PPP-416 (HV-8665)
same mainline pump 0360-PPP-417 (HV-8675)
PS1
0360-PPP-418 (HV-8685)
0360-PPP-419 (HV-8695)
Note that water will flow through the internal mainline pump suction and
discharge valves driven by the supply pressure and lack of back pressure in the
pump outlet piping.
When water comes from the vent vent valve near HV-8692
PS1
valve near the station outlet, close it
Check pressure at pump station PIT-8690
PS1
outlet
777-G-G-002, Rev. 0 53 September 2000

It is necessary to equalize the pressure between the pump station piping and the
mainline pipe such that the pig is not pushed back into the station when the manual
station isolation valve is opened. This is accomplished by operating one mainline
pump very slowly (less that 5% speed).
Pre-start selected mainline pump 0360-PPP-416
0360-PPP-417
PS1
0360-PPP-418
0360-PPP-419
Start selected mainline pump at 3 to 0360-PPP-416
5 % speed 0360-PPP-417
PS1
0360-PPP-418
0360-PPP-419
Continue pumping until station PIT-8690
pressure reaches 1000 kPa above PS1
starting pressure
Shut down selected mainline pump 0360-PPP-416
0360-PPP-417
PS1
0360-PPP-418
0360-PPP-419
Close mainline pump discharge 0360-PPP-416 (HV-8665)
valve 0360-PPP-417 (HV-8675)
PS1
0360-PPP-418 (HV-8685)
0360-PPP-419 (HV-8695)
Close mainline pump flush water 0360-PPP-416 (HV-8664)
valve 0360-PPP-417 (HV-8674)
PS1
0360-PPP-418 (HV-8684)
0360-PPP-419 (HV-8694)
Open manual station isolation valve PS1 HV-8692
Close manual station isolation valve HV-9222
VS1
at VS1
Open vent/drain valve to bleed off vent valve near FE-9202
VS1
VS1
dropped to zero
Open 8” blind flange on station inlet blind flange at HV-9222
VS1
piping
Install pig receiver VS1 attach to blind flange
Close vent/drain valve at VS1 VS1 vent valve near FE-9202
Open manual station isolation valve VS1 HV-9222
777-G-G-002, Rev. 0 54 September 2000

Preparations are complete to pig the PS1 to VS1 section of the pipeline. A normal
pipeline startup and operation on water (see Section 4.1.1) will push the pig
through to VS1. Pig bars in the VS1 station piping will prevent the pig from
entering the station and force it into the receiver. Transit time for the pig will be
approximately 24 hours. After that time, the pipeline should be shut down (see
Section 4.1.2) and the following steps taken to remove the pig.
VS1
at VS1
Open drain valve on the installed pig drain valve on receiver
VS1
receiver
VS1
dropped to zero
Open the pig receiver and recover pig receiver
VS1
pig
Remove pig receiver and reinstall blind flange at HV-9222
VS1
blind flange
It is possible that when the receiver is opened, the pig will be found wedged in the tee
just upstream of the receiver. To push it into the launcher, close the receiver and
drain valve, open the station isolation valve, close the station isolation valve and drain
the receiver. The initial draining will create a low pressure air pocket into which the
pipeline pressure will push the pig.
The pigging of the PS1 to VS1 section is now complete and the pipeline ready to be
returned to service.
4.1.5.2 Pigging VS1 to VS3
The table below summarizes the steps required to pig the pipeline from VS1 to VS3.

VS1
outlet
VS1
valve at VS1
VS1
VS1
dropped to zero
777-G-G-002, Rev. 0 55 September 2000

VS1
outlet piping
Install pig into the line VS1 blind flange at HV-9227
VS1
installed
Close the vent/drain valve at the vent valve near HV-9227
VS1
station outlet
It is necessary to equalize the pressure between the valve station piping and the
station isolation valve is opened. This is accomplished by opening the VS1 wear
and seal valves.
Open wear and seal valves VS1 HV-9216 and HV-9217
Confirm station pressure at outlet VS1 PIT-9221
Close wear and seal valves VS1 HV-9216 and HV-9217
VS3
at VS3
VS3
VS3
dropped to zero
VS3
piping
Install pig receiver VS3 attach to blind flange
Close vent/drain valve at VS3 VS3 vent valve near HV-9282
Preparations are complete to pig the VS1 to VS3 section of the pipeline. A normal
through to VS3. Pig bars in the VS3 station piping will prevent the pig from
VS3
at VS3
VS3
receiver
VS3
dropped to zero
777-G-G-002, Rev. 0 56 September 2000

VS3
pig
VS3
blind flange
pipeline water pressure will push the pig.
The pigging of the VS1 to VS3 section is now complete and the pipeline ready to be
4.1.5.3 Pigging VS3 to TS1
The table below summarizes the steps required to pig the pipeline from VS3 to TS1.

VS3
outlet
VS3
valve at VS3
VS3
VS3
dropped to zero
VS3
outlet piping
Install pig into the line VS3 blind flange at HV-9287
VS3
installed
Close the vent/drain valve at the vent valve near HV-9287
VS3
station outlet
777-G-G-002, Rev. 0 57 September 2000

It is necessary to equalize the pressure between the valve station piping and the
station isolation valve is opened. This is accomplished by opening the VS3 wear
and seal valves.
Open wear and seal valves VS3 HV-9277 and HV-9278
Confirm station pressure at outlet VS3 PIT-9280
Close wear and seal valves VS3 HV-9277 and HV-9278
TS1
at TS1
TS1
TS1
dropped to zero
TS1
piping
Install pig receiver TS1 attach to blind flange
Close vent/drain valve at TS1 TS1 vent valve near HV-9389
Open manual station isolation valve TS1 HV-9383
Preparations are complete to pig the VS3 to TS1 section of the pipeline. A normal
through to TS1. Pig bars in the TS1 station piping will prevent the pig from
TS1
at TS1
TS1
receiver
TS1
dropped to zero
TS1
pig
TS1
blind flange
Open manual station isolation valve TS1 HV-9383
777-G-G-002, Rev. 0 58 September 2000

pipeline water pressure will push the pig.
The pigging of the VS3 to TS1 section is now complete and the pipeline ready to be
4.2 Sub-System Operations
4.2.1 Tank Operations
This section discusses operations involving storage tanks. Some of these sequences
below may be part of larger sequences included elsewhere in this manual.
4.2.1.1 Copper Storage Tank Filling
Copper concentrate is delivered from the copper thickener (0340-TKF-067) to the

copper storage tanks using thickener underflow pumps (0340-PPS-067 and 0340-
PPS-068). While the pipeline operator is responsible for thickener operations, the
control systems are independent. HMI’s for both systems are available in the pipeline
control room.
The following sequences should be followed to fill the copper storage tanks.
4.2.1.1.1 Automatic Sequence
There is no automatic sequence for copper storage tank filling.
4.2.1.1.2 Manual Remote Sequence
The table below summarizes the steps to initiate copper storage tank filling. It is
assumed that the copper thickener (0340-TKF-067) is operating in re-circulation
mode at the start of this sequence.
Operator Action Tag Numbers

Select storage tank and open fill valve HV-8521 (0360-TKF-405)
HV-8522 (0360-TKF-406)
HV-8520 (0360-TKF-407)
Note that the tank inlet valves are interlocked such that one valve must be open at all
times. Therefore, when selecting a tank (or switching tanks), it is necessary to open
the selected valve prior to closing a valve.
Close the previously selected tank fill valve (if HV-8521 (0360-TKF-405)
changing tanks) HV-8522 (0360-TKF-406)
HV-8520 (0360-TKF-407)
777-G-G-002, Rev. 0 59 September 2000

Note that to correctly track the batches of different copper concentrate, the Pipeline
Advisor™ will ask the pipeline operator to identify the product being delivered to
the tank (low bismuth copper, high bismuth copper, or bornite). The tank will be
tagged so that the batch can be tracked when material from the tank is being pumped
to the terminal.
Start linear screen (0360-SCW-405) See Section 4.4.1
Open thickener underflow pump valve to tanks Manual Valve
(no valve number)
Close thickener re-circulation valve Manual Valve
(no valve number)
Note that the thickener valves are manual valves and must be opened by an outside
operator. An operator in the pipeline control room, using in-plant radio
communication to guide outside operator actions, should coordinate the valve
changes.
Start the copper concentrate sampler (0340-SAL-096) See Section 4.4.2
Confirm flow to the selected tank FI-7081 and visual by
outside operator
4.2.1.1.3 Local Sequence
All of the above steps can be completed locally with the exception of opening/
changing the selected tank fill valves. These valves are only operated through the
SCADA system to keep preprogrammed interlocks activated. Once the tank valve has
been selected, the remaining steps of the manual remote sequence can be completed
with all equipment operating in local mode.
4.2.1.2 Zinc Tank Filling
Zinc concentrate is delivered from the zinc thickener (0340-TKF-071) to the zinc
storage tanks using thickener underflow pumps (0340-PPS-071 and 0340-PPS-072).
While the pipeline operator is responsible for thickener operations, the control systems are
independent. HMI’s for both systems are available in the pipeline control room.
The following sequences should be followed to fill the zinc storage tanks.
There is no automatic sequence for zinc storage tank filling.
777-G-G-002, Rev. 0 60 September 2000

The table below summarizes the steps to initiate zinc storage tank filling. It is
assumed that the zinc thickener (0340-TKF-071) is operating in re-circulation mode
at the start of this sequence.

Select storage tank and open fill valve HV-8501 (0360-TKF-400)
HV-8502 (0360-TKF-401)
Note that the tank inlet valves are interlocked such that one valve must be open at all
times. Therefore, when selecting a tank (or switching tanks), it is necessary to open
the selected valve prior to closing a valve.
Close the previously selected tank fill valve (if HV-8501 (0360-TKF-400)
changing tanks) HV-8502 (0360-TKF-401)
Start linear screen (0360-SCW-400) See Section 4.4.1
Open thickener underflow pump valve to tanks Manual Valve
(no valve number)
Close thickener re-circulation valve Manual Valve
(no valve number)
Note that the thickener valves are manual valves and must be opened by an outside
operator. An operator in the pipeline control room, using in-plant radio communi-
cation to guide outside operator actions, should coordinate the valve changes.
Start the copper concentrate sampler (0340-SAL-097) See Section 4.4.2
Confirm flow to the selected tank FI-6981 and visual by
outside operator

All of the above steps can be completed locally with the exception of opening/
changing the selected tank fill valves. These valves are only operated through the
SCADA system to keep preprogrammed interlocks activated. Once the tank valve has
been selected, the remaining steps of the manual remote sequence can be completed
with all equipment operating in local mode.
4.2.1.3 Copper Tank Switching (While Pumping)

Pumping operations are commonly switched from one copper tank to another as a
tank is drained down. Under normal circumstances, the head in a tank is high enough
to initiate flow to the charge pump when the tank isolation valve is opened. However,
if the tank has not been used for an extended period or the level is low, it may be
necessary to back flush the line with process water. Pump station pressures and flow
should always be monitored carefully during tank switching.
777-G-G-002, Rev. 0 61 September 2000

There is no automatic sequence for copper tank switching.

This section summarizes the steps to be taken by the control room operator to switch
from one copper tank to another. When switching from low to high bismuth copper
concentrate, a minimum 1 hour water batch should be inserted between the
concentrates to facilitate product segregation at the terminal and mitigate product
cross-contamination. As with product switching (see Section 4.2.2 below), a 2 hour
water batch is preferred and concentrate pumping can not start during the window of
4 to 8 hours after water pumping is started.
Unlike product switching (zinc to copper), there is no timer interlock on switching
from low to high bismuth copper. Although the tanks have a “primary” designation
(0360-TKF-405 = low bismuth copper, 0360-TKF-406 = high bismuth copper, and
0360-TKF-407 = swing tank), it is possible that all three tanks may be used at some
time to store the same type of copper concentrate. Installation of an interlock would
complicate this operation.
Two general guidelines to be followed when switching copper tanks are:
• Always insert a 1-hour minimum water batch between high and low bismuth
copper, and
• Always use flush water when switching to and from the swing tank (0360-
TKF-407) to ensure piping is flushed of concentrate prior to shutdown.
The table below assumes that a 1 hour water batch is inserted between all copper tank
switches. If the tanks contain the same material, the wait step can be eliminated.
However, when switching to and from the swing tank (0360-TKF-407), it is necessary
to confirm that the water has reached the mainline pumps (DI-8621 reads 1.0) before
completing the switch to confirm pipe flushing.
Additionally, the valve sequence for switching to and from the swing tank varies
depending on which charge pump is in use. The base sequence in the table below
assumes 0360-PPS-412 is in use – the alternate (in parenthesis) provides the sequence
for 0360-PPS-413.
FROM→
0360-TKF-405 0360-TKF-406 0360-TKF-407
TO↓
Open HV-8543 Open HV-8543
Close HV-8524 Close HV-8535
Wait 1 hour Wait 1 hour or
0360-TKF-405 Open HV-8523 DI-8621 = 1.0
Close HV-8543 Open HV-8540
Open HV-8545
(or Open HV-8548)
777-G-G-002, Rev. 0 62 September 2000

Close HV-8546
(or Close HV-8547)
Close HV-8537
Open HV-8523
Close HV-8543
Wait 1 hour Wait 1 hour or
Open HV-8524 DI-8621 = 1.0
Close HV-8543 Open HV-8540
Open HV-8545
0360-TKF-406
(or Open HV-8548)
Close HV-8546
(or Close HV-8547)
Close HV-8537
Open HV-8524
Close HV-8543
Wait 1 hour or Wait 1 hour or
DI-8621 = 1.0 DI-8621 = 1.0
0360-TKF-407
(or Open HV-8547) (or Open HV-8547)
(or Close HV-8548) (or Close HV-8548)

The sequences summarized above for manual remote tank switching can be
completed by locally operating all valves. If the switch is to be made locally, two
operators are required – one to operate the valves in the tank area and one to monitor
the pressures and flow at the pumps. Any problems noted by the operator in the pump
station must be reported to the tank area operator and flush water flow should be
immediately initiated.
4.2.1.4 Zinc Tank Switching (While Pumping)

Pumping operations are commonly switched from one zinc tank to another as a tank is
drained down. Under normal circumstances, the head in a tank is high enough to
initiate flow to the charge pump when the tank isolation valve is opened. However, if
the tank has not been used for an extended period or the level is low, it may be
necessary to back flush the line with process water. Pump station pressures and flow
should always be monitored carefully during tank switching.
777-G-G-002, Rev. 0 63 September 2000

There is no automatic sequence for zinc tank switching.

This section summarizes the steps to be taken by the control room operator to switch
from one zinc tank to another. The zinc product quality is expected to be consistent
for all mining operations such that, unlike copper, there is no requirement for
segregation of zinc grades. A small amount of water may be introduced between zinc
batches during tank switching or a water batch may be pumped between zinc batches
for inventory management. As with product switching (see Section 4.2.2 below),
concentrate pumping can not start during the window of 4 to 8 hours after water
pumping is started.
The table below assumes that the water valve is not opened during tank switching. As
discussed above (see Section 4.2.1.4), if plugging of the tank suction line is a
possibility, opening the flush water valve (HV-8543) can provide a short burst of high
pressure flush water to flush the suction line back into the tank. Introducing a very
short water batch during tank switching may facilitate the switch.
FROM→
0360-TKF-400 0360-TKF-401
TO↓
Open HV-8503
0360-TKF-400
Close HV-8505
Open HV-8504
0360-TKF-401
Close HV-8503
The sequences summarized above for manual remote tank switching can be
completed by locally operating all valves. If the switch is to be made locally, two
operators are required – one to operate the valves in the tank area and one to monitor
the pressures and flow at the pumps. Any problems noted by the operator in the pump
station must be reported to the tank area operator and flush water flow should be
immediately initiated.
4.2.2 Product Switching (While Pumping)
Product switching from copper to zinc or zinc to copper is required when both
concentrates are being produced in the concentrator. The pipeline is operated in batch
mode with water batches inserted between the zinc and copper batches to mitigate
product cross-contamination. A pumping schedule should be developed in
conjunction with the concentrator operations (i.e., assess ore quality and concentrate
production rate) to minimize product switches.
777-G-G-002, Rev. 0 64 September 2000

When it is time to switch from one product to the other, the switch can be made using
automated, manual remote, or local sequences. These are discussed below.
The automated product switching is a prompted automatic sequence in the SCADA

system. The operator initiates the product switch and confirms continuation of the
switch during the automated process. For this sequence, it is assumed that the
pipeline is pumping one type of concentrate. If water is being pumped, see Section
4.1 above for initiation of concentrate pumping. The following steps are taken to
initiate the product switching sequence:
• Operator selects “product switch” on HMI
• Operator selects target concentrate storage tank and charge pump to be
used (opposite concentrate of that currently being pumped)
• Operator initiates product switch
Upon operator initiation of the product switch, the SCADA system automatically
opens the flush water valve and closes the tank isolation valve for the concentrate
being pumped. Water is fed to the pipeline through the same charge pump that was
pumping concentrate prior to the operator action. After 60 minutes of water pumping
(confirmed by pump station flow and density meters), the SCADA system alerts the
operator that the product switch can be continued.
The minimum water batch between two dissimilar concentrate batches is 60 minutes
– 1 hour. There is no minimum water batch requirement between two identical
concentrate batches. However, unless there is a severe shortage of tank space at the
pump station, a 2 hour minimum water batch should be pumped between dissimilar
concentrates. This facilitates product segregation at the terminal and mitigates cross-
contamination between the batches.
Note that the SCADA system will not allow water batches of 4 to 8 hours as
pumping of water batches of this length could lead to pipeline overpressure.
At the conclusion of the 1 hour wait, the SCADA system will alert the operator that
the switch can proceed. The system will alert the operator again at 2 hours, 4 hours
(just before the automatic block is imposed) and 8 hours. To continue the product
switch, the following action must be taken:
• Operator “continues” product switch
The SCADA system then opens the water supply valve to the new concentrate charge
pump, opens the charge pump isolation valves and starts the pump. Once the pump is
running, the SCADA system opens the main isolation valve to the mainline pump
777-G-G-002, Rev. 0 65 September 2000

suction header. Both concentrate systems are delivering water to the mainline pumps.
Because the mainline pumps are positive displacement, total flow to the pipeline will
not change despite the fact that two charge pumps are operating.
The SCADA system then closes the main isolation valve of the concentrate pumping
just completed. The SCADA system then shuts down the charge pump, closes the
isolation valves, and shuts the water valve. When this is complete, the SCADA
system opens the tank valve of the tank previously selected by the operator and closes
the water valve. The new concentrate is delivered to the pipeline.
The above sequence can be completed via the operator workstation as a step-by-step
sequence. The table below summarizes the step by step switching. Again, if the
pumps are operating on water, see Section 4.1.
Operator Action Copper to Zinc Zinc to Copper

Pumping at start of Copper Zinc
sequence
Open flush water valve HV-8543 HV-8543
Open water valve at tank HV-8540 (0360-TKF-405) HV-8514 (0360-TKF-400)
currently being pumped HV-8540 (0360-TKF-406) HV-8514 (0360-TKF-401)
HV-8537 (0360-TKF-407)
Close tank isolation HV-8523 (0360-TKF-405) HV-8503 (0360-TKF-400)
valve HV-8524 (0360-TKF-406) HV-8504 (0360-TKF-401)
HV-8535 (0360-TKF-407)
The SCADA system will not allow a product switch to occur until water has been
pumped for at least 1 hour. The recommended minimum water batch is 2 hours. The
SCADA system also blocks initiation of concentrate pumping following water
batches of 4 to 8 hours. The following steps should not be initiated until ready to
pump the new concentrate.
Open water valve at new HV-8514 (0360-TKF-400) HV-8540 (0360-TKF-405)
concentrate tank HV-8514 (0360-TKF-401) HV-8540 (0360-TKF-406)
HV-8537 (0360-TKF-407)
Open new charge pump HS-8701 (0360-PPS-410) HS-8704 (0360-PPS-412)
seal water valve HS-8702 (0360-PPS-411) HS-8705 (0360-PPS-413)
Open new charge pump HV-8583 (0360-PPS-410) HV-8545 (0360-PPS-412)
suction valve (except for HV-8584 (0360-PPS-411) HV-8548 (0360-PPS-413)
0360-TKF-407)
Open new charge pump N/A – only for switch to HV-8546 (0360-PPS-412)
suction valve (only for copper pumping HV-8547 (0360-PPS-413)
0360-TKF-407)
Start new charge pump 0360-PPS-410 or 0360-PPS-412 or
777-G-G-002, Rev. 0 66 September 2000

Operator Action Copper to Zinc Zinc to Copper
0360-PPS-411 0360-PPS-413
Open new charge pump HV-8596 (0360-PPS-410) HV-8556 (0360-PPS-412)
discharge valve HV-8595 (0360-PPS-411) HV-8555 (0360-PPS-413)
Open new concentrate HV-8629 HV-8630
isolation valve to (operation of this valve is (operation of this valve is
mainline pump suction restricted by the SCADA restricted by the SCADA
system per note above) system per note above)
Close old concentrate HV-8630 HV-8629
isolation valve
Close old charge pump HV-8556 (0360-PPS-412) HV-8596 (0360-PPS-410)
discharge valve HV-8555 (0360-PPS-413) HV-8595 (0360-PPS-411)
Stop old charge pump 0360-PPS-412 or 0360-PPS-410 or
0360-PPS-413 0360-PPS-411
Close old charge pump HV-8545 (0360-PPS-412) HV-8583 (0360-PPS-410)
suction valve (except HV-8548 (0360-PPS-413) HV-8584 (0360-PPS-411)
0360-TKF-407)
Close old charge pump HV-8546 (0360-PPS-412) N/A – only for switch from
suction valve (only 0360- HV-8547 (0360-PPS-413) copper pumping
TKF-407)
Close old charge pump HS-8704 (0360-PPS-412) HS-8701 (0360-PPS-400)
seal water valve HS-8705 (0360-PPS-413) HS-8702 (0360-PPS-401)
Close old water valve at HV-8540 (0360-TKF-405) HV-8514 (0360-TKF-400)
tank HV-8540 (0360-TKF-406) HV-8514 (0360-TKF-401)
HV-8537 (0360-TKF-407)
Inject conductivity pulse See procedure in Section N/A – only for starting zinc
4.1.1.4 above pumping
Open tank valve at new HV-8503 (0360-TKF-400) HV-8523 (0360-TKF-405)
concentrate tank HV-8504 (0360-TKF-401) HV-8524 (0360-TKF-406)
HV-8535 (0360-TKF-407)
Close water valve at new HV-8514 (0360-TKF-400) HV-8540 (0360-TKF-405)
tank HV-8514 (0360-TKF-401) HV-8540 (0360-TKF-406)
HV-8537 (0360-TKF-407)
Close flush water valve HV-8543 HV-8543
At the conclusion of the above sequence, concentrate pumping has been switched
from one product to the other and the pipeline will be controlled at density and flow
rates set prior to initiation of the switch. These set-points will have to be adjusted, if
required, at the conclusion of the product switch.
777-G-G-002, Rev. 0 67 September 2000

There is no local operation allowed for product switching. Valves HV-8629 and HV-
8630 can not be operated locally (they are locked into the remote position) as this
would jeopardize the product segregation in the pipeline. If local operation of these
valves is required, it should be coordinated through the pipeline superintendent.
4.2.3 Tank Draining Operation
There is no automatic sequence for tank draining.
There is no manual remote sequence for tank draining.
Tank draining is occasionally required to perform maintenance on the agitated storage

tank. This is accomplished by manually opening the drain valve at the tank to be
drained. The discussion below can be applied to either copper or zinc tanks.
Under normal circumstances, the tank being drained is pumped down to a minimum
level by transferring as much concentrate as possible to another tank (see Section
3.8.1.4). Then the remaining heel can be drained to the area sump. The area sump
recycles the concentrate back to the appropriate thickener (copper or zinc). It is
unlikely that all the concentrate will drain out of the tank or freely flow to the sumps –
some solids deposition is likely. Therefore, the tank and impoundment will need to
be flushed after draining is complete. The following drain valves should be opened to
drain the indicated tanks.
Tank Drain Valve

0360-TKF-400 HV-8510
0360-TKF-401 HV-8512
0360-TKF-405 HV-8530
0360-TKF-406 HV-8532
0360-TKF-407 HV-8536
Under very rare circumstances, it may be necessary to drain a full or partially full
tank. This could occur if the tank was filled with overly coarse concentrate not
suitable for pipeline transport. If the concentrate can not be blended (see Section
3.8.6), it will have to be drained from the tank and managed differently.
777-G-G-002, Rev. 0 68 September 2000

Two alternatives exist for dealing with overly coarse material in a storage tank – it
can be recycled to the regrind circuit or dried and transported by truck to the port.
Drying, mechanically recovering, and transporting the concentrate by truck should
only be a last resort as it will entail a significant cleanup effort of the impoundment
basin around the tanks.
To recycle the coarse material to the regrind circuit, the tank is drained to the area
sump. The discharge of the sump pump is routed to the regrind circuit (instead of the
thickener – it is the same line). If a large volume of slurry must be drained from a
tank to the sump, temporary piping or a hose should be routed from the tank drain
directly to the sump to minimize clean-up. Flow to the regrind circuit will be limited
depending on current concentrator production.
Note that the tank drain valve should not be used for throttling as this will cause
premature wear and failure of the valve. An on-off operation must be used to control
the flow to the area sump.
To dewater the concentrate for mechanical recovery and transport, the tank must be
drained to the impoundment. Note that the sump pump should be temporarily shutoff
during the initial draining. The tank should be drained to fill the designated side of
the impoundment (copper or zinc).
Note that each side of the impoundment will not contain an entire tank volume of
slurry. As the concentrate is dewatered, additional storage volume becomes available.
An on-off operation of the drain valve will be required.
Once the impoundment is filled, the solids will settle and the water will run to the
sump where it is returned to the thickener (likely with some fines). The concentrate
should be allowed to dry in the impoundment after which it can be mechanically
recovered and transported by truck. A ramp has been provided to each side of the
impoundment for equipment access.
4.2.4 Tank Re-circulation Operation
It may be necessary during plant operations to pump from one storage tank to another.
The sections below cover the steps required to complete these operations.
Note that it is not possible to pump from copper tanks to zinc tanks or vice versa.
However, it is possible to re-circulate copper tanks while pumping zinc concentrate
(or water) through the pipeline and vice versa.
4.2.4.1 Copper Tank Re-circulation
Re-circulation of the low bismuth (0360-TKF-405) and high bismuth (0360-TKF-

406) copper concentrate storage tanks is discussed in this section. For re-circulation
of the swing tank (0360-TKF-407), see Section 4.2.4.3 below.
777-G-G-002, Rev. 0 69 September 2000

There is no automatic sequence for copper tank re-circulation.
Re-circulation of a tank to another tank is not a common operation. Therefore, most

of the valves used to accomplish this operation are manual. Thus, although some of
the steps in the sequence can be completed remotely via the pipeline operator work
station, most valve setup must be done locally. Therefore, the sequence is assumed to
be a local sequence and is summarized in the section below.
As discussed above, some portions of this sequence can be completed remotely by the
pipeline operator via the HMI. However, most actions must be done locally so the
sequence is assumed to be a local sequence. Copper concentrate pumping from 0360-
TKF-405 or 0360-TKF-406 can not occur during re-circulation operations. It is
assumed that the charge pumps are not operating when the tank re-circulation
sequence is started.
Note that it is possible to re-circulate 0360-TKF-405 or 0360-TKF-406 while

delivering concentrate to the pipeline from the swing tank (0360-TKF-407). Valves
are available to segregate charge pump operation.
Either charge pump can be used for re-circulating the tanks. For the sequence below,
0360-PPS-412 is assumed to be used with operations for 0360-PPS-413 in
parenthesis.
FROM→
0360-TKF-405 0360-TKF-406
TO↓
Confirm HV-8568 closed Confirm HV-8568 closed
Open HS-8704 Open HS-8704
0360-TKF-405 (or Open HS-8705) (or Open HS-8705)
Start 0360-PPS-412 Start 0360-PPS-412
(or Start 0360-PPS-413) (or Start 0360-PPS-413)
0360-TKF-406 Open HV-8528 Open HV-8528
777-G-G-002, Rev. 0 70 September 2000

(or Open HS-8705) (or Open HS-8705)
At the conclusion of the re-circulation operation, the above sequence should be

reversed with all manual valves returned to their original positions.
4.2.4.2 Zinc Tank Re-circulation
Re-circulation of the zinc storage tanks (0360-TKF-400 and 0360-TKF-401) is

discussed in this section.
There is no automatic sequence for zinc tank re-circulation.
Re-circulation of a tank to another tank is not a common operation. Therefore, most

of the valves used to accomplish this operation are manual. Thus, although some of
the steps in the sequence can be completed remotely via the pipeline operator work
station, most valve setup must be done locally. Therefore, the sequence is assumed to
be a local sequence and is summarized in the section below.
sequence is assumed to be a local sequence. Zinc concentrate pumping from 0360-
TKF-400 or 0360-TKF-401 can not occur during re-circulation operations. It is
assumed that the charge pumps are not operating when the tank re-circulation
sequence is started.
parenthesis.
777-G-G-002, Rev. 0 71 September 2000

FROM→
0360-TKF-400 0360-TKF-401
TO↓

4.2.4.3 Swing Tank Re-circulation
Re-circulation of the swing tank (0360-TKF-407) to the low bismuth (0360-TKF-405)

and high bismuth (0360-TKF-406) copper concentrate storage tanks is discussed in
this section. Re-circulation of the swing tank to itself should never be required.
Therefore piping was not included for this operation.
There is no automatic sequence for swing tank re-circulation.
777-G-G-002, Rev. 0 72 September 2000

Re-circulation of the swing tank to another tank is not a common operation.

Therefore, most of the valves used to accomplish this operation are manual. Thus,
although some of the steps in the sequence can be completed remotely via the pipeline
operator work station, most valve setup must be done locally. Therefore, the
sequence is assumed to be a local sequence and is summarized in the section below.
sequence is assumed to be a local sequence. Copper concentrate pumping from 0360-
TKF-407 can not occur during re-circulation operations. It is assumed that the charge
pumps are not operating when the tank re-circulation sequence is started.
Note that it is possible to re-circulate 0360-TKF-407 while delivering concentrate to

the pipeline from the low or high bismuth copper tanks (0360-TKF-407 or 0360-TKF-
406). Valves are available to segregate charge pump operation.
parenthesis.
TO→
0360-TKF-405 0360-TKF-406
FROM↓

777-G-G-002, Rev. 0 73 September 2000

4.2.5 Test Loop Operation
The test loop is designed to simulate operating conditions in the pipeline. Pumping
concentrate through the test loop (and back to the storage tank) provides valuable data
regarding the transport of concentrates. The test loop will be used to validate
operating parameters during the initial pipeline startup and when new grades or types
of concentrate (bornite, for example) are introduced for transport.
All test loop valves are manual requiring specific operator setup to run the loop. The
charge pumps and some tank valves can be operated remotely once the manual valves
have been setup for the test. Operation of the test loop is expected to be a coordinated
activity between the pipeline operator who controls the remotely available equipment,
the outside operator who actuates the manual valves, and the process engineer that
administers the test.
There is only one test loop for both copper and zinc. As such, there is a possibility for
cross-contamination through the loop. The outside operator must double check the
position of all valves to avoid mixing copper and zinc concentrates.
4.2.5.1 Copper Concentrate Testing
The following steps should be followed to operate the test loop on copper concentrate.
Note that a recirculation line has not been installed to the swing tank (0360-TKF-407)
as test loop operation was only installed for high and low bismuth copper concentrate
at this time.
Operator action Tag Numbers

Select tank to be recirculated through the test loop
0360-TKF-405 (HV-8526)
and open return valve 0360-TKF-406 (HV-8528)
Open test loop valves HV-8633 and HV-8631
Ensure test loop is properly isolated from process
HV-8553, HV-8554,
(other valves closed) HV-8558, and HV-8630
Open flush water valve to startup test loop HV-8543
Open water valve at copper tanks HV-8540
Select charge pump to be used and open seal 0360-PPS-412 (HS-8704)
Open charge pump suction valve 0360-PPS-412 (HV-8545)
0360-PPS-413 (HV-8548)
Start charge pump and confirm discharge pressure 0360-PPS-412 (PSL-8552)
clears low pressure switch 0360-PPS-413 (PSL-8551)
Open charge pump discharge valve 0360-PPS-412 (HV-8556)
0360-PPS-413 (HV-8555)
777-G-G-002, Rev. 0 74 September 2000

The test loop is now running on water (confirm flow at FIT-8626) and should be
switched to concentrate as soon as possible to avoid diluting the slurry in the
storage tank.
Open valve at selected storage tank 0360-TKF-405 (HV-8523)
0360-TKF-406 (HV-8524)
Close flush water valve HV-8543
The test loop is now running on concentrate slurry (confirm at DIT-8624) and
testing can be completed. After testing, the test loop should be flushed and isolated
from the process piping by completing the following steps.
Open flush water valve HV-8543
Close valve at selected storage tank and flush test 0360-TKF-405 (HV-8523)
loop 0360-TKF-406 (HV-8524)
Close pump discharge valve when flushing is 0360-PPS-412 (HV-8556)
complete 0360-PPS-413 (HV-8555)
Stop charge pump and close suction valve 0360-PPS-412 (HV-8545)
0360-PPS-413 (HV-8548)
Close seal water valve 0360-PPS-412 (HS-8704)
0360-PPS-413 (HS-8705)
Close water valve at copper tanks HV-8540
Close test loop valves HV-8633 and HV-8631
Close selected tank recirculation valve 0360-TKF-405 (HV-8526)
0360-TKF-406 (HV-8528)
At the conclusion of testing, the test loop is full of water and isolated from the
process.
4.2.5.2 Zinc Concentrate Testing
The following steps should be followed to operate the test loop on zinc concentrate.

Select tank to be recirculated through the test loop 0360-TKF-400 (HV-8506)
and open return valve 0360-TKF-401 (HV-8508)
Open test loop valves HV-8634 and HV-8632
Ensure test loop is properly isolated from process HV-8593, HV-8594,
(other valves closed) HV-8599, and HV-8629
Open flush water valve to startup test loop HV-8543
Open water valve at zinc tanks HV-8514
Select charge pump to be used and open seal 0360-PPS-410 (HS-8701)
777-G-G-002, Rev. 0 75 September 2000

Open charge pump suction valve 0360-PPS-410 (HV-8583)
0360-PPS-411 (HV-8584)
Start charge pump and confirm discharge pressure 0360-PPS-410 (PSL-8592)
clears low pressure switch 0360-PPS-411 (PSL-8591)
Open charge pump discharge valve 0360-PPS-410 (HV-8596)
0360-PPS-411 (HV-8595)
The test loop is now running on water (confirm flow at FIT-8626) and should be
switched to concentrate as soon as possible to avoid diluting the slurry in the
storage tank.
Open valve at selected storage tank 0360-TKF-400 (HV-8503)
0360-TKF-401 (HV-8504)
The test loop is now running on concentrate slurry (confirm at DIT-8624) and
testing can be completed. After testing, the test loop should be flushed and isolated
from the process piping by completing the following steps.
Open flush water valve HV-8543
Close valve at selected storage tank and flush test 0360-TKF-400 (HV-8503)
loop 0360-TKF-401 (HV-8504)
Close pump discharge valve when flushing is 0360-PPS-410 (HV-8596)
complete 0360-PPS-411 (HV-8595)
Stop charge pump and close suction valve 0360-PPS-410 (HV-8583)
0360-PPS-411 (HV-8584)
Close seal water valve 0360-PPS-410 (HS-8701)
0360-PPS-411 (HS-8702)
Close water valve at zinc tanks HV-8514
Close test loop valves HV-8634 and HV-8632
Close selected tank recirculation valve 0360-TKF-400 (HV-8506)
0360-TKF-401 (HV-8508)
At the conclusion of testing, the test loop is full of water and isolated from the
process.
4.2.6 Sump Product Recirculation
Three sumps have been installed as part of this project – a copper area sump, a zinc
area sump and a mainline pump building sump. The following sections discuss
operating options for these pumps.
777-G-G-002, Rev. 0 76 September 2000

4.2.6.1 Copper Area Sump
To prevent inadvertent improper routing of sump flows, all valves are manual and
locked in position. Therefore, all sump operations must be completed in local mode.
4.2.6.1.1 Normal Operation
The copper storage tank area is sloped to an area sump with sump pump 0360-PPS-
415 located inside the pump building. This sump is expected to normally collect
mostly water (rainwater and linear screen flush water) with a very small amount of
copper concentrate. Therefore, the discharge of this sump is routed back to the
copper concentrate thickener through valve HV-8564.
The sump pump will start automatically when the liquid level in the sump reaches 700
mm and shut off when the level drops to 500 mm. Valve HV-8564 is locked open to
prevent accidental or inadvertent closure of the valve blocking flow from the pump.
Seal water is required for this pump. Since the pump is expected to stop and start
automatically, valve HS-8706 should remain open at all times.
The copper area sump can also pump to the copper storage tanks, the copper regrind
circuit, and to tailings. Those procedures are summarized below.
4.2.6.1.2 Recycle to Storage Tanks
The copper area sump pump can return copper concentrate to the storage tanks. This
should only be done if a large volume of on-specification concentrate has been spilled
(such as a tank rupture or overflow). Do not return off-specification or dilute slurry to
the storage tank.
To route the pump discharge to the storage tank, complete the following steps (note
that it is likely that the sump pump will be running during this operation due to the
large spill).
• Unlock and open valve HV-8566
• Close valve HV-8564
When the containment area has been pumped out, the valves should be returned to
their original position. It is likely that residual spilled concentrate that does not freely
flow to the sump will remain in the impoundment. This should be washed with a
hose into the sump. Do not pump washed material to the storage tank. This material
must be sent to the copper concentrate thickener.
777-G-G-002, Rev. 0 77 September 2000

4.2.6.1.3 Recycle to Regrind Circuit
The copper area sump can return copper concentrate to the copper regrind circuit at
the concentrator. This should only be done if off-specification (too coarse)
concentrate has been spilled or dumped to the impoundment area. Close coordination
with concentrator operators is required to ensure ongoing production is not impacted.
The sump pump is sized to deliver a maximum of 50 m3/h of concentrate to the
regrind circuit.
Prior to returning coarse concentrate to the regrind circuit, properties should be

reviewed with the pipeline process engineer. It may be possible to slowly blend the
coarse material with current concentrate production for pipeline transport to the
terminal.
The return line to the copper regrind circuit is common with the line to the copper
thickener at the pump station (i.e., pump through HV-8564). At the copper thickener,
the following steps are required to route pump discharge to the regrind circuit.
• Unlock and open valve HOLD FOR BECHTEL INFORMATION
• Close valve HOLD FOR BECHTEL INFORMATION
Note that all coarse material should be washed from the impoundment into the sump
and returned to the regrind circuit before returning pump discharge to the thickener.
Once this operation is complete, return the valves to their original position.
4.2.6.1.4 Pump to Tailings
The copper area sump pump can deliver material from the impoundment to tailings.
This operation is expected to be extremely rare (if it ever is required at all). Copper
concentrate would only be pumped to tailings if it was contaminated with zinc
concentrate or if the concentrator process engineer determined that it could not be
recovered.
Note that ramps have been constructed into the impoundment to permit entry of a
small front-end loader. If the copper concentrate can not be recycled at the
concentrator, it could be allowed to de-water, mechanically removed, trucked to
Huarmey, and slowly blended into on-specification dry concentrate.
In summary, all options to reclaim off-specification or contaminated concentrate

should be examined prior to permanent disposal to the tailings pond.
The following steps should be taken to route the discharge of the copper area sump to
the tailings pond.
777-G-G-002, Rev. 0 78 September 2000

• Make sure that mainline pump building sump 0360-PPR-420 is not
operating during valve switch to avoid possible product contamination.
Note that all off-specification material should be washed from the impoundment into
the sump and pumped to tailings before returning pump discharge to the thickener.
4.2.6.2 Zinc Area Sump
The zinc storage tank area is sloped to an area sump with sump pump 0360-PPS-414
located inside the pump building. This sump is expected to normally collect mostly
water (rainwater and linear screen flush water) with a very small amount of zinc
concentrate. Therefore, the discharge of this sump is routed back to the zinc
concentrate thickener through valve HV-8604.
The sump pump will start automatically when the liquid level in the sump reaches 700
mm and shut off when the level drops to 500 mm. Valve HV-8604 is locked open to
Seal water is required for this pump. Since the pump is expected to stop and start
automatically, valve HS-8703 should remain open at all times.
The zinc area sump can also pump to the zinc storage tanks, the zinc regrind circuit
and to tailings. Those procedures are summarized below.
4.2.6.2.2 Recycle to Storage Tanks
The zinc area sump pump can return zinc concentrate to the storage tanks. This
should only be done if a large volume of on-specification concentrate has been spilled
(such as a tank rupture or overflow). Do not return off-specification or dilute slurry to
the storage tank.
To route the pump discharge to the storage tank, complete the following steps (note
that it is likely that the sump pump will be running during this operation due to the
large spill).
777-G-G-002, Rev. 0 79 September 2000

When the containment area has been pumped out, the valves should be returned to
flow to the sump will remain in the impoundment. This should be washed with a
hose into the sump. Do not pump washed material to the storage tank. This material
must be sent to the zinc concentrate thickener.
4.2.6.2.3 Recycle to Regrind Circuit
The zinc area sump can return zinc concentrate to the zinc regrind circuit at the
concentrator. This should only be done if off-specification (too coarse) concentrate
has been spilled or dumped to the impoundment area. Close coordination with
concentrator operators is required to ensure ongoing production is not impacted. The
sump pump is sized to deliver a maximum of 50 m3/h of concentrate to the regrind
circuit.
Prior to returning coarse concentrate to the regrind circuit, properties should be

reviewed with the pipeline process engineer. It may be possible to slowly blend the
coarse material with current concentrate production for pipeline transport to the
terminal.
The return line to the zinc regrind circuit is common with the line to the zinc
thickener at the pump station (i.e., pump through HV-8604). At the zinc thickener,
the following steps are required to route pump discharge to the regrind circuit.
• Unlock and open valve HOLD FOR BECHTEL INFORMATION
• Close valve HOLD FOR BECHTEL INFORMATION
Note that all coarse material should be washed from the impoundment into the sump
and returned to the regrind circuit before returning pump discharge to the thickener.
4.2.6.2.4 Pump to Tailings
The zinc area sump pump can deliver material from the impoundment to tailings.
This operation is expected to be extremely rare (if it ever is required at all). Zinc
concentrate would only be pumped to tailings if it was contaminated with copper
concentrate or if the concentrator process engineer determined that it could not be
recovered.
Note that ramps have been constructed into the impoundment to permit entry of a
small front-end loader. If the zinc concentrate can not be recycled at the concentrator,
it could be allowed to de-water, mechanically removed, trucked to Huarmey, and
slowly blended into on-specification dry concentrate.
777-G-G-002, Rev. 0 80 September 2000

In summary, all options to reclaim off-specification or contaminated concentrate
should be examined prior to permanent disposal to the tailings pond.
The following steps should be taken to route the discharge of the zinc area sump to
the tailings pond.
• Make sure that mainline pump building sump 0360-PPR-420 is not

operating during valve switch to avoid possible product contamination.
Note that all off-specification material should be washed from the impoundment into
the sump and pumped to tailings before returning pump discharge to the thickener.
4.2.6.3 Mainline Pump Building Sump


The mainline pump building area is sloped to an area sump with sump pump 0360-
PPS-420 located inside the pump building. This sump is expected to normally collect
mostly water (centrifugal pump seal water, station wash down, etc.) with a very small
amount of concentrate (from mainline pump flushing and other maintenance
activities). However, the concentrate will usually be a mixture of zinc and copper and
therefore not recyclable at the concentrator site. As the quantity of concentrate in this
sump discharge stream will normally be very small, the discharge of this sump is
routed back to the tailings splitter box (420-TK-01) through valve HV-8676.
The sump pump will start automatically when the liquid level in the sump reaches
1600 mm and shut off when the level drops to 500 mm. Valve HV-8676 is locked open to
The mainline pump building area sump pump can also deliver material to the zinc and
copper area sumps. Those procedures are summarized below.
4.2.6.3.2 Recycle to Copper Area Sump

The mainline pump building area sump pump can recycle spilled concentrate to the
copper area sump. If a large quantity of copper concentrate is spilled in the mainline
pump building due to a line rupture, relief valve opening or other event, recovery of
the material should be attempted. However, it must be noted that rapid operator
response to any of the above upset conditions should mitigate the quantity of spilled
concentrate.
777-G-G-002, Rev. 0 81 September 2000

To re-route the pump discharge to the copper area sump, complete the following steps
(note that it is likely that the sump pump will be running during this operation due to
the large spill).
When the pump station spill has been pumped out, the valves should be returned to
flow to the sump will remain in the pump station. This should be washed with a hose
into the sump and should be recovered to the copper area sump prior to resetting the
valves.
4.2.6.3.3 Recycle to Zinc Area Sump

The mainline pump building area sump pump can recycle spilled concentrate to the
zinc area sump. If a large quantity of zinc concentrate is spilled in the mainline pump
building due to a line rupture, relief valve opening or other event, recovery of the
material should be attempted. However, it must be noted that rapid operator response
to any of the above upset conditions should mitigate the quantity of spilled
concentrate.
To re-route the pump discharge to the zinc area sump, complete the following steps
(note that it is likely that the sump pump will be running during this operation due to
the large spill).
When the pump station spill has been pumped out, the valves should be returned to
flow to the sump will remain in the pump station. This should be washed with a hose
into the sump and should be recovered to the zinc area sump prior to resetting the
valves.
4.2.7 Charge Pump Switching Operation
Charge pump switching refers to changing from one operating concentrate charge
pump to another in the same concentrate. Switching from zinc to copper (or vice
versa concentrate) is covered in section 4.2.2 above.
4.2.7.1 Copper Charge Pumps
Switching from one copper concentrate charge pump to the other may be required
from time to time while the pipeline is operating. It is not necessary to shutdown the
777-G-G-002, Rev. 0 82 September 2000

mainline pumps during the switch. However, to protect the mainline pumps, the new
charge pump should always be started prior to shutting down the old charge pump.

There is no automatic sequence for switching copper charge pumps.

Switching of copper charge pumps can be completed from the pipeline operator work
station by following the steps in the table below. The base operation assumes a
switch while pumping from the low bismuth (0360-TKF-405) or high bismuth (0360-
TKF-406) copper concentrate tanks. The optional case (in parenthesis) is for a switch
while pumping from the swing tank (0360-TKF-407).
FROM→
0360-PPS-412 0360-PPS-413
TO↓
Open HS-8704
Open HV-8545
(or Open HV-8546)
Start 0360-PPS-412
Open HV-8556
Close HV-8555
0360-PPS-412 Check operations (see below)
Stop 0360-PPS-413
Close HV-8548
(or Close HV-8547)
Flush 0360-PPS-413
(see Section 4.2.8)
Close HS-8705
Open HS-8705
Open HV-8548
(or Open HV-8547)
Start 0360-PPS-413
Open HV-8555
Close HV-8556
Stop 0360-PPS-412
Close HV-8545
(or Close HV-8546)
Flush 0360-PPS-412
(see Section 4.2.8)
Close HS-8704
When changing pumps, the spare pump is brought on line while the operating pump
remains on line. Subsequently, the discharge valve of the operating pump is closed
before the pump is shutdown to confirm the newly started spare is performing
777-G-G-002, Rev. 0 83 September 2000

adequately. If there is a problem, the valve can be re-opened to maintain the flow to
the mainline pumps.
Note that it is also necessary to close the pump discharge valve prior to pump
shutdown to prevent re-circulation of slurry backwards through the pump when it is
stopped. While operating the charge pumps against a closed discharge is permissible
for short periods, this operation should be minimized to prevent premature wear of
the pump internals.

The above sequence can be completed locally at the pumps and valves. However,
during the switch, the operator must monitor delivery of the concentrate to the
mainline pumps. As such, it is easier and faster to monitor operating conditions and
respond to upset conditions via the operator work station. Therefore, it is not
recommended that this operation be completed in local mode.
4.2.7.2 Zinc Charge Pumps

Switching from one zinc concentrate charge pump to the other may be required from
time to time while the pipeline is operating. It is not necessary to shutdown the
mainline pumps during the switch. However, to protect the mainline pumps, the new
charge pump should always be started prior to shutting down the old charge pump.

There is no automatic sequence for switching zinc charge pumps.

Switching of zinc charge pumps can be completed from the pipeline operator work
station by following the steps in the table below. The table below summarizes the
sequence.
FROM→
0360-PPS-410 0360-PPS-411
TO↓
Open HS-8701
Open HV-8583
Start 0360-PPS-410
Open HV-8596
Close HV-8595
Stop 0360-PPS-411
Close HV-8584
Flush 0360-PPS-411
(see Section 4.2.8)
Close HS-8702
777-G-G-002, Rev. 0 84 September 2000

FROM→
0360-PPS-410 0360-PPS-411
TO↓
Open HS-8702
Open HV-8584
Start 0360-PPS-411
Open HV-8595
Close HV-8596
Stop 0360-PPS-410
Close HV-8583
Flush 0360-PPS-410
(see Section 4.2.8)
Close HS-8701
When changing pumps, the spare pump is brought on line while the operating pump
remains on line. Subsequently, the discharge valve of the operating pump is closed
before the pump is shutdown to confirm the newly started spare is performing
adequately. If there is a problem, the valve can be re-opened to maintain the flow to
the mainline pumps.
Note that it is also necessary to close the pump discharge valve prior to pump
shutdown to prevent re-circulation of slurry backwards through the pump when it is
stopped. While operating the charge pumps against a closed discharge is permissible
for short periods, this operation should be minimized to prevent premature wear of
the pump internals.
The above sequence can be completed locally at the pumps and valves. However,
during the switch, the operator must monitor delivery of the concentrate to the
mainline pumps. As such, it is easier and faster to monitor operating conditions and
respond to upset conditions via the operator work station. Therefore, it is not
recommended that this operation be completed in local mode.
4.2.8 Charge Pump Flushing
When a charge pump (0360-PPS-410, 0360-PPS-411, 0360-PPS-412, or 0360-PPS-

413) is shut down after pumping water, it is not necessary to flush the pump. When
the charge pump is shut down on slurry (for example, during an on-line charge pump
change), the pump being shutdown should be flushed to remove the slurry at the
earliest convenience.
There is no automatic or manual remote sequence to flush the charge pumps – it must
be done locally. The procedure summarized below can be used to flush all of the
777-G-G-002, Rev. 0 85 September 2000

charge pumps listed above. The procedure assumes that the charge pump has been
shut down and the suction and discharge isolation valves are closed.
• Open the flush water valve on the flush water line connected to the
discharge side of the charge pump to be flushed.
• Open the drain valve on the bottom of the basket strainer on the discharge
side of the charge pump to be flushed (0360-ZMB-410, 0360-ZMB-411,
0360-ZMB-412, or 0360-ZMB-413).
• Flush until clear water is coming from the drain valve (should be less than
30 seconds).
• Close drain valve on basket strainer.
• Open drain valve on suction piping of the charge pump to be flushed.
• Flush until clear water is coming from the drain valve (should be less than
60 seconds).
• Close the drain valve on the pump suction line.
• Close the flush water valve on the pump discharge line.
The charge pump is now flushed and ready for future use or can be drained for
maintenance.
4.2.9 Mainline Pump Switching
Under normal operating circumstances, three mainline pumps are required when
transporting slurry or water through the pipeline. Mainline pump switching
comprises taking one of the operating pumps off line and replacing it with the standby
unit.
The automatic sequence for mainline pump switching is prompted in that the
sequence will request operator confirmation at intermediate steps prior to continuing.
The following steps are required to complete the mainline pump switch:
• Operator selects mainline pump switch function.
• Operator selects mainline pump to take off line.
• Operator selects mainline pump to bring on line (this pump must in a shut
down but available status).
• Operator starts the mainline pump switch.
At this point, the SCADA system will pre-start the selected standby pump and open
the suction and discharge isolation valves. When these activities are successfully
777-G-G-002, Rev. 0 86 September 2000

completed, the standby pump is ready to be brought on line. The SCADA system will
ask the operator if the process should continue.
• Operator confirms mainline pump switch should continue.
The SCADA system will ramp down the pump selected for shutdown while ramping
up the standby pump. When the change is complete, the operator will be asked to
confirm continuation of the sequence. The operator should verify that the standby
pump is operating correctly prior to continuing.
• Operator confirms mainline pump switch should continue.
The SCADA system will shut down the mainline pump auxiliaries and close the
suction and discharge valve. The operator will then be required to flush the pump (if
it was shut down on slurry) per Section 4.2.10.
A mainline pump switch can also be done in manual remote mode. The sequences are
summarized in the table below. Note that the actions are summarized for each pump
though in reality only one pump will be started or stopped for each switch. The
actions required to complete the sequence can be found under each pump number.
Actions that do not apply to any individual pump are highlighted.
The table below assumes that three mainline pumps are operating and that one of the
operating pumps will be shutdown while the standby pump is brought on line.
Operator Action 0360-PPP- 0360-PPP- 0360-PPP- 0360-PPP-

416 417 418 419
Open suction valve of HV-8663 HV-8673 HV-8683 HV-8693
standby pump
Open discharge valve of HV-8665 HV-8675 HV-8685 HV-8695
standby pump
Pre-start the auxiliaries of the Pre-start Pre-start Pre-start Pre-start
standby pump
After giving the pre-start command, all auxiliary motors will start and, if there are
no problems, indicate the pump is ready. Once the pre-start command has been
issued, the pump must be started within 5 minutes or the auxiliaries will
automatically shutdown.
Switch pipeline control from automatic to manual. To manually control the speed
of individual pumps, the pipeline control must be in manual mode.
Select operating pump that Select Select Select Select
will be shutdown
Reduce selected pump speed Ramp Ramp Ramp Ramp
by 10 percent down down down down
777-G-G-002, Rev. 0 87 September 2000

416 417 418 419
Increase standby pump speed Ramp up Ramp up Ramp up Ramp up
to 10 percent
Repeat this process until Ramp Ramp Ramp Ramp
standby pump reaches desired down then down then down then down then
speed and operating pump is ramp up ramp up ramp up ramp up
shutdown
Return pipeline to automatic control mode. Ensure that the standby pump is up and
running with no problems prior to continuing the sequence.
Close recently shut down HV-8665 HV-8675 HV-8685 HV-8695
pump discharge valve
Close recently shut down HV-8663 HV-8673 HV-8683 HV-8693
pump suction valve
Flush recently shut down See Section 4.2.10
pump
It is not recommended that the mainline pump switch be performed in local mode. To
complete the switch, an operator will be needed at the control panel for each pump
and must also be able to monitor overall pump station parameters (flow rate, pump
discharge pressure, etc.).
The sequence summarized above can be used as a basis. However, if a local pump
switch is required, a situation specific procedure should be developed to ensure a
smooth transition.
Under extreme circumstances (only with approval of the pipeline manager), operation
with only two pumps during the switch can be considered. See section 4.3.2.2 for
additional information.
4.2.10 Mainline Pump Flushing
Mainline pump flushing is required when one (or all) mainline pump(s) is (are)
shutdown on slurry. This usually occurs when a single pump is taken off line for
maintenance but can also occur during emergency shutdowns.
For planned shutdowns, water pumping should be initiated prior to shutdown of the
pumps (see Section 4.1.2) such that flushing is not required.
There is no automatic sequence for mainline pump flushing.
777-G-G-002, Rev. 0 88 September 2000

When flushing a mainline pump, the pump should be shutdown and isolated from the
process. The table below summarizes the steps required to complete the mainline
pump flushing.

416 417 418 419
Confirm pump status Shutdown Shutdown Shutdown Shutdown
Confirm pump suction valve HV-8663 HV-8673 HV-8683 HV-8693
closed
Confirm pump discharge HV-8665 HV-8675 HV-8685 HV-8695
valve closed
CAUTION – mainline pump suction and discharge dampeners include gas-filled
bladders that will hold fluid in the pump at the pressure at which the pump was
stopped (i.e., full discharge pressure). Always make sure there are no personnel
working in the area near the discharge drain line prior to initiating pump flushing.
Open discharge drain valve HV-8666 HV-8677 HV-8686 HV-8696
Open flush water valve HV-8664 HV-8674 HV-8684 HV-8694
Flush until clear water is coming from the discharge drain valve (about 1 minute)
Close discharge drain valve HV-8666 HV-8677 HV-8686 HV-8696
Close flush water valve HV-8664 HV-8674 HV-8684 HV-8694
The above sequence leaves the pump full of water and ready for operation. If the
pump will be opened for maintenance, leave the discharge drain open and close the
flush water valve. Then open the drain valve on the suction piping to drain the water
from the pump.
The above flushing operation can be completed with all valves and equipment in local
mode. As noted in the sequence above, special care should be taken to keep
personnel clear of the discharge drain line during flushing operations.
4.3 Emergency Operations
The following sections summarize operator responses to the following:
4.3.1 Charge Pump Failure
During operation, a charge pump may trip off line. If this is caused by a large scale
problem (like a power failure) all pump station equipment (including the mainline
777-G-G-002, Rev. 0 89 September 2000

pumps) will shut down. If the problem is local (impacts only the charge pump),
emergency actions will be required.
If the charge pump goes off line while pumping water, the process water supply
pressure is likely high enough to maintain adequate flow to the suction of the
mainline pumps. Suction pressure to the mainline pumps must be kept above 207 kPa
or they will shut down.
Whether or not the mainline pumps trip, the pipeline operator must assess the cause of
the charge pump trip. If it is not apparent, the operator should attempt to restart the
charge pump. Should this fail, the operator must switch to the standby charge pump
by following the procedures in Section 4.2.7.
If neither charge pump can be successfully started, pumping should be switched to

water immediately (if not already operating on water). This is accomplished by
opening the flush water valve (HV-8543) and closing the relevant tank valve. Water
pumping should be continued while the charge pump problem is being investigated.
If the mainline pumps trip, they should be restarted after the charge pump has been
restarted, the spare charge pump has been started, or water pumping has been
switched to water. See also Section 4.1.2.4.2 for operator actions required for a
mainline pump trip.
4.3.2 Mainline Pump Failure
This section covers failure or a trip off line of a single mainline pump. The system
response to a shutdown of all operating mainline pumps is covered in Section
4.1.2.4.2 above.
4.3.2.1 Automatic Mode
Under normal circumstances, pumping is maintained in automatic mode. In this

mode, the operator selects a pump speed or a volumetric flow rate and the SCADA
system monitors and maintains pump operation at the operator-selected set point
automatically. Normally, three of four mainline pumps are operating. This section
discusses SCADA system and operator response to the shutdown of a single mainline
pump.
When in automatic mode, the SCADA system will attempt to maintain a constant
flow in the line to match the operator set point. The pump speed is adjusted
automatically to maintain the set flow rate. Should one of the three operating pumps
trip off line, the SCADA system will attempt to speed up the remaining two pumps to
achieve the set flow.
The mainline pumps have been sized such that two operating pumps can achieve the
minimum pumping rate required to meet the minimum flow velocity in the pipeline
777-G-G-002, Rev. 0 90 September 2000

(264 m3/h). Thus, the SCADA system will ramp up the two remaining pumps to
100% of speed achieving minimum flow for the pipeline (although this may be below
the operator set point). The pumps can not operate at more than a 100% speed
setting.
When the operator restarts the tripped pump or the standby pump, the SCADA system
will ramp up the third pump while ramping down the other two. The system will
resume operation at the selected operator set point.
If a second pump should trip during this upset condition, the pipeline flow rate will
drop below the minimum allowable. This will initiate a timer within the SCADA
system that will automatically shut down the pipeline if a second pump is not brought
on line within 5 minutes to reestablish pipeline minimum flow.
4.3.2.2 Manual Mode
If the mainline pumps are operating in manual mode, the operator has set the speed of
the three operating pumps. If one of the pumps should trip off-line, the remaining two
pumps will continue to operate at the speed set by the operator. The speed of these
pumps must be increased to 100% (to keep the pipeline flow above the minimum) or
the tripped or standby pump brought on line. If the operator does not take action, the
timer within the SCADA system will automatically shut down the pipeline after 5
minutes.
4.3.3 Power Failure
4.3.3.1 PS1
A power failure at PS1 will trip all the equipment in the pump station. The SCADA
system is provided with a UPS such that the pipeline operator can remotely shut down
the pipeline (if necessary).
The pipeline operator should assess the extent of the power failure prior to taking
action. The failure could have been caused by a power surge or dip that is quickly
corrected and permits expeditious restart of the pump station equipment. In this case,
the pipeline should not be shutdown and the pump station operations resumed as
quickly as possible. If the power outage is expected to extend beyond 5 minutes, the
pipeline should be shut down. Note that the PS1 instruments are tied to the UPS
system such that the low pipeline flow will trigger an automatic pipeline shutdown
after 5 minutes if the problem is not corrected.
The concentrator area includes an emergency power system that can be activated in
the event the power outage is extended. Within the pump station, only the storage
tank agitators have been linked to the emergency power system. For more
information on the emergency power supply, see Section 4.4.9.
777-G-G-002, Rev. 0 91 September 2000

Note that for an extended shutdown (longer that 15 minutes), all pump station
equipment should be flushed to avoid restart difficulties.
4.3.3.2 Intermediate Stations
Power for all intermediate stations is provided by self-contained, solar charged, DC

batteries. The batteries provide approximately 5 days of stored power (i.e., fully
charged batteries will last 5 days even if solar generation stops). The power supply
systems are equipped with low charging (solar generation problems) and low power
(battery problems) alarms to alert the operators to potential problems.
Portable generators have been supplied with the solar power units to provide backup
power if there is a problem with the solar panels (or, they are stolen). A quick-
connect cable connection has been provided at each site to permit easy connection of
the generator to the batteries. The generator can be left at the site or, given the 5 day
battery life, moved off site if required.
If power is lost at any given station, the result will be a loss of communication with
the station. The operator response to this loss of communication is discussed in
Section 4.3.5.2. An outside operator must be dispatched to the blacked out station.
Additionally, a technician should be dispatched to troubleshoot the problem.
Once at the station, it may be necessary to use the generator to operate the station
valves. Note that manual operation of the actuated station valves is not advised.
Although manual handwheels have been provided, opening or closing the valves will
take in excess of 500 turns. The design of the system assumes that local operation of
the valves will be accomplished using the portable generators if required. Therefore,
a total of 4 generators were supplied with the power supply system (one each for VS1,
VS2, VS3 and VS4 valve operation).
4.3.3.3 TS1
Power for the terminal station is AC power provided from the general grid at the port
facility. If power is lost, an operator should be dispatched from the terminal to
operate the station locally. There are no batteries or facilities for using an emergency
generator at the terminal station.
Unlike the intermediate stations, manual operation of the AC actuated valves does not
pose as great a difficulty as the station valves. Therefore, pipeline operation could
continue with local operation until power is restored.
4.3.4 Extended Shutdown
The pipeline has been installed such that short-term shutdowns (up to 4 hours in
duration) are not expected to pose restart problems. This has been accomplished by
restricting the installed slope of the pipeline. When flow is stopped in the line, the
777-G-G-002, Rev. 0 92 September 2000

concentrate particles tend to settle in place rather than migrating to a low point and
possibly generating a plug.
Longer shutdowns are likely feasible. Numerous commercial operations can achieve
24 hour shutdowns on slurry without restart problems. Specific pipelines have been
successfully restarted following shutdowns of more than 72 hours on slurry. Testing
during pipeline startup will identify the shutdown and restart characteristics of the
pipeline. This information will be compared to operating data from other pipelines to
estimate the safe shutdown period for the pipeline.
Pipeline shutdowns on slurry should not be a part of normal operations (i.e., as a

means to control throughput). If a shutdown on slurry is necessary (as the result of an
emergency operation), efforts must be made to minimize the duration. It is also
critical to avoid shutting the pipeline down twice while the same slurry batches are in
the line. The loss of heterogeneity the concentrate slurry experiences during a
shutdown is exacerbated by a second shutdown increasing the likelihood of a plug or
a difficult restart.
If the shutdown duration exceeds 4 hours, the pipeline should be operated at or near
the maximum throughput to displace the material that was shutdown in the pipeline.
Operating at the higher velocity will increase turbulence in the line and thereby
improve re-suspension of any solids. Pressure drops should be monitored along the
pipeline and compared to historical values to ensure that any settled solids have been
flushed from the line.
4.3.5 Communications Failure
Communications failure for this manual is limited to problems sending commands to

or receiving information from the remote stations. Telephone system or radio
problems are not included in this manual. The sections below discuss possible
communication system failures.
4.3.5.1 Fiber Optic Cable Cut
A fiber optic cable has been installed from the pump station to the terminal along the
pipeline right-of-way (in the same trench as the pipeline). Although the cable is
marked and somewhat protected by the pipeline, it is possible that the cable is cut by a
fault movement, a landside, a third party excavation along the pipeline, or other
events.
During normal operating circumstances, the PS1 PLC sends operator commands to
and receives process data from intermediate and terminal stations. These signals are
sent via the fiber optic cable. If the cable is cut, it is likely that all strands will be
severed and that any stations below the cut will not be available to the PS1 PLC.
777-G-G-002, Rev. 0 93 September 2000

A radio link has been provided for SCADA data transmittal from the pump station to
the port facility along the pipeline right-of-way. This radio is a direct link from PS1
to the main port control room – it does not connect the individual intermediate
stations. The channel is “live” in that it is always operational. However, the SCADA
system will not use this channel unless it fails to receive data from a station.
In the event of a fiber cut, all stations below the cut will be blacked out to the SCADA
system. The SCADA system will then poll these stations via the radio link. As the
fiber will be intact below the cut point, signals to and from all stations below the cut
will be routed through the terminal PLC and radio system to the PS1 PLC.
The transition from fiber to radio should be seamless for the pipeline operator – there
is no change in operating procedures. The SCADA system will alarm that the radio
system is being used to poll certain stations thus identifying the probable location of
the cut. Operation of the pipeline should continue with no noticeable changes.
4.3.5.2 Station Failure
Another possible communication failure is the loss of an individual station. This

could be caused by a power failure at the station, a cable cut within the station, or a
problem with the system electronics.
The structure of the fiber system is a collapsed ring – although the fiber is in the same
cable, a loop has been created from PS1 to TS1 and back to PS1. Intermediate
stations are alternately connected to either side of the loop. See the system block
diagram in Appendix G for more details on this configuration.
If the communication link is lost at a station, the pipeline operator will receive an
alarm. Additionally, all stations below the blacked out station will momentarily be
lost. The communications system will automatically reroute the operation stations
through the other side of the ring making them available to the operator (via the
SCADA system) within 15 seconds.
If a station is lost, the pipeline operator should immediately dispatch an outside

operator to the station for data collection (monitor pressure, flow, etc.) and to stroke
valves locally in support of pipeline operations. Note that the outside operator vehicle
should be equipped with a portable generator as the communication loss may be the
result of a power problem (see Section 4.3.3.2). A technician must also be dispatched
to repair the problem.
It is possible that the communication link is lost at the pump station – i.e., the PS1
PLC does not receive information or send operator commands. In this event, the
pipeline can be operated from the HMI located in the port control room. This HMI
has full control capabilities but it is password protected from use. If communication
is lost at PS1, the pipeline operator can contact the terminal operator to control the
777-G-G-002, Rev. 0 94 September 2000

pipeline (or shut it down until the problem is fixed or a fully trained pipeline operator
can be dispatched to the terminal).
Under normal circumstances, pipeline operation will continue with the loss of
communication at a single station. Data from the stations on either side of the
blacked out station can be used to interpolate pressures at the lost station (the Pipeline
AdvisorTM will perform this function). Once an operator is in place, the station can be
operated locally until the problem is fixed.
Operation without communication at PS1 will depend on operating conditions.

Steady state operation (the pipeline full of one type of concentrate) could continue.
Batch operation (multiple concentrate and water batches in the line) could continue if
a well trained operator were available at the terminal. Otherwise, a short-term
shutdown may be the most prudent decision.
4.3.6 PLC Failure
Each pipeline station (except pressure monitoring stations and cathodic protection
station) has a PLC. Loss of the PLC at any station will result in the same actions as
loss of communication at the station. Operator functions must be completed locally
until the problem can be fixed.
As with the communication system outage, loss of the PS1 PLC necessitates
operation of the pipeline from the HMI in the terminal control room. The decision to
continue operations or shut down the pipeline will depend on current conditions in the
pipeline (steady state or batch operations) and the availability of qualified personnel at
the terminal.
4.3.7 Mainline Valve Failure
Remotely actuated mainline valves may not open or close as required by the pipeline
operator or SCADA system initiated commands. Limit switches are provided to
confirm successful movement of the valve. Failure of a valve during a pipeline
startup or shutdown can cause problems with pipeline pressures if not addressed by
the operator.
During startups, the operator “pre-starts” the pipeline in preparation for initiating
pipeline flow. All station choke valves are set and the seal and isolation valves are
opened on the fixed choke legs in VS1, VS3, and TS1. When only the wear valves
are left to open, the pipeline startup can be commenced. If any valve problems are
noted during the pre-start, the pipeline operator must address these before advancing
the sequence.
The pipeline startup procedure calls for the pipeline to be opened from TS1 up to
PS1. Each successive station wear valve is only opened when flow is confirmed
downstream of the station by a pressure drop. Therefore, any failure of a wear valve
777-G-G-002, Rev. 0 95 September 2000

to open will be noted and addressed before advancing the sequence. Thus, there
should never be a situation where a failure of a valve to open results in an
overpressure of the pipeline.
During operator or SCADA driven pipeline shutdown, the sequencing of the valves is
very tight in order to keep the pipeline full after shutdown. The station is closed from
PS1 to TS1. If an upstream valve fails to close it is possible to overpressure the
downstream station (if the downstream valve is also closing).
The pipeline operator must be aware of the valve positions when initiating a remote
manual shutdown. For automated SCADA sequences, the sequence will stop
automatically if a failure to close alarm is received. The sequence can only be
restarted after resolving the problem with the valve closure.
If a valve fails to open or close in sequence and the problem is not addressed by the
pipeline operator, an overpressure situation will develop. In this event, it is likely that
a rupture disc will burst in the overpressured station (see Section 4.3.8).
4.3.8 Rupture Disc Failure
If a rupture disc should burst, operation of the pipeline should continue in a controlled
fashion until the pipeline can be safely shutdown full of slurry. This means an outside
operator will have to be at the station where the disc has burst to manually close the
valve. This prevents uncontrolled draining of the pipeline, which can lead to the
formation of very high density slurry waves and plugs.
Note that the valves under the station rupture discs are locked open to prevent
accidental closure. The outside operator must have the key to unlock the valve in
order to close it.
The sections below describe operator actions should a rupture disc burst at a given
station. Each rupture disc is equipped with an electronic sensor that will indicate if
the disc has burst. A disc burst will also be indicated by a sudden drop in station inlet
pressure and will be detected by the leak detection system in the Pipeline AdvisorTM.
There is no automatic sequence for this operation – the pipeline operator must
complete these sequences in remote manual mode.
4.3.8.1 VS1 Rupture Disc Failure
The following sequence should be completed for a rupture disc failure at VS1. It is
assumed that the pipeline operator immediately upon detection of the rupture disc
alarm dispatches an outside operator to VS1.

Reduce pumping to minimum PS1 FIT-8623
777-G-G-002, Rev. 0 96 September 2000

throughput
Initiate water pumping by opening HV-8543
flush water valve (if pumping PS1
concentrate)
Stop concentrate pumping by closing 0360-TKF-400 (HV-8503)
tank valve (if necessary) 0360-TKF-401 (HV-8504)
PS1 0360-TKF-405 (HV-8523)
0360-TKF-406 (HV-8524)
0360-TKF-407 (HV-8535)
Shut wear valves sequentially at VS1 HV-9207 or HV-9217
VS1, VS2, VS3, VS4, and TS1 per VS2 HV-9243
shutdown procedure in Section 4.1.2 VS3 HV-9268 or HV-9278
VS4 HV-9303
TS1 HV-9356 or HV-9376
Shut seal valves sequentially at VS1, VS1 HV-9206 or HV-9216
VS2, VS3, VS4, and TS1 per VS2 HV-9242
VS4 HV-9302
TS1 HV-9355 or HV-9375
At this point, the pipeline operator should wait for the outside operator to arrive at
VS1. Once there, the sequence can be completed.
Shut down the mainline pumps in 0360-PPP-416
accordance with the procedure in 0360-PPP-417
PS1
Section 4.1.2 0360-PPP-418
0360-PPP-419
Unlock and close rupture disc HV-9229
VS1
isolation valve
Shut down the pump station valves Pump isolation valves, charge
and equipment in accordance with PS1 pumps, seal water, etc.
the procedure in Section 4.1.2
At this point the pipeline can be released to maintenance for replacement of the
rupture disc. Once the new disc is installed, the manual isolation valve should be
opened and locked. The pipeline can then be restarted in accordance with the
procedures in Section 4.1.1.
Do not continue to operate the pipeline while the rupture disc is being replaced as the
pipeline is then unprotected against overpressure conditions.
777-G-G-002, Rev. 0 97 September 2000


Reduce pumping to minimum FIT-8623
PS1
throughput
concentrate)
PS1 0360-TKF-405 (HV-8523)
0360-TKF-406 (HV-8524)
0360-TKF-407 (HV-8535)
Shut wear valves sequentially at VS2 HV-9243
VS2, VS3, VS4, and TS1 per VS3 HV-9268 or HV-9278
shutdown procedure in Section 4.1.2 VS4 HV-9303
TS1 HV-9356 or HV-9376
Shut seal valves sequentially at VS2, VS2 HV-9242
VS3, VS4, and TS1 per shutdown VS3 HV-9267 or HV-9277
procedure in Section 4.1.2 VS4 HV-9302
TS1 HV-9355 or HV-9375
PS1
Section 4.1.2 0360-PPP-418
0360-PPP-419
VS2
isolation valve
777-G-G-002, Rev. 0 98 September 2000


PS1
throughput
concentrate)
PS1 0360-TKF-405 (HV-8523)
0360-TKF-406 (HV-8524)
0360-TKF-407 (HV-8535)
VS3, VS4, and TS1 per shutdown VS4 HV-9303
procedure in Section 4.1.2 TS1 HV-9356 or HV-9376
VS4, and TS1 per shutdown VS4 HV-9302
procedure in Section 4.1.2 TS1 HV-9355 or HV-9375
PS1
Section 4.1.2 0360-PPP-418
0360-PPP-419
VS3
isolation valve
777-G-G-002, Rev. 0 99 September 2000


PS1
throughput
concentrate)
PS1 0360-TKF-405 (HV-8523)
0360-TKF-406 (HV-8524)
0360-TKF-407 (HV-8535)
Shut wear valves sequentially at
VS4 HV-9303
VS4 and TS1 per shutdown
TS1 HV-9356 or HV-9376
procedure in Section 4.1.2
Shut seal valves sequentially at VS4
VS4 HV-9302
and TS1 per shutdown procedure in
TS1 HV-9355 or HV-9375
Section 4.1.2
PS1
Section 4.1.2 0360-PPP-418
0360-PPP-419
VS3
isolation valve
777-G-G-002, Rev. 0 100 September 2000

4.3.8.5 TS1 Rupture Disc Failure
A failure of the TS1 rupture disc results in a different response plan due to the
available nearby personnel and the routing of the rupture disc discharge line. If the
rupture disc bursts, pipeline flow will continue to be directed to the concentrates
distribution box (0510-STP-500) above the terminal storage tanks. The valves out of
this box properly direct the concentrate to the storage tank.
The following steps should be taken if the TS1 rupture disc should burst. It is
assumed that a terminal operator is mobilized to TS1 immediately upon detection of
the rupture disc alarm.

PS1
throughput
concentrate)
PS1 0360-TKF-405 (HV-8523)
0360-TKF-406 (HV-8524)
0360-TKF-407 (HV-8535)
TS1. Once there, the sequence can be completed.
VS1, VS2, VS3, VS4, and TS1 per VS2 HV-9243
VS4 HV-9303
TS1 HV-9356 or HV-9376
VS2, VS3, VS4, and TS1 per VS2 HV-9242
VS4 HV-9302
TS1 HV-9355 or HV-9375
PS1
Section 4.1.2 0360-PPP-418
0360-PPP-419
TS1
isolation valve
777-G-G-002, Rev. 0 101 September 2000

rupture disc. As the TS1 rupture disc discharge line runs up to the top of the tanks,
it will have to be drained of slurry prior to changing the rupture disc and should be
flushed to prevent an accumulation of solids. Once the new disc is installed, the
manual isolation valve should be opened and locked. The pipeline can then be
restarted in accordance with the procedures in Section 4.1.1.
4.3.8.6 Recovery of Spilled Concentrate
At VS1, VS2, VS3, and VS4, emergency dump ponds have been constructed to
receive concentrate spilled through the station rupture disc. The ponds are sized to
contain a minimum of 6 hours of full pipeline flow – adequate containment to permit
mobilization to the station in the event of a rupture disc failure.
Once in the pond, the concentrate will settle fairly quickly. The water from the slurry
should be pumped off and recycled to the mine site thickener or terminal clarifier to
ensure recovery of entrained solids and proper treatment of the water. The
concentrate can then be allowed to dry and mechanically removed from the pond (an
access ramp has been provided to permit the entry of equipment into the pond.
Recovered concentrate can be delivered to the terminal for blending with filtered
concentrate.
4.3.9 Pipeline Leak
Leaks can occur throughout the pipeline system and response will vary based on the
location and magnitude of the leak. Note that due to the erosive nature of slurry, a
small leak often quickly becomes more severe – rapid response to leaks is necessary
to mitigate the impact on operations.
4.3.9.1 PS1 – Suction of Mainline Pumps
All pump station piping is unlined carbon steel and subject to corrosion. The
relatively low design pressure of the piping (1965 kPa or less) means an overpressure
situation is unlikely. If a leak develops, it is likely due to the failure of a component
(flange, valve, instrument, etc.) or corrosion in the line.
Should a leak develop, the operator has the following options depending on location
and severity of the leak and the availability of maintenance staff and materials:
• Switch to another tank, concentrate, or water pumping to bypass the leak

(if possible) while the problem is repaired.
777-G-G-002, Rev. 0 102 September 2000

• Clamp the leak while a replacement part is obtained or fabricated –
continue to operate until the repair can be scheduled.
• Shutdown the entire system in accordance with Section 4.1.2 and repair
the leak immediately.
4.3.9.2 PS1 – Discharge of Mainline Pumps
All pump station piping on the discharge side of the mainline pumps (ANSI 1500
class) is polyurethane lined for erosion and corrosion protection. Additionally,
pressure relief valves on the pump discharge lines protect the station piping from
overpressure conditions. A leak could develop as a result of faulty polyurethane or at
a component (flange, valve, instrument, etc.).
Due to the high pressure in the pump discharge piping, a leak will be very dangerous
to equipment and personnel in the area. Should a leak develop, the pump station and
pipeline should be shut down immediately by following the procedures in Section
4.1.2.4. If necessary, unlock and close the manual station isolation valve (HV-8692)
to prevent back-draining of the pipeline.
Once the station is shut down, the leak should be repaired before commencing
operations.
4.3.9.3 Mainline Pipe and Intermediate Stations
The mainline pipe is HDPE lined and the intermediate station piping is polyurethane
lined to protect the steel pipe against corrosion and erosion. Station rupture discs
provide overpressure protection for the pipe. Pipeline leaks are possible at
components (flanges, valves, chokes, instruments, etc.), due to defects in the lining,
and due to events along the pipeline right-of-way (earthquakes, landslides, or third
party excavations).
The Pipeline AdvisorTM is equipped with a leak detection system that will provide
early warning to the operators of possible leak sites. Sudden pressure drops in the
line during normal operations (i.e., not during pipeline startups or shutdowns) are also
an indication of a pipeline leak.
If a pipeline leak is detected, the pipeline should be immediately shutdown in

accordance with the procedures in Section 4.1.2.4. An outside operator and repair
crew should be dispatched immediately to assess the impact of the leak, effect
temporary or permanent repairs, and clean up any spilled concentrate. If the leak is in
a station, it may be possible to bypass the leak location (if in a fixed choke leg) and
continue operations through the other leg.
Operation of the pipeline can only resume after the pipeline repair has been
completed. After a pipeline leak, dried concentrate may exist in some sections of the
777-G-G-002, Rev. 0 103 September 2000

line. The pipeline should be operated on water for a minimum of 24 hours to ensure
proper flushing and prevent the buildup of solids in the line.
4.3.9.4 TS1
Like the intermediate valve stations, the choke station piping is polyurethane lined to
protect the steel pipe against corrosion and erosion. Like the valve stations, leaks can
develop due to faulty lining or at station components (valves, flanges, chokes,
instruments, etc.). If possible, the leak can be bypassed and operation continued.
Otherwise the pipeline must be shutdown while repairs are made.
The piping from the choke station to the terminal storage tanks is bare carbon steel
and is susceptible to corrosion. However, the design pressure is very low as the pipe
is open-ended at the entrance to the distribution box. If a leak should develop in this
piping, two options exist depending on the severity of the leak.
• Clamp the leak, continue to operate, and make permanent repairs during a
scheduled pipeline shutdown.
• Shutdown immediately in accordance with procedures in Section 4.1.2 and

repair the leak.
4.3.10 Pipeline Plug
Pipeline plugs can occur in station piping or in the mainline pipe. Removing plugs
can be difficult, expensive, and a major restriction to concentrator operations (and
concentrate production). The pipeline facilities and operating procedures have been
designed and developed to minimize the likelihood of plugs. Following these
procedures is critical in avoiding plug formation.
The following key procedures must be followed to minimize the likelihood of plugs:
• Always flush pump station equipment and piping if it has been shut down
on slurry.
• Avoid transport of overly coarse concentrate (outside the design range) as

coarse particles can accumulate in the pipeline.
• Always maintain minimum flow in the pipeline – operation below the

minimum can permit solids to settle and accumulate in the pipeline.
In general, concentrate slurry that is not allowed to dry out remains soft enough that a
small amount of applied pressure can reestablish flow in the line. However, the
longer the slurry has been shut in the line, the more difficult it can be to restart flow.
The following sections provide some guidelines for dealing with plugs.
777-G-G-002, Rev. 0 104 September 2000

4.3.10.1 Pump Station Plug
A pump station plug is most likely the result of slurry sitting in an unused line or
section of line for an extended period. The plug should be removed with flush water
from the supply header (on the suction side of the charge pumps) or pumped flush
water using the charge pumps (on the discharge side of the charge pumps). This
provides the maximum pushing pressure on the plug without overpressuring the
piping or equipment.
If the flush water can not push the plug out of the line, the piping must be
disassembled and cleaned manually.
4.3.10.2 Valve/Terminal Station Plug
A valve station plug is usually the result of not using one of the fixed choke legs (at
VS1, VS3, and TS1) for a period of time, if the leg was shut down on slurry.
Normally, when the legs are switched, the pipeline pressure is adequate to push the
slurry from the leg. If the leg is plugged, upstream pressure will build up and flow
should be returned to the originally operating leg. If the new leg can not be
unplugged in two attempts, the station piping should be disassembled and cleaned
manually.
Note that the station valves should always be checked for proper operation and proper
position in advance of disassembling the pipe. A failure of a station valve (such as a
broken valve stem) will appear the same as a plug in the fixed choke leg.
4.3.10.3 Mainline Pipe Plug

A mainline pipe plug, though uncommon in commercial pipeline operations, is the
most difficult problem to solve with the operating pipeline. If operating procedures
are followed, a mainline pipe plug is unlikely unless there is a significant upset
condition (such as an extended, multi-day pipeline shutdown or a pipeline leak).
The pipeline hydraulic gradient should always be monitored. A buildup in pipeline
friction losses can indicate the accumulation of solids in the line. Flush water should
be introduced and the pipeline flow rate increased to a maximum to flush the solids
from the pipeline.
After pipeline shutdowns – planned or unplanned – pipeline pressures are normally
adequate to push any plugs from the line. If flow can not be established because of a
plug, a specific procedure needs to be developed. The goal of the procedure is to
pressurize the plug to the maximum without overpressuring the pipeline in an effort to
remove the plug. Maintaining a high pressure on the plug provides the greatest
chance for its removal.
Follow the steps below to develop an “unplugging” procedure:
777-G-G-002, Rev. 0 105 September 2000

• Assess the location of the plug – this can best be established by reviewing
pressure and flow data from the attempted pipeline restart. Closing the
downstream station and measuring the static head gives a possible
elevation of the plug.
• Calculate the maximum pressure that can be applied on the upstream side
of the plug such that the pipeline can not be overpressured.
• Open the upstream station valves (or start the mainline pumps) to
pressurize the line to the maximum
• Shut in the system with high pressure applied to the plug
If pressurizing the plug is not adequate to dislodge it, the pipeline must be excavated,
opened and cleaned manually. As it is clear this will be a huge effort, the pipeline
operator must take every possible step to avoid the formation of a plug in the line.
4.3.11 Mainline Pump Overpressure
Operation of a positive displacement pumps (the mainline pumps for this pipeline)
against a closed valve or otherwise blocked pipeline can result in an overpressure
condition. In order to protect the pumps and piping from damage, three pressure
control/relief sequences have been provided with the mainline pumps and SCADA
system. These systems are discussed in the following sections.
4.3.11.1 Discharge Pressure Ramp Down
The discharge pressure of the mainline pumps is measured at the pump station outlet
piping (PIT-8960 and PIT-8960A). If this pressure reaches 23,442 kPa it is above the
maximum design conditions for the pipeline. The SCADA system will alarm the
condition to the pipeline operator and automatically ramp the pump speed down by 2
percent. This will continue each time the pressure reaches 23,442 kPa until the
pipeline is operating at minimum flow conditions.
If the pressure continues to rise (or if the pipeline is already operating at minimum
throughput), the SCADA system will automatically shutdown the pumps (and
pipeline) if the pressure reaches 24,476 kPa.
4.3.11.2 Wirth-Installed Protection
HOLD FOR WIRTH MANUAL
4.3.11.3 Pump Discharge Relief Valves
Relief valves have been installed on the discharge of each individual pump. They
provide the final protection for the pump and piping. The valves are set at 25,855 kPa
and discharge to the pump station sump. If any one relief valve opens, all operating
777-G-G-002, Rev. 0 106 September 2000

mainline pumps and the pipeline will be shut down automatically by the SCADA
system.
If these valves open, the pump station operator should attempt to recover any spilled
concentrate in accordance with procedures in Section 4.2.6.3.
4.4 Individual Equipment Procedures
4.4.1 Linear Screens
HOLD FOR DELKOR MANUAL
4.4.2 Samplers
HOLD FOR OUTOKUMPU MANUAL
4.4.3 Agitators
HOLD FOR HAYWARD GORDON MANUAL
4.4.4 Centrifugal Pumps
HOLD FOR ASH MANUAL
4.4.5 Mainline, Positive Displacement Pumps
HOLD FOR WIRTH MANUAL
4.4.6 Vertical Sump Pump
HOLD FOR GALLAGHER MANUAL
4.4.7 Automatic Valves
4.4.7.1 Knife Gate Valves
HOLD FOR TYCO MANUAL
4.4.7.2 Ball Valves
HOLD FOR VALVTECHNOLOGIES
4.4.8 Salt Water Injection Skid
HOLD FOR SPECTRUM INTERNATIONAL MANUAL
777-G-G-002, Rev. 0 107 September 2000

4.4.9 Concentrator Emergency Power Supply
777-G-G-002, Rev. 0 108 September 2000

5.0 MAINTENANCE PROCEDURES
This section discusses basic maintenance philosophy and requirements for

each element of the pipeline. The sections below provide guidelines and input
for use in developing preventive maintenance checklists. Specific procedures
for repairing equipment can be found in the vendor manuals and Pipeline
Standard Job Procedures.
5.1 Linear Screens
The primary purpose of the linear screens is to minimize oversize top size particles
and tramp material from entering the slurry storage tanks and ultimately entering the
mainline pumps. Particles larger than 6mm can interfere with check valve operation
within the mainline pumps and can reduce or stop pump flow. If significant oversize
is observed to be reporting to the oversize discharge bins (0360-BNS-400 or –401) is
an indication that the filter cloth is too fine or excessive coarse oversize is being
produced by the concentrator. Other debris can enter the pipeline through the open
top of the storage tanks. In-line strainers (0360-ZMB-410 through 413) located
downstream of each charge pump provide the final protection for tramp oversize
reaching the mainline piston pumps.
Condition of the screen cloth can be determined by visual inspection. A log should be
kept of the weight of screen oversize weight each time each bin is unloaded and the
date and time. This can provide an independent means to track oversize amount and
screen condition.
The cloth is the primary wear component of the linear screens. According to
manufacturer’s data, the selected cloth area (6 m2) is greater than required for the
design thickener underflow pumping rate, which should prolong life. Operating data
indicates the cloth should last 6 to 12 months.
5.2 Storage Tanks
The storage tanks provide storage space for slurry while it is being produced in the
concentrator until sufficient volume is available for pumping.
The primary concern regarding the tanks is the corrosion rate of the shell plate (the
tank bottom is concrete coated) damage to internal concrete and build-up of packed
solids in the tank fillets (bottom corners). Bi-annual ultrasonic measurements at
marked locations provide a good means to monitor wall loss in the shell. Corrosion is
not expected to be high (the tanks will operate at or near minimum levels much of the
time) but if it becomes so, consideration can be given to urethane or other coating
systems.
The bottoms of the tanks are coated with concrete for protection against corrosion and
erosion. This concrete may spawl or crack. If concrete pieces get into the slurry
piping, damage can occur to the piping, valves, pumps, or instruments. Bi-Annual
inspections should be made to check and repair the concrete.
777-G-G-002, Rev. 0 109 September 2000

A build-up of packed solids does not necessarily negatively impact the performance
of the tanks, but will make clean out more difficult. The copper thanks at the pump
station have been provided with concrete fillets to facilitate draining and mitigate
solids build-up. This additional concrete must also be inspected during tank
shutdowns.
5.3 Agitators
The key to long agitator life is maintaining gear box oil so it does not become
contaminated and maintain gearbox reservoir level within recommended norms. Oil
analysis monitoring will mitigate possible contamination before and during use.
There is a circulating oil flow switch that should provide an alarm if the oil pump
becomes worn and does not produce sufficient flow, this should be kept in good
operating condition. A periodic check by feeling temperature of each branch line will
tell how well the oil is being distributed. If a line is cold, it could be blocked.
Investigation is in order if this occurs.
How much noise a gearbox makes is a good indicator of its condition. If a sudden
increase in noise occurs, should signal when something has failed and be the trigger to
initiate a scheduled down time for an open cover inspection.
An immersion heater is provided for the oil for when the unit is down during cold
weather to minimize condensation and maintain oil viscosity to a low enough level
for restart with minimum damage to the unit or circulating oil pump. This heater
requires cleaning and inspection during each oil change.
The impeller blades are rubber coated and the shaft is epoxy coated. These
components must be inspected and repaired as required during tank inspections.
Proper alignment and balance of the impeller are also critical to achieving long life of
the gearbox. Any vibration problems must be promptly addressed to avoid premature
failure.
5.4 Pumps
5.4.1 Mainline Positive Displacement Pumps
The mainline pumps have expendable components in those areas subject to slurry
wear such as the pistons, liners, valves and seats. There are two sections of the pump;
the fluid end and the power end which are covered separately below.
Note that the SCADA screen has a maintenance management page which tracks
operating hours for the pumps. This page should be utilized to monitor parts lives.
An hour counter has also been provided for tracking valve lives and can be reset at
each change out. Developing a reliable parts lives historical record is a key factor in
improving overall system reliability.
777-G-G-002, Rev. 0 110 September 2000

5.4.1.1 Fluid End
The fluid end parts include the following with their respective typical part lives based
on similar presently operating systems:
Urethane Pistons 1,000 hours
Ceramic Liners 8,000 hours1
Valves 1,500 hours
Valve Elastomers 400-800 hours
Valve Seats 1,500 hours
Valve Bushings 400 hours
5.4.1.1.1 Pistons and Liners
Ceramic liners with urethane pistons have been selected as the result of Miller
abrasivity tests performed on pilot plant slurry at pH levels from 7 to 12 with the
standard chrome iron test block. The results indicated that a pH level in excess of 11
would have to be maintained in the concentrator to provide what is normally
considered acceptable wear life on chrome iron liners, hence ceramic liners have been
selected. Once the system begins operation, further evaluation will continue which
may show that the practical solution is conventional high chrome liners.
The basis for the station and pump design is to provide for the capability to retrofit a
piston-diaphragm fluid end should it be found necessary as driven by the cost of
cylinder liners and pistons that are consumed with the piston pump.
Ceramic liners require special care in handling and installation. They are subject to
damage if dropped or improperly tightened during installation. They also have a
critical run-in period of about one week whereby a glaze is developed inside the liner
bore. The alignment of each piston rod/cross-head and cross-head guide clearance
impacts how even the wear occurs between the piston and liner. Even distribution of
wear is accomplished by periodic rotation of liner in one direction with pistons
rotated the opposite every 12 to 24 hours depending upon experience.
It is particularly critical to catch piston leakage early or liner life can degrade rapidly.
Liners can be re-honed to remove scores and improve life if a suitable source can be
lined up near the site. Replacement of liner spray water is necessary to maintain it in
a clean condition. Spray water temperature must be less than 700 C or it will impact
1
Based on drilling fluid-mud pump experience with similar abrasivity
777-G-G-002, Rev. 0 111 September 2000

piston life. The pump vendor indicates that a cooler is not necessary to maintain
water temperature below 700 C.
The alignment of the cross-heads, cross-head clearance and bearing clearance can
impact piston and liner life. The vendor claims these tolerances are built-in during
manufacture and cannot be changed. If a particular pump is having poor piston-liner
life an inspection should be scheduled. A special rubber self-alignment pad
specifically designed for ceramic liners has been incorporated into the intermediate
piston-extension rod coupling to assist in alignment corrections. These pads require
periodic inspection/replacement as they become fatigued or worn.
A working high-pressure hydraulic hand pump is a top priority, otherwise there is no

way to remove valves or change liners. Hydraulically pre-tensioned bolts are used for
clamping liners in-place as well as valve housing cover fasteners. The valve seat
removal system utilizes hydraulic pressure between two o-rings on the OD of each
seat.
The power end has an immersion heater, oil cooler and 2 circulating oil pumps which
require inspection during each oil change.
5.4.1.1.2 Valves
The valves are a standard mud pump design made for the pump vendor in an API 8
size. They are available from several sources – directly from pump manufacturers or
from parts manufacturers.
It is a top and bottom guided poppet type valve that utilizes approximately a 45° seat
with a metal portion in contact on the seat for strength purposes and with an
elastomeric section on top to provide a bubble-tight seal.
The failure mechanism is normally the result of a combination of the following two
phenomena:
1. The metal and elastomer contact areas form individual annular grooves
in the seat. The area between metal and elastomer does not wear at the
same rate, which causes the elastomer seal to flex and eventually crack,
causing a leak to occur.
2. The clearances between the top rod and bushing and the bottom wing
pads and the ID of the seat become larger due to slurry lap wear and
fluid flow abrasion. As clearances increase the vertical motion of the
valve becomes less stable causing more random lateral or angled motion.
If the valve closes against a larger particle on one side the valve can
pivot around the high spot caused by the particle. If the displacement is
such that the elastomer doesn’t have 100% circular contact at closure, a
high pressure leak will occur. If the damage caused by the leak wears
777-G-G-002, Rev. 0 112 September 2000

away sufficient metal that the elastomer cannot bridge a gap the valve
will begin leaking during each close cycle.
Valve leaks are normally detected by the noise they make. Motor current or torque
will begin to noticeably fluctuate normally after significant damage has occurred to
the valve seat which can occur over the course of 10-15 minutes. If allowed to occur
too long, the fluid cut will wear through the valve seat and damage the fluid end seat
taper bore. Fluid ends and higher velocity manifold components normally require
weld repair, stress relieving, heat treatment and re-machining as part of normal
maintenance. A fluid end typically can only be rebuilt once before the material
properties of the fluid end become marginal.
Each time valves are removed from a pump they need to be measured to determine
metal and elastomer loss. This data is plotted relative to failures to assist in predictive
maintenance.
5.4.1.2 Power End
The power end condition (good piston alignment during all pressure levels) is key to
good piston and liner part life. The vendor advises that very little wear occurs except
for normal bearing and gear wear and intermediate extension alignment pads. A worn
bearing can also impact extension rod sideways movement. The condition of the
power end oil is also important for equipment longevity. Water content should be
kept less than 50 ppm to minimize corrosion and premature bearing wear. This pump
is designed with a pressurized extension rod seal which should keep water out from
piston water spray.
The power end comprises:
• Piston rods which are the rods connected to the pistons
• Extension rods or rods that connect the piston rod to the cross-heads.
There is an intermediate rod also that connects the piston rod to the
extension rod.
• Extension rod seals of which there are three per rod
• Cross-heads
• Cross-head guides
• Connecting rods with bearings
• Crankshaft with bearings
• Crankshaft Gear
777-G-G-002, Rev. 0 113 September 2000

• Pinion Shaft with Bearings
• Lube Oil Filtration Pump (equipped with suction strainer with bypass
and duplex discharge filter)
• Cooler Lube Oil Circulation And Fan
Piston rod seals are monitored by the amount of oil in the liner spray water, however,
the vendor advises they do no require replacement more frequently than every 3 years.
Extension rod alignment verically and horizontally should be verified during start-up
and could be checked if one liner position or one pump is experiencing abnormally
high replacement rates relative to other pumps.
Gear contact can be visually inspected as a part of each oil change. If pitting or
spalling is observed, photos should be taken to document the progression of the
damage.
Oil samples and analyses should be taken for new and expended oil during each oil
change. There is a sample tap in the oil filtration piping which can be used for taking
samples.
A vibration survey should be done during start-up to troubleshoot problems and

provide a baseline measurement to compare with annual surveys performed thereafter.
If higher than normal vibration is sensed it should be reason to schedule another
survey at any time.
Synthetic oils will not be necessary since the operating temperatures should be 50-
600C with the use of the external oil cooler.
The external cooler will accumulate dust which will require flushing with water
occasionally.
Oil leaks can occur. When one becomes excessive, a scheduled shutdown should be
made to make corrections.
5.4.1.3 Drive
The drive comprises the main motor with two blowers, the external gearbox with
shaft mounted circulating oil pump and external air-oil cooler with fan.
The main motor fans have filters that require periodic servicing. The motor has
grease lubricated bearings. Care is required to not overgrease which can cause
overheating.
777-G-G-002, Rev. 0 114 September 2000

The external cooler will accumulate dust which will require flushing with water
occasionally.
Oil leaks can occur. When one becomes excessive, a scheduled shutdown should be
made to make corrections.
5.4.2 Horizontal, Centrifugal Pumps
5.4.2.1 Charge Pumps
The purpose of the charge pumps is to maintain suction pressure fed to the mainline
pumps which should be in the range of 207-620 kPa. During start-up, commissioning
or when the characteristics of the slurry has changed, charge pumps will be used to
circulate slurry through the test loop to obtain head-flow and critical velocity data.
There are four charge pumps, two for Copper (360-PPS-412 &-413) and two for zinc
(360-PPS-410 & 411). Each drive motor is connected to a variable frequency
convertor. Normally only one pump is necessary to be running out of the four. When
the product changes, the charge pump does as well.
The control system provides control of charge pump speed to maintain a constant
discharge pressure. When a tank is full, the operating charge pump will operate at a
lower RPM than at tank minimum level. The minimum speed for proper operation of
a charge pump is 1,000 RPM. The set point for suction pressure should be 500 kPa.
Shaft sleeves and packing should be monitored daily. There is a flow indicating
switch that is available to verify flow rate, however, it is also important to keep the
packing just tight enough to maintain a small water leakage rate coming through the
packing.
Gland seal water quality should be kept within limit established by vendor manual.
Impeller end adjustment should be made periodically to minimize recirculation and

attendant wear as recommended in the vendor manual. The vee-belt will require
alignment re-tensioning after each significant change in shaft position.
As with the mainline pumps, the operating hours for the charge pumps are tracked by
the SCADA maintenance page. Repairs to packing, impellers, or other components
should be tracked against operating hours to develop effective preventative
maintenance procedures.
5.4.2.2 Area Sump Pumps
There are two area sump pumps, for the copper storage area (360-PPS-415) and one
for the zinc storage area (360-PPS-414). Both of these units are located inside the
pump house in a sunken dry well but receive drainage from the storage tank area
777-G-G-002, Rev. 0 115 September 2000

adjacent to the pump house. These units are horizontal shaft type like the charge
pumps. The maintenance for these units is the same as charge pumps except they are
not as frequently used.
5.4.3 Vertical, Centrifugal Pump
One vertical sump pump is provided for the pump house (360-PPR-420). This is a
cantilevered shaft design pump, hence gland seal is not required. Otherwise, the
maintenance for this unit is the same as charge pumps except they are not as
frequently used.
5.5 Pipeline and Components
5.5.1 Unlined station piping
Unlined station piping is provided on all piping on the suction side of the mainline
pumps including water and slurry. Key monitoring points will be established during
start-up, commissioning for ultrasonic monitoring of wall thickness. As operating
velocities in these lines are less than 3 m/s, erosion should not be an issue, metal loss
will most likely be the result of corrosion.
5.5.2 Lined station piping
Lined piping is provided on the discharge side of the mainline pumps and at valve
stations. One spool should be removed yearly to allow for inspection. This piping is
near the mainline pumps which generate vibration. There is potential for
polyurethane fatigue failure due to pulsations and vibration.
Polyurethane lining was selected for resistance to both erosion and corrosion. Slow
within the stations is more turbulent than in the mainline pipe. This turbulence can
lead to higher wear rates for which polyethylene (HDPE) offers only limited
resistance.
To add mechanical strength to the lining, a wire mesh has been installed to strengthen
the attachment to the pipe. Polyurethane spools should last 5 to 20+ years.
5.5.3 Mainline pipe and liner
The mainline pipe is lined with HDPE using the United Pipeline lining system.
Internal wear of HDPE is expected to be minimal since the velocities in the pipeline
are expected to be in the 1.5 to 3.2 m/s range. Monitoring efforts should be focused
on the 8” sections of the system, namely the test spools at VS1, VS3, and VS4. The
test spools are designed to permit measurement of internal HPE liner without opening
the line. Particular attention should be paid to bottom wear on the line. Test spools
will provide an indication of wear in the mainline pipe.
The liner thickness in the mainline pipe has been selected based on possible operating
conditions. For 9- and 10-inch pipe, the operating velocities are less than 3 m/s such
777-G-G-002, Rev. 0 116 September 2000

that a standard 7mm liner thickness was selected. Higher operating velocities in the
8-inch pipe meant additional protection is needed and a 9mm liner was installed.
Sections of line at risk for slack flow were installed with a 12mm thick liner. The
mainline pipe should meet the 25-year project design life.
5.5.4 Knife gate valves
Knife gate valves are located in all low pressure (150 LB Class rated at 100 psi) slurry
piping at the pump station and the terminal. The section between the discharge of the
charge pumps and the suction of the mainline pumps include 300 LB flanged knife
gate valves rated for 300 psi. These valves are field repairable by replacing seal
sleeves and gates.
The one unique feature of this type of valve is that they leak slurry during
actuation/travel. The bodies must be kept open so this leakage can occur without
internal buildup. The 150 LB models have a slot in the bottom which must be kept
open. There is a tendency for personnel who are not aware of the valve design to put
a plate on the bottom of the valve to keep it from leaking. The 300 LB bodies have
tapped drain ports. At least 2 of these ports should be kept open at the lower most
portion of the body.
The elastomers in the valves are natural rubber which will swell if grease is used as a
gate lubricant. Dow 111 silicone valve sealant is recommended for gate lubricant
which should be applied to frequently used gates weekly. Occasionally used valves
should be greased monthly. The most common problem to occur with knife gate
valves is bent gates, usually caused from pressure transients. If a gate gets bent it is
not long before damage is done to the seals.
5.5.5 Ball Valves
Ball valves are used on all high pressure slurry piping.

There is no lubrication required for this type of valve. Only periodic inspection to see
that the actuator works properly is necessary. The best monitoring technique for these
valves is to periodically measure torque.
The premise for sealing a ball valve is near perfect contact between the ball and seat.
Near perfect contact will wipe the ball so that no particles come between the ball and
the seat. Once particles are brought in there is a leakage path. When a ball valve goes
into a failure mode, a coating of solids begins to appear on the ball which increases
torque dramatically. Once a valve is detected to have a significant increase in torque
it should be kept in the open position if feasible until such time that it can be
removed, dismantled and inspected.
Major damage can occur during a very short period that a valve is allowed to leak.
Ideally only small surface blemishes occur before detection. A small amount of field
repair is possible by relapping a ball to a seat. If a ball is damaged on one side it can
possibly be rotated 1800 to the undamaged side and lapped to the seat in the area used for
closure seating. In order to do lapping 3 micron diamond lapping compound is required.
777-G-G-002, Rev. 0 117 September 2000

Ball and seat wear will occur in valves that open and/or close against a high
differential pressure on slurry. The valves that see this high differential are mainline
pump discharge and drain valves and station wear valves. Under normal
circumstances, the mainline pumps will be shut down on water so valve wear should
be minimized. As such, the maintenance page in the SCADA system tracks wear valve
cycles (open or closed) to facilitate maintenance planning. Commercial operating
experience suggests that wear valve ball and seat lives will be 100 to 300 cycles.
5.5.6 Ceramic Chokes
5.5.6.1 General
Ceramic chokes have been installed along in the pipeline control flow in the pipeline.
These chokes are expected to wear even though they have been constructed from
ceramic material. The table below summarizes the choke sizes and tag numbers for
easy reference.
Choke Size Nominal Tag Numbers

(opening) Diameter
A (2.800”) 8” FO-9381D, FO-9382L
B (2.500”) 8” FO-9381C, FO-9382K
C (2.250” 8” FO-9381B, FO-9382J
D (2.125”) 8” F0-9211A, FO-9211B, FO-9212A, FO-9212B, FO-9213A,
FO-9214A, FO-9214B, FO-9215A, FO-9215B, FO-9215C,
FO-9215D, FO-9215E, FO-9215F, FO-9215G, FO-9215H,
FO-9272A, FO-9272B, FO-9273A, FO-9273B, FO-9275A,
FO-9275B, FO-9275C, FO-9275D, FO-9275E, FO-9275F,
FO-9275G, FO-9275H, FO-9275J, FO-9276A, FO-9290A,
FO-9290B, FO-9290C, FO-9378A, FO-9378B, FO-9379A,
FO-9379B, FO-9380A, FO-9381A, FO-9382A, FO-9382B,
FO-9382C, FO-9382D, FO-9382E, FO-9382F, FO-9382G,
FO-9382H
E (1.540”) 8” FO-9270A, F0-9270B, FO-9271A, FO-9271B, FO-9368A,
FO-9368B, FO-9371A, FO-9371B
F (6.750”) 10” FO-8607, FO-9359
G (1.561”) 4” FO-9210A, FO-9289A, FO-9307A, FO-9352A, FO-9374A
H (2.148”) 4” FO-9210B, FO-9289B, FO-9307B, FO-9352B, FO-9374B
I (2.771”) 4” FO-9210C, FO-9289C, FO-9307C, FO-9352C, FO-9374C
J (3.196”) 4” FO-9210D, FO-9289D, FO-9307D, FO-9352D, FO-9374D
5.5.6.2 Choke Wear
The ceramic chokes will wear with use – more operating hours means more wear.
The main pipeline chokes may need replacement as often as every six months.
777-G-G-002, Rev. 0 118 September 2000

SCADA has a maintenance page containing process data for choke loops. Upstream
and downstream pressures are logged with flow rate to calculate the effective choke
coefficient. Comparison over time of choke coefficient provides a predictive means
to determine when to replace chokes.
Ceramic chokes installed at the conductivity meters (FO-8607 and FO-9359) have a
relatively large internal opening and, correspondingly, a low pressure drop. Operating
velocities are low enough that these chokes should last for many years.
Water chokes are installed at VS3 and TS1 (FO-9270A&B, FO-9271A&B, FO-
9368A&B, and FO-9371A&B). These chokes are designed to reduce head when the
pipeline is operating on water. Therefore, these chokes will see very little (if any)
exposure to erosive slurry. Thus, these chokes are also expected to have a multi-year
service life.
5.5.6.3 Cavitation
The installed chokes have been selected to consume surplus head during operating
conditions. Sufficient back-pressure is maintained on the downstream side of the
chokes to avoid cavitation. However, during startup, low operating pressures on the
downstream side of the valve stations (notably VS1 and VS3) can result in short term
conditions during which cavitation can occur.
To minimize the impact of the possible cavitation event, care must be taken to follow
the pipeline shutdown sequence. This sequence has been developed to safely
shutdown the pipeline while minimizing possible slack conditions of the downstream
side of the valve stations. However, the last ceramic chokes at each station should be
inspected regularly for cavitation damage – particularly if a reduction in pressure drop
across the station is evident.
5.5.7 Rupture Discs
Rupture discs are installed in the line upstream of powered valves at each valve
station. Their purpose is to protect the pipeline from rupture in the event the pump
station and valve stations are not shutdown in the proper sequence. All rupture disks
are piped downstream through chokes each to an emergency pond. Each disc is
instrumented with a blown disc sensor which requires replacement when a disc has
blown.
Three spare discs have been purchased for each disc location one of which should be
stored at each valve station site inside the building.
5.6 Pipeline right of way
The entire pipeline right-of-way must be patrolled by plane or vehicle monthly as

required by ANSI/ASME B31.11. The primary concern is encroachment by outside
777-G-G-002, Rev. 0 119 September 2000

parties and environmental damage to the right-of-way that could endanger the
integrity of the pipeline. Known high activity sections may require more frequent
patrols.
Pipeline repairs must be covered under a maintenance plan consistent with API RP
1107 and API RP 1111.
Right-of-way should be maintained for clear visability and provide for reasonable
access for maintenance. Diversion ditches or dikes must be maintained where needed
to protect against washouts of the line and erosion of the landowner’s property.
An emergency plan is required by ANSI/ASME B31.11 to be in place to mitigate
system failures by training personnel, providing for necessary equipment, proper
communication, procedures and rapid dispatch of trained personnel to emergency site.
Specific plans are being prepared under a separate document.
777-G-G-002, Rev. 0 120 September 2000

6.0 SUBSYSTEM OPERATING AND MAINTENANCE PROCEDURES
The following systems are part of the pipeline. Specific operating and maintenance
instructions can be found in the referenced manuals.
6.1 SCADA System
The SCADA system is key to operating the concentrate pipeline and has been
designed to achieve a high level of reliability. The pump station and terminal
SCADA is backed up with a UPS by Bechtel and PSI respectively. Intermediate sites
are powered by conservatively sized solar power units. Back-up portable generators
are available for key sites (valve stations). Specific operating and maintenance
instructions can be found in PSI Document 777.01-S-I-009.
6.1.1 Control Room
The primary control point for the pipeline is the operator work station in the pipeline
control room. In addition to the HMI’s, there are several support computers and
SCADA/telecommunications panels. Specific maintenance of these items is
discussed in the relevant manuals.
The main maintenance issue in the control room is dust control. Dried concentrate
will be tracked into the control room by operators, mechanics, and visitors. Simple
sweeping of the control room can exacerbate the problem.. Scheduled cleaning of the
room and equipment (vacuuming, cleaning filters, etc.) must occur to prevent
premature or unplanned component failure.
6.1.2 Intermediate Sites
There are no specific, unique requirements for the SCADA components at the
intermediate sites. The key to SCADA system reliability is maintenance of the
remote power systems (see section 6.4).
6.2 Telecommunications Systems
There are two communication systems that provide voice and data communication
along the pipeline – a primary fiber optic system and a backup land mobile radio
system. These are briefly discussed in the sections below.
6.2.1 Fiber Optics
A fiber optic communication system provides the primary voice and data link between
the pump station and the intermediate and terminal stations. In addition, the fiber
carries voice and data for the concentrator and terminal facilities. A complete
description of the fiber optic system can be found in PSI document 831-S-T-001.
777-G-G-002, Rev. 0 121 September 2000

6.2.2 Radio
The pipeline radio system provides two basic functions – it allows communications
between the control room and field personnel at points between intermediate stations
and provides a backup data channel for the pipeline SCADA system. Complete
operating and maintenance instructions can be found in Bechtel document _______.
6.2.3 Video
Video monitoring has been provided for key intermediate sites – the valve stations.
The video is primarily a security measure to discourage vandalism and/or theft of
station components. Only the valve station are monitored as they are key control
points in operating the pipeline. Proper maintenance of the video system is part of the
pipeline security plan, but is not the only component. Damage or theft at any station
must be promptly addressed to maintain system reliability.
Complete operating and maintenance instructions for the video system can be found
in PSI Document 831-S-T-001.
6.3 Cathodic Protection System
This section provides a summary of the cathodic protection system. Complete

operating and maintenance procedures can be found in PSI document 775-G-P-009,
“Operation and Maintenance Manual for Cathodic Protection System”.
The cathodic protection system consists of six, impressed current systems at sites
along the pipeline as summarized in the table below.
Site Rectifier Anode Bed

PS1 AC input/40V, 10A DC output Horizontal, 60 m long, 9 anodes
PMS2 DC input/30V, 5A DC output Horizontal, 100 m long, 15 anodes
VS1 DC input/36V, 5A DC output Horizontal, 100 m long, 15 anodes
VS4 DC input/32V, 5A DC output Horizontal, 100 m long, 15 anodes
CPS1 DC input/10V, 5A DC output Vertical, 60 m deep, 4 anodes
TS1 AC input/60V, 10A DC output Horizontal, 140 m long, 20 anodes
Piping and facilities at PS1, VS1, VS2, VS3, VS4, and TS1 have been electrically
isolated from the cathodic protection system to protect facilities from damage and
personnel from electric shock. The pipe spools at PMS1, PMS2, PMS3, and PMS4
(there are none at CPS1) are energized as part of the cathodic protection system.
As discussed in the operation and maintenance manual, the cathodic protection

system requires monthly and annual checks to ensure proper operation. Rectifier
output voltage should be checked monthly and overall system performance should be
777-G-G-002, Rev. 0 122 September 2000

checked annually. Full details of these inspections can be found in the system
manual.
It is important to note that improper operation of the cathodic protection system can
result in premature failure of the mainline pipe. It is imperative that annual checks be
completed to ensure the pipeline can achieve its design life.
6.4 Remote Power Systems
The remote power systems at the intermediate sites are the most important part of the
pipeline control system. The systems provide power for the SCADA system,
telecommunications, and valve actuation, as well as video, lighting, and cathodic
protection. Without these systems, remote station operation is impossible.
The power systems are sized to provide approximately 5 days of reserve power,
assuming average power draw and no generation. This scenario equates to removal or
theft of the solar panels. Four plug-in, back-up generators have been provided with
the power systems. These generators are portable and can be moved to and from the
problem sites.
Over time, battery capacity is expected to decay (see manufacturer information for
specific data). It is imperative that battery charge rates, stored power, and draw rates
are monitored such that timely battery replacement can be arranged. Complete
operating and maintenance instructions can be found in Northern Power Document
____________________.
777-G-G-002, Rev. 0 123 September 2000

APPENDICES
777-G-G-002, Rev. 0 September 2000

APPENDIX A
Pipeline Corridor Route Map, Drawing 775-D-C-001

APPENDIX B
System Block Diagram, Drawing 0000-F-110

APPENDIX C
Process Flow Diagrams

APPENDIX D
Piping and Instrument Diagrams

APPENDIX E
Operating Range Diagram

APPENDIX F
Profile and Hydraulic Gradient

APPENDIX G
Fiber Optic Channel Diagram

Operating and Maintenance Manual

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Operating and Maintenance Manual

Hochgeladen von

Copyright:

Verfügbare Formate

Pipeline Systems Incorporated

COMPAÑÍA MINERA ANTAMINA S.A.

OPERATING AND MAINTENANCE MANUAL

DOCUMENT NO. 777-G-G-002

777-G-G-002, Rev. 0 i September 2000

777-G-G-002, Rev. 0 ii September 2000

777-G-G-002, Rev. 0 iii September 2000

777-G-G-002, Rev. 0 iv September 2000

5.0 MAINTENANCE PROCEDURES ................................................................................ 109

777-G-G-002, Rev. 0 v September 2000

777-G-G-002, Rev. 0 vi September 2000

777-G-G-002, Rev. 0 vii September 2000

This document provides general technical information as well as specific instruction

1.2 Project Background

777-G-G-002, Rev. 0 1 September 2000

2.1 Process Design Reference Documents

Document Number Title

2.2 System Control Philosophy Reference Documents

Document Number Title

777-G-G-002, Rev. 0 2 September 2000

Document Number Title

2.4 Vendor Reference Documents

The following vendor-supplied documents are available to supplement the operating

Document Number Title

777-G-G-002, Rev. 0 3 September 2000

3.1.1 Pipeline Stations

Station Title Kilometer Facility Abbreviation

SCADA Supervisory control and data acquisition

777-G-G-002, Rev. 0 4 September 2000

head Hydraulic energy expressed in an equivalent column of the

777-G-G-002, Rev. 0 5 September 2000

3.2 System Description

Drawing Number Title

777-G-G-002, Rev. 0 6 September 2000

3.2.2 Pump Station

Three of four mainline slurry pumps (0360-PPP-416, 0360-PPP-417, 0360-PPP-418,

777-G-G-002, Rev. 0 7 September 2000

Section Pipe size

3.2.4 Pressure Monitoring Stations

777-G-G-002, Rev. 0 8 September 2000

3.2.6 Terminal Station

The zinc concentrate distributor (0510-STP-501) is controlled by the terminal

The copper concentrate distributor (0510-STP-502) is also controlled by the terminal

777-G-G-002, Rev. 0 9 September 2000

3.3 Process Design

The following sections summarize the limits of the Antamina pipeline.

3.3.2 Design Slurry Characteristics

3.3.2.1 Particle Size Distribution

Size Fine Coarse Notes

777-G-G-002, Rev. 0 10 September 2000

The minimum concentration for transport is 55 wt%.

The maximum reduced viscosity for transport is 12.64

The minimum reduced viscosity for transport is 3.52

The maximum yield stress for transport is 2.78 dynes/cm2

The minimum yield stress for transport is 64.82 dynes/cm2

The minimum pH for transport is 10.0.

The maximum pH for transport is 11.5.

The minimum temperature for transport is 10o C.

The maximum temperature for transport is 15o C.

3.3.2.6 Specific Gravity of Solids

3.4 Operating Range Limits

3.4.1 Throughput Limits

777-G-G-002, Rev. 0 11 September 2000