AAC Kemix Pumpcell Plant Operating Installation Manual_Yamana_Chile Minera Florida Limitada Project_Rev0

Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

KEMIX

 (Pty)  (P ty) Lt d

Reg. No. 1989/003259/07 Incorporating

STALLION STAL LION MIXERS MIXERS 47 Kyalami Boulevard, Kyalami Business Park, PO Box 31949, Kyalami, 1684 SOUTH AFRICA Tel. (+27 11) 466-2490 Fax. (+27 11) 466-2190 email: [email protected] web site: www.kemix.com

 AAC Pumpcell Plant Operating and Maintenance Manual

Client Proj ect Equipm ent Cont ract rac t Numb er Date Revision

YAMANAGOLD - MINERA MINERA FLORIDA LIMITADA MINERA MINERA FLORIDA LIMITADA PROJECT - CHILE 1 x 135m 135m3, 8 STAGE PUMPCELL PLANT INCLUDING MPS0470(P) INTERSTAGE SCREENS E70444/20 E70444/2011 11 TH 28  JULY  J ULY 2011 0

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Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Table of Contents 1

CONTACT CONTACT DETAILS ........................... ........................................ ........................... ............................ ........................... ........................... ...................... ........1

2

INTRODUCTION .............................................................................................................. 2 2.1  AAC Pumpcell Description Description .......... ............ .......... ........... ........... .......... ............ ........... . 2 2.2  AAC Pumpcell Process Process Description ........... ............ .......... ............ .......... ............ ....... 5 2.3  AAC Pumpcell Control Control Systems and Philosophies Philosophies........... ............ .......... ............. ...... 6 2.3.1 Pumpcell Plant Start Up ........................... ......................................... ............................ ........................... .......................... .............6 2.3.2 Lead Pumpcell Isolation ........................... ......................................... ............................ ........................... .......................... .............9 2.3.3 Pumpcell Drainage .......................... ....................................... ........................... ............................ ........................... .................... ....... 10 2.3.4 Tail Pumpcell Sequencing ........................... ......................................... ........................... ........................... ..................... ....... 10 2.3.5 Pumpcell Pumpcell Bypassing............ Bypassing .......................... ........................... ........................... ........................... ........................... ................... ..... 11 2.3.6 Regenerated Regenerated Carbon Return .......................... ........................................ ........................... ........................... ................... ..... 12 2.3.7 Plant Stoppage ........................... ......................................... ............................ ........................... ........................... ......................... ...........13

3

 AAC PUMPCELL DATA SHEET .......... .......... ............ ........... .......... ........... ........... ........ 14

4

SPARE PARTS........... .......... ........... ........... .......... ........... ........... ........... ........... .......... ... 15 4.1

5

UNPACKING A ND ASSEMBL Y PROCEDURE AFTER TRANSPORTATION. ............ 18 5.1 5.2 5.3 5.4 5.5 Partial

6

Spare Parts Numbering Designations ..................................................................... 15

Step 1 - Removal of the Rotating Cage Support A-Frame ................ ............ .......... 18 Step 2 - Removal of the front 1st shaft Locking Brackets ........... ............ ............ ..... 21 Step 3 - Removal of the Pump Support Brackets. ........... ............ ........... ............. .... 22 Step 4 - Removal of the Rotating Cage Locking Brackets ............ ............ ............ ... 24 Step 5 – Assembly of t he Kemix Interstage Screen from the Transported State of Assembly ................................................................................................................ 26

COMPLETE BREAK DOWN OF MECHANISM FOR ASSEMBLY ............. ............. ...... 27 6.1 Pre-Assembly requirements 1 to 8 .......................................................................... 27 6.1.1 Pre-Assemble 1: the Pulse Blades to the Rotating Cage .......... ........... ........... 27 6.1.2 Pre-Assemble 2: the Hydraulic Hydraulic Leg to Screen ................. ............ ........... ........ 29 6.1.3 Pre-Assemble 3: the Female Rigid Coupling to the Gearbox Output Shaft ..... 31 6.1.4 Pre-Assemble 4: the Gearbox to Base Plate .......... ........... ............ ........... ...... 32 6.1.5 Pre-Assembly 5: Assemble the pump ........... .......... ............ ........... ........... ...... 34 6.1.6 Pre-Assembly 6 – Assemble the pump coupling to the first shaft .. ............ ..... 36 6.1.7 Pre-Assemble 7: Agitator Blades Blades to agitator shaft....... ............ ........... ............ . 37 6.1.8 Pre-Assemble 8: Volute Interface Seal to Volute ........... ........... ........... ........... 38 6.2 Position the Volute into the maintenance maintenance structure ................ ........... .......... ............ 39 6.3 Position the Pumping Impeller into the Volute ............ .......... ............ ........... ............ 40 st 6.4  Assemble the 1  Shaft into Pumping Impeller ........... .......... ............ ........... ........... .. 42 6.5 Position the Internal Frame Frame Into the Volute .......... ........... ........... ........... .......... ........ 44 6.6  Assemble the Gearbox and and Base Plate Assembly Assembly onto the Internal Frame ............ 46 st 6.7  Assemble the Gearbox Gearbox coupling onto the 1  Shaft ................................................. 48 6.8  Assemble the Hydraulic Hydraulic Leg and Screen Assembly Assembly to the Volute .......... ............ ..... 50 st 6.9  Assemble the Rotating Rotating Cage to the 1  Shaft .......................................................... 52 6.10  Assemble Agitator to the Mechanism Mechanism ........... .......... ............ ........... ........... ........... .... 54

7 CHECKING AND A DJUSTMENT OF THE MPSP INTERSTAGE SCREEN BEFORE OPERATION.......................................................................................................................... 7.1 8

55

Perform Alignment Checks on Shaft and Rotating Cage .......... ........... ........... ......... 56

INSTALL ATION A ND REMOVAL OF AN AAC AA C PUMPCELL INTERSTAGE SCREEN. 57 8.1 Installation ............................................................................................................... 57 8.1.1 Open Hook Mounting Bracket and Hold Down Clamp .................... ............ .... 57 8.1.2 Lower And Position The Mechanism In The Tank............. Tank.......................... ........................... ................. ... 57 8.1.3 Position And Secure The Mechanism ........... .......... ............ ........... ........... ...... 57

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Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Table of Contents 1

CONTACT CONTACT DETAILS ........................... ........................................ ........................... ............................ ........................... ........................... ...................... ........1

2

INTRODUCTION .............................................................................................................. 2 2.1  AAC Pumpcell Description Description .......... ............ .......... ........... ........... .......... ............ ........... . 2 2.2  AAC Pumpcell Process Process Description ........... ............ .......... ............ .......... ............ ....... 5 2.3  AAC Pumpcell Control Control Systems and Philosophies Philosophies........... ............ .......... ............. ...... 6 2.3.1 Pumpcell Plant Start Up ........................... ......................................... ............................ ........................... .......................... .............6 2.3.2 Lead Pumpcell Isolation ........................... ......................................... ............................ ........................... .......................... .............9 2.3.3 Pumpcell Drainage .......................... ....................................... ........................... ............................ ........................... .................... ....... 10 2.3.4 Tail Pumpcell Sequencing ........................... ......................................... ........................... ........................... ..................... ....... 10 2.3.5 Pumpcell Pumpcell Bypassing............ Bypassing .......................... ........................... ........................... ........................... ........................... ................... ..... 11 2.3.6 Regenerated Regenerated Carbon Return .......................... ........................................ ........................... ........................... ................... ..... 12 2.3.7 Plant Stoppage ........................... ......................................... ............................ ........................... ........................... ......................... ...........13

3

 AAC PUMPCELL DATA SHEET .......... .......... ............ ........... .......... ........... ........... ........ 14

4

SPARE PARTS........... .......... ........... ........... .......... ........... ........... ........... ........... .......... ... 15 4.1

5

UNPACKING A ND ASSEMBL Y PROCEDURE AFTER TRANSPORTATION. ............ 18 5.1 5.2 5.3 5.4 5.5 Partial

6

Spare Parts Numbering Designations ..................................................................... 15

Step 1 - Removal of the Rotating Cage Support A-Frame ................ ............ .......... 18 Step 2 - Removal of the front 1st shaft Locking Brackets ........... ............ ............ ..... 21 Step 3 - Removal of the Pump Support Brackets. ........... ............ ........... ............. .... 22 Step 4 - Removal of the Rotating Cage Locking Brackets ............ ............ ............ ... 24 Step 5 – Assembly of t he Kemix Interstage Screen from the Transported State of Assembly ................................................................................................................ 26

COMPLETE BREAK DOWN OF MECHANISM FOR ASSEMBLY ............. ............. ...... 27 6.1 Pre-Assembly requirements 1 to 8 .......................................................................... 27 6.1.1 Pre-Assemble 1: the Pulse Blades to the Rotating Cage .......... ........... ........... 27 6.1.2 Pre-Assemble 2: the Hydraulic Hydraulic Leg to Screen ................. ............ ........... ........ 29 6.1.3 Pre-Assemble 3: the Female Rigid Coupling to the Gearbox Output Shaft ..... 31 6.1.4 Pre-Assemble 4: the Gearbox to Base Plate .......... ........... ............ ........... ...... 32 6.1.5 Pre-Assembly 5: Assemble the pump ........... .......... ............ ........... ........... ...... 34 6.1.6 Pre-Assembly 6 – Assemble the pump coupling to the first shaft .. ............ ..... 36 6.1.7 Pre-Assemble 7: Agitator Blades Blades to agitator shaft....... ............ ........... ............ . 37 6.1.8 Pre-Assemble 8: Volute Interface Seal to Volute ........... ........... ........... ........... 38 6.2 Position the Volute into the maintenance maintenance structure ................ ........... .......... ............ 39 6.3 Position the Pumping Impeller into the Volute ............ .......... ............ ........... ............ 40 st 6.4  Assemble the 1  Shaft into Pumping Impeller ........... .......... ............ ........... ........... .. 42 6.5 Position the Internal Frame Frame Into the Volute .......... ........... ........... ........... .......... ........ 44 6.6  Assemble the Gearbox and and Base Plate Assembly Assembly onto the Internal Frame ............ 46 st 6.7  Assemble the Gearbox Gearbox coupling onto the 1  Shaft ................................................. 48 6.8  Assemble the Hydraulic Hydraulic Leg and Screen Assembly Assembly to the Volute .......... ............ ..... 50 st 6.9  Assemble the Rotating Rotating Cage to the 1  Shaft .......................................................... 52 6.10  Assemble Agitator to the Mechanism Mechanism ........... .......... ............ ........... ........... ........... .... 54

7 CHECKING AND A DJUSTMENT OF THE MPSP INTERSTAGE SCREEN BEFORE OPERATION.......................................................................................................................... 7.1 8

55

Perform Alignment Checks on Shaft and Rotating Cage .......... ........... ........... ......... 56

INSTALL ATION A ND REMOVAL OF AN AAC AA C PUMPCELL INTERSTAGE SCREEN. 57 8.1 Installation ............................................................................................................... 57 8.1.1 Open Hook Mounting Bracket and Hold Down Clamp .................... ............ .... 57 8.1.2 Lower And Position The Mechanism In The Tank............. Tank.......................... ........................... ................. ... 57 8.1.3 Position And Secure The Mechanism ........... .......... ............ ........... ........... ...... 57

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Kemix Pty Ltd AAC Pumpcell Plant Operating Manual 8.1.4  Adjusting the Hook Hook Mounting bracket ............ .......... ............ ........... ............ .... 57 8.1.5 Tighten Hook Mounting Bracket and Hold Down Clamp ........... ............. ......... 58 8.2 Removal.................................................................................................................. 61 8.2.1 Open Hook Mounting Bracket and Hold Down Clamp .................... ............ .... 61 8.2.2 Lift the Interstage Screen Out Of The Tank ..................... ........... ............ ........ 61 9

MAINTENANCE A ND INSPECTION PROCEDURE PROCEDURE............ ........... ........... ........... ......... 62 9.1 Maintenance and Inspection Procedure during normal operation ................... ........ 62 9.1.1 Maintenance and Inspection of the Wedge Wire Screen ............. ............. ...... 62 9.1.2 Maintenance and Inspection of the Drive Unit. .................... ........... ............ .... 64 9.1.3 Maintenance and Inspection of the Protective coatings of Entire Interstage Screen Assembly. .......................................................................................................... 64 9.2 Maintenance and Inspection Procedure during Storage.............. Storage........................... ........................... ................ 65 9.2.1 Maintenance and Inspection of the Drive Unit during Storage ............... ......... 65 9.2.2 Maintenance and Inspection of the Entire Interstage Screen Assembly during Storage 65

10 10.1 11

SPARES REPLACEMENT PROCEDURES .............................................................. 66 Wedge-Wire Screen Replacement .......................................................................... 66 INSTALL ATION A ND MAINTENANCE INSTRUCTIONS INSTRUCTIONS FOR ELECTRIC MOTORS 69

11.1 Receiving Check ..................................................................................................... 69 11.2 Handling and Transportation ................................................................................... 69 11.3 Storage Storage .......................... ....................................... ........................... ............................ ........................... ........................... ........................... ..................... ........69 11.4 Insulation Resistance Check ................................................................................... 70 11.5 Installation ............................................................................................................... 70 11.5.1 Safety Safety .......................... ........................................ ........................... ........................... ........................... ........................... ............................ ................ 70 11.5.2 Operating Conditions ............ ........... .......... ............ .......... ............ ........... ........ 70 11.5.3 Foundation ..................................................................................................... 71 11.5.4 Drain Holes.......... .......... ........... ............ .......... ........... ........... ........... ........... .... 71 11.5.5 Balancing ........................................................................................................ 71 11.5.6  Alignment .......... ........... .......... ........... ............ .......... ........... ........... ........... ...... 71 11.5.7 Belt Drive ........... ............ .......... ........... ........... .......... ........... ........... .......... ....... 72 11.5.8 Connection ..................................................................................................... 72 11.5.9 Starting Methods ............................................................................................ 72 11.5.10 Start-Up ...................................................................................................... 73 11.6 Maintenance ........................................................................................................... 74 11.6.1 General Inspection ......................................................................................... 74 11.7 LUBRICATION ........................................................................................................ 74 11.7.1 Machines without without Grease Nipples Nipples .................. ............ ........... ............ ............ . 74 11.7.2 Machines Fitted with with Grease Nipples ............ ........... ........... ........... ............ .... 74 ® 11.7.3 Compatibility Compatibility of Polyrex  EM grease with other types of grease ............. ........ 76 11.8  ASSEMBLY AND AND DISASSEMBLY DISASSEMBLY .......... .......... ........... ............ .......... ........... .......... 76 11.9 SPARE PARTS.......... ............ .......... ........... ........... .......... ........... ........... .......... ....... 77 11.10 MOTORS FOR HAZARDOUS LOCATIONS.......... ............ ........... .......... ............ .... 77 11.10.1 Installation .................................................................................................. 77 11.10.2 Maintenance ............................................................................................... 77 11.11 MOTORS DRIVEN BY VFD .................................................................................... 78 11.11.1 Standard Motors ......................................................................................... 78 11.11.2 Inverter Duty Motors ................................................................................... 78 11.12 WARRANTY TERMS - SERIES AND ENGINEERING ENGINEERING PRODUCTS ..... ............. .... 78 12

BOLT TORQUE TORQUE TABLE ........................... ........................................ ........................... ........................... ........................... ......................... ........... 80

13

TOOLS REQUIREMENT............................................................................................ 80

14

TECHNICAL DRAWINGS 1 – G.A OF AAC AA C PUMPCELL PL ANT ............. .............. .. 81

15

TECHNICAL DRAWINGS 1 – G.A OF A AC PUMPCELL MECHANISM........... ........ 82

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Kemix Pty Ltd AAC Pumpcell Plant Operating Manual 16

TECHNICAL DRAWINGS 3 – P & I D AND PFD ........................ ........................ ........ 83

18

GEARBOX OPERATING INSTRUCTIONS ............................................................... 84

19

LUBRICATION SCHEDULE ...................................................................................... 85

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Kemix Pty Ltd Interstage Screen Operating Manual

1

CONTACT DETAILS

Kemix may be contacted directly at: KEMIX HOUSE 47 KYALAMI BOULEVARD KYALAMI BUSINESS PARK MIDRAND P O BOX 31949 Kyalami 1684 South Africa Tel: (+27 11) 466-2490 Fax: (+27 11) 466-2190 Email: [email protected]

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Kemix Pty Ltd Interstage Screen Operating Manual

2 2.1

INTRODUCTION AAC Pumpcell Descrip tion

The ability of activated carbon to adsorb gold from a cyanide solution has been known for over one hundred years. However, it was not until the 1950’s that carbon based processes began to attract attention in the gold mining industry, when it was demonstrated by the US Bureau of Mines that gold and silver could be recovered directly from pulp onto granules of activated carbon. There are three basic carbon adsorption processes used in the gold mining industry today, carbon in pulp (CIP), carbon in leach (CIL) and carbon in columns (CIC). The first two processes recover gold directly from pulps or slurries containing up to 55 % solids, while the CIC process is used for the treatment of solution. Kemix (Pty) Ltd (Kemix) in conjunction with Anglo American Corporation (AAC) developed the Mineral Processing Separating (MPS) and Mineral Processing Separating (Pumping) (MPS(P)) Interstage Screens. The MPS and MPS(P) Interstage Screens are typically utilised in CIP and CIL applications to separate activated carbon from gold bearing pulp in leach or adsorption contactors. The development of the MPS(P) Interstage Screen was instrumental in the ultimate development of the AAC Pumpcell. The AAC Pumpcell is in essence a complete CIP plant incorporating a Pumpcell mechanism and launder system enabling the carousel mode of operation to be employed. The design of the AAC Pumpcell circuit allows for all contactors to be placed at the same evaluation, in contrast to the stepped arrangement used for conventional cascade CIP adsorption plants. This feature facilitates the carousel mode of operation, that is the pulp feed and tailings discharge positions are rotated in such a manner that a counter current movement of pulp and carbon is achieved without the need to physically move carbon from one Pumpcell to another. The carousel mode of operation has been shown to result in significant improvements in adsorption efficiency, due to the elimination of 'backmixing' inherent in the conventional CIP circuits. The Pumpcell mechanism consists of a drive unit combining the three functions of pumping, screen cleaning and agitation on one common drive shaft. The pumping impeller is a mixflo type specially designed to handle high flowrates at a low tip speed. The up-pumping impeller operates in a stable manner over a wide range of flow conditions. The up-pumping impeller develops a head in the open volute, which is connected to the internal launder, sufficient to overcome launder losses and allows for the velocity flow of pulp to the next contactor. The pitch blade turbine ensures that pulp contained within the screen is maintained in a fully suspended state even when there is no pulp flow through the mechanism. In the event of a plant stoppage the pulp inside the screen may settle out, this pulp is re-suspended when the drive unit is restarted. The Pumpcell mechanism can therefore be operated at reduced pulp flowrates without the settling of pulp occurring inside the cylindrical screen.

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Kemix Pty Ltd Interstage Screen Operating Manual The unique rotating cage sets up a pulse and sweeping action around the screen, which keeps carbon off the screen. These features reduce the possibility of carbon or grit pegging in the screen apertures, which in turn ensures that pulp flowrate through the screen, is maintained. The screen is manufactured from stainless steel wedge wire. Attached to the bottom of the screen and around the shaft is a hydraulic seal. The hydraulic seal is a static pipe which passes through the center of the pumping impeller extending up beyond the pulp operating level thus forming a very effective seal which has no moving parts.  Attached to the bottom of the shaft is a down pumping hydrofoil. This hydrofoil is situated in the cell to ensure that an efficient high velocity flow pattern is achieved and maintained thus reducing the possibility to pulp and carbon settlement occurring within the cell. The Pumpcell tank comprises of an internal launder system, discharge and feed pipes, launder gates and plug valves. The internal launder is arranged such that it facilitates the individual functions of feeding pulp to the Pumpcell, discharging pulp from the Pumpcell and bypassing the Pumpcell in the event of taking the particular Pumpcell off line. This launder connects the adjacent Pumpcells together. The nature of this launder arrangement enables the carousel mode of operation to be employed.

Figure 1 – The AAC Pumpcell mech anism i n a tank

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Kemix Pty Ltd Interstage Screen Operating Manual

Figure 2 – The Cross Section View of AAC Pumpcell mechanism

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Kemix Pty Ltd Interstage Screen Operating Manual

2.2

AAC Pumpcell Process Descript ion

Pulp should be screened either prior to or post the leach circuit to remove grit or fibrous material present in the CIP feed. The screened pulp exiting the leach circuit either gravitates or is pumped to the AAC Pumpcell feed launder. The lead Pumpcell receives fresh pulp from the feed launder which is located above the Pumpcell top platform. The feed launder valve arrangement directs the flow of pulp into the desired Pumpcell. The pulp enters the Pumpcell via a feed box and feed pipe and is directed to an area below the down pumping hydrofoil, thus reducing the possibility of short circuiting. The down pumping hydrofoil imparts sufficient energy into the pulp resulting in good mixing of the pulp and carbon which in turn results in gold being adsorbed onto the carbon.  As all the Pumpcells are at the same horizontal elevation the cascade flow of pulp between the individual Pumpcells is not possible. The movement of pulp between the Pumpcells is effected by the Pumpcell mechanism. Pulp is drawn through the wedge wire screen by virtue of the up-pumping impeller developing a head in the open volute, which is connected to the internal launder. The head created is sufficient to overcome launder losses and allows for the velocity flow of pulp to the next Pumpcell. The wedge wire screen aperture is appropriately sized to allow for the flow of pulp through the screen while ensuring that the carbon remains in the Pumpcell as a discreet batch. The pulp is pumped through all the stages in the Pumpcell circuit. The pulp exiting the last Pumpcell in the carousel sequence is directed via a residue valve and manifold to the residue linear or vibrating screen. When the gold on carbon loading in the lead Pumpcell has reached the predetermined value the lead Pumpcell is isolated and the feed material will be directed to the second Pumpcell in the carousel sequence. The isolation of the lead Pumpcell and direction of the feed to the second Pumpcell is achieved by opening and closing the appropriate gate and plug valves. This procedure will be detained in Section 2.3.2, Operating Philosophy. The second Pumpcell effectively becomes the new lead Pumpcell. The entire contents of the lead Pumpcell is drained and pumped via a recessed impeller pump to the loaded carbon screen. The loaded carbon typically gravitates into a loaded carbon hopper from where it is directed to the elution and regeneration circuits prior to been returned to the Pumpcell circuit. When the content of the original lead Pumpcell has been drained and the Pumpcell is brought back on line as the new tail Pumpcell. Putting the original lead Pumpcell on line as the new tail Pumpcell is achieved by opening and closing the appropriate gate and plug valves and replenishing the Pumpcell with a predetermined amount of regenerated or virgin carbon. This procedure will be detained in Section 2.3.4, Operating Philosophy. During the draining of the lead Pumpcell the entire Pumpcell plant operates with one cell less in the carousel sequence. It is therefore prudent to get the original lead Pumpcell back on line as the new tail cell in as short a time period as is practically possible thereby not negatively impacting on the overall metallurgical performance of the Pumpcell plant.

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Kemix Pty Ltd Interstage Screen Operating Manual

2.3

AAC Pumpcell Control Systems and Philosophies

The Pumpcell operating philosophy will detail the procedure and valve sequencing required when performing the following tasks :      

Pumpcell Plant Start Up. Head Pumpcell Isolation. Head Pumpcell Drainage. Tail Pumpcell Sequencing. Pumpcell Bypassing. Plant Stoppage.

For the purposes of this exercise Pumpcell No. 1, (922 – TK – 114), will be the head Pumpcell and Pumpcell No. 8, (922 – TK – 107), will be the tail Pumpcell.

2.3.1 Pumpcell Plant Start Up  

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Prior to starting the Pumpcell plant, ensure that the residue section is prepared to receive and dispose of pulp. Identify which Pumpcell is to be the head, second, third, fourth, fifth, sixth, seventh and eighth Pumpcells. For the purpose of this example Pumpcell 1, (922 – TK – 114), will be the head Pumpcell and Pumpcell 8, (922 – TK – 107), will be the tail Pumpcell. Ensure that the predetermined amount of carbon is available to be added to each Pumpcell once pulp has been introduced into the Pumpcell. All Pumpcell drive motors must be stopped. The manual loaded carbon drain diaphragm valves on all eight the Pumpcells must be opened. The manual loaded carbon drain diaphragm valves to be opened are (922 – 150 – HD – 107), (922 – 150 – HD – 207), (922 – 150 – HD – 307), (922 – 150 – HD – 407), (922 – 150 – HD – 507), (922 – 150 – HD – 607), (922 – 150 – HD – 707) and (922 – 150 – HD – 807). The automated loaded carbon drain diaphragm valves on all eight the Pumpcells must be closed. The automated loaded carbon diaphragm valves to be closed are (922 – 150 – HD – 108), (922 – 150 – HD – 208), (922 – 150 – HD – 308), (922 – 150 – HD – 408), (922 – 150 – HD – 508), (922 – 150 – HD – 608), (922 – 150 – HD – 708) and (922 – 150 – HD – 808). Open the automated feed plug valves on Pumpcell No. 2, (922 – TK – 113), to Pumpcell No. 8, (922 – TK – 107), in the carousel sequence. The automated feed plug valves to be opened are (922 – 300 – KXHP – 201), (922 – 300 – KXHP – 301), (922 – 300 – KXHP – 401), (922 – 300 – KXHP – 501), (922 – 300 – KXHP – 601), 922 – 300 – KXHP – 701) and (922 – 300 – KXHP – 801). Close the automated feed plug valve on the head Pumpcell, Pumpcell No. 1, (922 – TK – 114).The automated feed plug valve to be closed is (922 – 300 – KXHP – 101). Open the manual Pumpcell Mechanism discharge gate valves on all eight the Pumpcells. The manual Pumpcell Mechanism discharge gate valves to be opened are (922 – 450 – KXHG – 106), (922 – 450 – KXHG – 206), (922 – 450 – KXHG – 306), (922 – 450 – KXHG – 406), (922 – 450 – KXHG – 506), (922 – 450 – KXHG – 606), (922 – 450 – KXHG – 706) and (922 – 450 – KXHG – 806). Close the automated residue plug valves on Pumpcell No. 1, (922 – TK – 114), to Pumpcell No.7, (922 – TK – 108), in the carousel sequence. The automated residue plug valves to be closed are (922 – 300 – KXHP – 102),

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Kemix Pty Ltd Interstage Screen Operating Manual

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(922 – 300 – KXHP – 202), (922 – 300 – KXHP – 302), (922 – 300 – KXHP – 402), (922 – 300 – KXHP – 502), (922 – 300 – KXHP – 602) and (922 – 300 – KXHP – 702). Open the automated residue plug on the tail Pumpcell in the carousel sequence, Pumpcell No. 8, (922 – TK – 107). The automated residue plug valve to be opened is (922 – 300 – KXHP – 802). Close the manual bypass gate valves on all eight the Pumpcells. The manual bypass gate valves to be closed are (922 – 400 – KXHG – 104), (922 – 400 – KXHG – 105), (922 – 400 – KXHG – 204), (922 – 400 – KXHG – 205), (922 – 400 – KXHG – 304), (922 – 400 – KXHG – 305), (922 – 400 – KXHG – 404), (922– 400 – KXHG – 405), (922 – 400 – KXHG – 504), (922 – 400 – KXHG – 505), (922 – 400 – KXHG – 604), (922 – 400 – KXHG – 605), (922 – 400 – KXHG – 704), (922 – 400 – KXHG – 705), (922 – 400 – KXHG – 804) and (922 – 400 – KXHG – 805). Open the automated interconnecting tank gate valves on Pumpcells No. 1, (922 – TK – 114) to Pumpcell No. 7 (922 – TK – 108) in the carousel sequence. The automated interconnecting tank gate valves to be opened are (922 – 450 – KXHG – 103), (922 – 450 – KXHG – 203), (922 – 450 – KXHG – 303), (922 – 450 – KXHG – 403), (922 – 450 – KXHG – 503), (922 – 450 – KXHG – 603) and (922 – 450 – KXHG – 703). Close the automated interconnecting tank gate valve on the tail Pumpcell, Pumpcell No. 8, (922 – TK – 107), in the carousel sequence. The automated interconnecting tank gate valve to be closed is (922 – 450 – KXHG – 803). Open the automated feed launder plug valve feeding the head Pumpcell, Pumpcell No. 1 (922 – TK – 114). The automated feed launder plug valve to be opened is (922 – 250 – KXHP – 001). Close the automated feed launder plug valves feeding Pumpcell No. 2, (922 – TK – 113), to Pumpcell No. 8, (922 – TK – 107), in the carousel sequence. The automated feed launder plug valves to be closed are (922 – 250 – KXHP – 003), (922 – 250 – KXHP – 005), (922 – 250 – KXHP – 007), (922 – 250 – KXHP – 009), (922 – 250 – KXHP – 011), (922 – 250 – KXHP – 013) and (922 – 250 – KXHP – 015). Close all the automated feed launder isolation gate valves. The automated feed launder isolation gate valves to be closed are (922 – 400 – KXHG – 002), (922 – 400 – KXHG – 004), (922 – 400 – KXHG – 006), (922 – 400 – KXHG – 008), (922 – 400 – KXHG – 010), (922 – 400 – KXHG – 012) and (922 – 400 – KXHG – 014). On completion of the above steps, the carousel valve sequencing can be considered complete. Pulp can now be introduced into the Pumpcell plant. The feed to the Pumpcell plant can be initiated. When pulp enters the head Pumpcell, Pumpcell No. 1, (922 – TK – 114), in the carousel sequence the predetermined amount of carbon is added to the Pumpcell. When the hydrofoil is submerged by pulp in the head Pumpcell, Pumpcell No. 1, (922 – TK – 114), the Pumpcell Mechanism, (922 – SC – 114), drive motor must be started. When the pulp level in the head Pumpcell, Pumpcell No. 1, (922 – TK – 114), approaches the same vertical elevation as the pumping impeller, pulp will be pumped to the second Pumpcell, Pumpcell No. 2 (922 – TK – 113), in the carousel sequence.

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Kemix Pty Ltd Interstage Screen Operating Manual 

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When pulp enters the second Pumpcell, Pumpcell No. 2, (922 – TK – 113), in the carousel sequence the predetermined amount of carbon is added to the Pumpcell. When the hydrofoil is submerged by pulp in the second Pumpcell, Pumpcell No. 2, (922 – TK – 113), the Pumpcell Mechanism, (922 – SC – 113), drive motor must be started. When the pulp level in the second Pumpcell, Pumpcell No. 2, (922 – TK – 113), approaches the same vertical elevation as the pumping impeller, pulp will be pumped to the third Pumpcell, Pumpcell No. 3 (922 – TK – 112), in the carousel sequence. When pulp enters the third Pumpcell, Pumpcell No. 3, (922 – TK – 112), in the carousel sequence the predetermined amount of carbon is added to the Pumpcell. When the hydrofoil is submerged by pulp in the third Pumpcell, Pumpcell No. 3, (922 – TK – 112), the Pumpcell Mechanism, (922 – SC – 112), drive motor must be started. When the pulp level in the third Pumpcell, Pumpcell No. 3, (922 – TK – 112), approaches the same vertical elevation as the pumping impeller, pulp will be pumped to the fourth Pumpcell, Pumpcell No. 4 (922 – TK – 111), in the carousel sequence. When pulp enters the fourth Pumpcell, Pumpcell No. 4, (922 – TK – 111), in the carousel sequence the predetermined amount of carbon is added to the Pumpcell. When the hydrofoil is submerged by pulp in the fourth Pumpcell, Pumpcell No. 4, (922 – TK – 111), the Pumpcell Mechanism, (922 – SC – 111), drive motor must be started. When the pulp level in the fourth Pumpcell, Pumpcell No. 4, (922 – TK – 111), approaches the same vertical elevation as the pumping impeller, pulp will be pumped to the fifth Pumpcell, Pumpcell No. 5 (922 – TK – 110), in the carousel sequence. When pulp enters the fifth Pumpcell, Pumpcell No. 5, (922 – TK – 110), in the carousel sequence the predetermined amount of carbon is added to the Pumpcell. When the hydrofoil is submerged by pulp in the fifth Pumpcell, Pumpcell No. 5, (922 – TK – 110), the Pumpcell Mechanism, (922 – SC – 110), drive motor must be started. When the pulp level in the fifth Pumpcell, Pumpcell No. 5, (922 – TK – 110), approaches the same vertical elevation as the pumping impeller, pulp will be pumped to the sixth Pumpcell, Pumpcell No. 6 (922 – TK – 109), in the carousel sequence. When pulp enters the sixth Pumpcell, Pumpcell No. 6, (922 – TK – 109), in the carousel sequence the predetermined amount of carbon is added to the Pumpcell. When the hydrofoil is submerged by pulp in the sixth Pumpcell, Pumpcell No. 6, (922 – TK – 109), the Pumpcell Mechanism, (922 – SC – 109), drive motor must be started. When the pulp level in the sixth Pumpcell, Pumpcell No. 6, (922 – TK – 109), approaches the same vertical elevation as the pumping impeller, pulp will be pumped to the seventh Pumpcell, Pumpcell No. 7 (922 – TK – 108), in the carousel sequence. When pulp enters the seventh Pumpcell, Pumpcell No. 7, (922 – TK – 108), in the carousel sequence the predetermined amount of carbon is added to the Pumpcell.

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Kemix Pty Ltd Interstage Screen Operating Manual 

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When the hydrofoil is submerged by pulp in the seventh Pumpcell, Pumpcell No. 7, (922 – TK – 108), the Pumpcell Mechanism, (922 – SC – 108), drive motor must be started. When the pulp level in the seventh Pumpcell, Pumpcell No. 7, (922 – TK – 108), approaches the same vertical elevation as the pumping impeller, pulp will be pumped to the tails Pumpcell, Pumpcell No. 8 (922 – TK – 107), in the carousel sequence. When pulp enters the tails Pumpcell, Pumpcell No. 8, (922 – TK – 107), in the carousel sequence the predetermined amount of carbon is added to the Pumpcell. When the hydrofoil is submerged by pulp in the tails Pumpcell, Pumpcell No. 8, (922 – TK – 107), the Pumpcell Mechanism, (922 – SC – 107), drive motor must be started. When the pulp level in the tails Pumpcell, Pumpcell No. 8, (922 – TK – 107), approaches the same vertical elevation as the pumping impeller, pulp will be pumped via the automated residue plug valve (922 – 300 – KXHP – 802), to the residue manifold. The Pumpcell plant is now considered on line. The predetermined and regular sampling campaign can now commence. Periodic inspection for traces of carbon on the residue screen will be required to determine if carbon is leaking through the interstage screens. Periodic carbon inventory sampling is required to determine if a Pumpcell is leaking carbon to the succeeding Pumpcell.

2.3.2 Lead Pumpcell Isolati on 

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The lead Pumpcell is isolated after either a predetermined time period or when the gold on carbon loading within that Pumpcell, (Pumpcell No. 1, (922 – TK – 114), has achieved a level suitable for transferring the loaded carbon to the elution circuit. Open the automated feed launder plug valve feeding the second Pumpcell, Pumpcell No. 2 (922 – TK – 113), in the carousel sequence. The automated feed launder plug valve that must open is (922 – 250 – KXHP – 005). Open the two automated feed launder gate isolation valves allowing pulp to gravitate to the second Pumpcell, Pumpcell 2, (922 – TK – 113) in the carousel sequence. The two automated feed launder gate isolation valves that must be opened are (922 – 400 – KXHG – 002) and (922 – 400 – KXHG – 004). Close the automated feed launder plug valve feeding the original head Pumpcell, Pumpcell No. 1, (922 – TK – 114), in the carousel sequence. The automated feed launder plug valve that must close is (922 – 250 – KXHP – 001). Close the automated feed plug valve on the new head Pumpcell, Pumpcell No. 2, (922 – TK – 113). The automated feed plug valve to be closed is (922- 300 – KXHP – 201). Close the automated interconnecting tank gate valve between the original head Pumpcell No. 1, (922 – TK – 114), and second Pumpcell, Pumpcell No. 2, (922 – TK – 113), in the carousel sequence. The automated interconnecting tank gate valve that must close is (922 – 450 – KXHG – 103). The original head Pumpcell, Pumpcell No. 1, (922 – TK – 114), in the carousel sequence is isolated. The Pumpcell Mechanism, (922 – SC – 114), drive motor must not be stopped, the pulp and carbon must be suspended to allow for the efficient drainage of the isolated Pumpcell. The second Pumpcell, Pumpcell No. 2, (922 – TK – 113), in the carousel sequence the new head Pumpcell.

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Kemix Pty Ltd Interstage Screen Operating Manual 

The Pumpcell plant is effectively operating with seven Pumpcells on line. It is therefore imperative that the following two Operating Procedures, Head Pumpcell Drainage and Tail Pumpcell Sequencing be performed expediently thus ensuring that all eight Pumpcells are brought on line to ensure that metallurgical efficiencies are maximised.

2.3.3 

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Pumpcell Drainage

Prior to draining the original head Pumpcell, Pumpcell No. 1, (922 – TK – 114), ensure that the loaded carbon screen is ready to receive pulp and that there is sufficient capacity in the loaded carbon hopper to receive a batch of loaded carbon. Start the loaded carbon screen. Start the loaded carbon drain pump. Open the automated loaded carbon diaphragm drain valve on the original head Pumpcell, Pumpcell No. 1, (922 – TK – 114). The automated loaded carbon diaphragm drain valve that must be opened is (922- 150 – HD – 108). Ensure that there is sufficient wash water on the loaded carbon screen to wash all entrapped pulp form the loaded carbon. When the pulp level in the original head Pumpcell, Pumpcell No. 1, (922 – TK – 114), approaches the same elevation as the hydrofoil, the Pumpcell Mechanism, (922 – SC – 114), drive motor must be stopped. When the pulp level in the original head Pumpcell, Pumpcell No. 1, (922 – TK – 114), approaches the loaded carbon discharge manifold it is recommended that the Pumpcell be hosed out with water to ensure that all the loaded carbon exits the Pumpcell and is recovered on the loaded carbon screen. When the original head Pumpcell, Pumpcell No. 1, (922 – TK – 114), is empty the washing is terminated. Close the automated loaded carbon diaphragm drain valve on the original head Pumpcell, Pumpcell No. 1, (922 – TK – 114). The automated loaded carbon diaphragm drain valve that must be closed is (922- 150 – HD – 108). Stop the loaded carbon pump. Stop the loaded carbon screen. The original head Pumpcell, Pumpcell No. 1, (922 – TK – 114), is ready to be brought back on line as the new tail Pumpcell.

2.3.4 Tail Pumpc ell Sequencing 

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Ensure that the predetermined amount of carbon is available to be added to the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114), once pulp is introduced into this Pumpcell. Open the automated feed plug valve on the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114). The automated feed plug valve to be opened is (922- 300 – KXHP – 101). Open the manual Pumpcell Mechanism discharge gate valve on the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114). The manual Pumpcell Mechanism discharge gate valve to be opened is (922 – 450 – KXHG – 106). Open the automated residue plug valve on the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114). The automated residue plug valve to be opened is (922 – 300 – KXHP – 102). Close the manual bypass gate valves on the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114). The manual bypass gate valves to be closed are

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Kemix Pty Ltd Interstage Screen Operating Manual

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(922 – 400 – KXHG – 104) and (922 – 400 – KXHG – 105). Close the automated interconnecting tank gate valve on the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114), in the carousel sequence. The automated interconnecting tank gate valve to be closed is (922 – 450 – KXHG – 103). Open the automated interconnecting tank gate valve between the original tail Pumpcell, Pumpcell No. 8, (922 – TK – 107), and the original head Pumpcell, Pumpcell No. 1, (922 – TK – 114). The automated interconnecting tank gate valve to be opened is (922 – 450 – KXHG – 803). Close the automated residue plug valve on the original tail Pumpcell, Pumpcell 8, (922 – TK – 107), in the carousel sequence. The automated residue plug valve to be closed is (922 – 300 – KXHP – 802). Pulp will now be pumped from the original tail Pumpcell, Pumpcell No. 8, (922 – TK – 107), to the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114). When pulp enters the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114), in the carousel sequence the predetermined amount of carbon is added to the Pumpcell. When the hydrofoil is submerged by pulp in the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114), the Pumpcell Mechanism, (922 – SC – 114), drive motor must be started. When the pulp level in the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114), approaches the same vertical elevation as the pumping impeller, pulp will be pumped via the automated residue plug valve (922 – 300 – KXHP – 102), to the residue manifold. The Pumpcell plant is back on line. Regular sampling and observations can commence.

2.3.5 Pumpcell Byp assin g  A Pumpcell is bypassed if it is expected that the Pumpcell in question has a damaged wedge wire screen and is leaking carbon into the next Pumpcell or if the drive mechanism has failed. The Pumpcell Plant design allows for the changing of a complete Pumpcell mechanism without having to interrupt the feed to the plant. The Pumpcell in question is bypassed and the mechanism is removed and replaced by a mechanism that is maintained in good working order and is located in the maintenance bay (922 – MB – 001) provided. For the purpose of this example Pumpcell No. 1, (922 – TK – 114), will be the head Pumpcell and Pumpcell 8, (922 – TK – 107), will be the tail Pumpcell. Pumpcell No. 2, (922 – TK – 113), will be the Pumpcell that has a damaged wedge wire screen or drive mechanism and therefore requires replacement. 

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Open the manual bypass gate valves on the Pumpcell No. 2, (922 – TK – 113). The manual bypass gate valves that must be opened are (922 – 400 – KXHG – 204) and (922 – 400 – KXHG – 205). Close the automated feed plug valve on Pumpcell No. 2, (922 – TK – 113).The automated feed plug valve that must be closed is (922 – 300 – KXHP – 201). Stop the Pumpcell Mechanism, (922 – SC – 113), drive motor. Close the manual Pumpcell Mechanism discharge gate valve on Pumpcell No. 2, (922 – TK – 113). The manual Pumpcell Mechanism discharge gate valve that must be closed is (922 – 450 – KXHG – 206). Pumpcell No. 2, (922 – TK – 113), is effectively being bypasses. Pulp exiting the head Pumpcell, Pumpcell No. 1, (922 – TK – 114), bypasses Pumpcell No. 2, (922 – TK – 113), and is fed into Pumpcell No. 3, (922 – TK – 112).

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Kemix Pty Ltd Interstage Screen Operating Manual   

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The malfunctioning Pumpcell Mechanism, (922 – SC – 113), is lifted out of Pumpcell No. 2, (922 – TK – 113), by means of the crane. The malfunctioning Pumpcell Mechanism, (922 – SC – 113), is placed in the Maintenance Bay, (922 – MB – 001). The spare Pumpcell Mechanism, (922 – SC – 106), is hoisted from the Maintenance Bay, (922 – MB – 001), and placed into Pumpcell No. 2, (922 – TK – 113), by means of the crane. With the spare Pumpcell Mechanism, (922 – SC – 106), correctly inserted into Pumpcell No. 2, (922 – TK – 113), this Pumpcell is brought back on line. Open the manual Pumpcell Mechanism discharge gate valve on Pumpcell No. 2, (922 – TK – 113). The manual Pumpcell Mechanism discharge gate valve that must be opened is (922 – 450 – KXHG – 206). Start the spare Pumpcell Mechanism, (922 – SC – 106), drive motor. Open the automated feed plug valve on Pumpcell No. 2, (922 – TK – 113). The automated feed plug valve that must be opened is (922 – 300 – KXHP – 201). Close the manual bypass gate valves on the Pumpcell No. 2, (922 – TK – 113). The manual bypass gate valves that must be closed are (922 – 400 – KXHG – 204) and (922 – 400 – KXHG – 205). Pumpcell No. 2, (922 – TK – 113), is back on line. It is important to repair the damage to the malfunctioning Pumpcell Mechanism, (922 – SC – 113). A mechanism that is in working order must always be available in the Maintenance Bay, (922 – MB – 001), thus preventing any prolonged Pumpcell bypassing from occurring in the event of unforeseen Pumpcell Mechanism malfunctions or routine maintenance.

2.3.6 Regenerated Carbo n Return The Pumpcell circuit is equipped with an automated Regenerated Carbon Return manifold. This manifold is used to direct virgin or regenerated carbon from the elution circuit to a new tail Pumpcell. For the purpose of this example, Pumpcell No. 1, (922 – TK – 114), will be the new tail Pumpcell requiring regenerated carbon from the elution circuit while in the process of being brought back on line.  

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This sequence can only be performed in parallel with sequence “5.4 Tail Pumpcell Sequencing”. Open the automated regenerated carbon return diaphragm valve feeding the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 113). The automated regenerated carbon return diaphragm valve is (922 – 75 – HD – 016). Close the remaining automated regenerated carbon return diaphragm valves feeding the remainder of the Pumpcell circuit. The automated regenerated carbon return diaphragm valves that are to be closed are (922 – 75 – HD – 017), (922 – 75 – HD – 018), (922 – 75 – HD – 019), (922 – 75 – HD – 020), (922 – 75  – HD – 021), (922 – 75 – HD – 022), (922 – 75 – HD – 023), (922 – 75 – HD – 024), (922 – 75 – HD – 025), (922 – 75 – HD – 026) and (922 – 75 – HD – 027). Open the regenerated carbon isolation valve feeding Pumpcells 1 – 4, (922 – TK – 114) to (922 – TK – 111), valve (by others). Close the regenerated carbon isolation valve feeding Pumpcells 5 – 8, (922 – TK – 110) to (922 – TK – 107), valve (by others). A predetermined volume of regenerated carbon is transferred from the elution circuit via the regenerated carbon return manifold, through the automated regenerated carbon return diaphragm valve, (922 – 75 – HD – 016), feeding the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114).

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Kemix Pty Ltd Interstage Screen Operating Manual 

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Once the regenerated carbon has been transferred to the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114), the regenerated carbon return line must be flushed. Once the regenerated carbon return line has been flushed, the automated regenerated carbon return diaphragm valve feeding the new tail Pumpcell, Pumpcell No. 1, (922 – TK – 114), must be closed. The regenerated carbon return diaphragm valve to be closed is (922 – 75 – HD – 016).

2.3.7 Plant Stopp age When the feed to the Pumpcell circuit is stopped, the pulp level throughout the circuit equalizes. The equalization involves the back flow of pulp and carbon through a Pumpcells open feed plug valve, the pulp will flow back through the interconnecting launder and eventually enter the Pumpcell mechanism. As it is not desirable to get back flow of pulp and carbon into the superseding Pumpcell mechanism, a procedure is required to prevent this pulp and carbon back flow. This procedure involves the closing of all automated feed plug valves and automated interconnecting launder gate valves. With the before mentioned valves in the closed position, the back flow of pulp and carbon through the circuit will be eliminated. The procedure detailing valve sequencing that should be adopted during a plant stoppage is as follows: For the purposes of this exercise Pumpcell No.1, (922 – TK – 114), will be the head Pumpcell and Pumpcell No. 8, (922 – TK – 107), will be the tail Pumpcell. Plant Stoppage 

The automated feed plug valve on Pumpcell No. 1, (922 – TK – 114), will be in the closed position, valve (922 – 300 – KXHP – 101). This valve must remain closed when the Plant Stoppage procedure is initiated.  The automated feed plug valves on Pumpcells No. 2, (922 – TK – 113), to Pumpcell No. 8, (922 – TK - 107), must be closed. The automated feed plug valves to be closed are valves (922 – 300 – KXHP – 201), (922 – 300 – KXHP – 301), (922 – 300 – KXHP – 401), (922 – 300 – KXHP – 501), (922 – 300 – KXHP – 601), (922 – 300 – KXHP – 701) and (922 – 300 – KXHP – 801).  The automated interconnecting gate valve between Pumpcell No. 8, (922 – TK – 107), and Pumpcell No. 1, (922 – TK – 114), will be in the closed position, valve (922 – 450 – KXHG – 803). This valve must remain closed when the Plant Stoppage procedure is initiated.  The automated interconnecting gate valves on Pumpcells No. 1, (922 – TK – 114), to Pumpcell No. 7, (922 – TK - 108), must be closed. The automated interconnecting gate valves to be closed are valves (922 – 450 – KXHG – 103), (922 – 450 – KXHG – 203), (922 – 450 – KXHG – 303), (922 – 450 – KXHG – 403), (922 – 450 – KXHG – 503), (922 – 450 – KXHG – 603) and (922 – 450 – KXHG – 703). The AAC Pumpcell operating philosophy will detail the procedure and valve sequencing required when performing the tasks.

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Kemix Pty Ltd Interstage Screen Operating Manual

3

AAC PUMPCELL DATA SHEET

Table 1 - AAC Pumpc ell Data Sheet MECHANICAL EQUIPMENT DATA SHEET PROJECT INFORMATION CLIENT PLANT LOCATION DESCRIPTION QUANTITY

MINERA FLORIDA LIMITADA CHILE  ALHUE DATE CHILE COMPILED B Y 3 135m  PUMPCELL PLANT REVISION 1 X 8 STAGE OPERATIONAL + 1 SPARE MECHANISM

DUTY DETAILS NORMAL FLOWRATE MAXIMUM FLOWRATE SLURRY RELATIVE DENSITY SLURRY PERCENTAGE SOLIDS SLURRY P80 SLURRY VISCOSITY SLURRY pH SOLIDS SPECIFIC GRAVITY PRE-SCREEN APERTURE CARBON SIZE CARBON CONCENTRATION

MECHANISM DETAILS

3

m /h per unit 3 m /h per unit t/m

3

%

253 330

MODEL NUMBER NUMBER OF UNITS

 AAC MPS 0470(P) 9

1.433

SERIAL NUMBERS

SM/2025/11-SM/2033/11

EQUIPMENT NUMBERS

922-SC-114,922-SC-113, 922-SC-112, 922-SC-111, 922-SC-110, 922-SC-109, 922-SC-108, 922-SC-107, 922-SC-106

47

m -1

cP @ 124s pH 3 t/m m mesh g/l

75 100 10 – 12 2.8 800 6x16 25

MOTOR DETAILS VOLTAGE FREQUENCY PHASE ENCLOSURE FRAME  MOUNTING  SPEED  AMB IENT TEMPERATURE SUPPLIER 

V(AC) Hz

380 50

3 IEC IP66 IEC FLANGE 4 POLE 25 WEG kg kg kg Nm Nm kN

kW RATING MOTOR SIZE SERVICE FACTOR  ABSORB ED POWER SERVICE FACTOR OUTPUT SPEED

kW kW INSTALLED kW  ABSORBED RPM

67.875 30 2.26 23.62 2.87 33.75

SCREEN DETAILS TYPE PERCENTAGE OPEN AREA SCREEN APERTURE SCREEN SURFACE AREA SCREEN PROFILE  SCREEN MATERIAL

WEDGE WIRE % m 2 m

26.7 800 4.67 28CP 304 SS WEDGE WIRE

CAGE DETAILS

SUPPORT STRUCTURE LOADS TOTAL NETT MASS OPERATING MASS 2 TOTAL GROSS MASS BENDING MOMENT TORQUE  AXIAL LOA D NOTE:

MARCH 2011 G VAN ASWEGEN TH 0 5  MARCH 2010

4980 6445 9655 5303 6310 106

NUMBER OF BLADES 5 PULSE RATE pulses/sec 2.81 CAGE TIP SPEED m/min 182 MATERIALS OF CONSTRUCTION SCREEN 304 STAINLESS STEEL ROTATING CAGE 300WA NATURAL RUBBER LINED VOLUTE 300WA NATURAL RUBBER LINED CORROSION PROTECTION IMMERSION EPOXY 375 m DFT 2

Total gross mass is calculated as total nett mass + 80 % of the cylinder volume containing settled pulp having 80 % dry solids mass. This is an unlikely operating condition.

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Kemix Pty Ltd Interstage Screen Operating Manual

4 4.1

SPARE PARTS Spare Parts Numberin g Designati ons

For the purposes of clarity during the assembly and the procurement of spare parts, it is worth understanding the numbering sequence by which the relevant subassemblies and the individual components are identified.  An example of a component number is given below. (Note: The number is an example only and is not necessarily specific to your contract.) A description of each segment of the part number follows.

E70444 - 71- 03-04 1

2

3

4

1. This section of the number gives the unique Kemix contract number specific to your equipment. This number should be quoted when inquiring about any information from Kemix regarding your equipment. The prefix has the following meanings:  ‘C’ indicates a local, South African supply contract.  ‘L’ indicates an indirect export contract.  ‘E’ indicates a direct export contract. 2. This section of the number is an internal number used to identify the type of equipment that has been supplied. ‘71’ is typical for Pumpcell technology. 3. This section indicates a sub-assembly. Each subassembly has a unique number e.g. ‘03’. 4. This section indicates a specific part number. Each part number within a subassembly has a unique number e.g. ‘04’.

The following di agram indicates all the individual parts and there associ ated part numbers related t o the K emix AAC Interstage Screen The descript ion detail of the parts and ex-works manufacturing lead tim e can be obtained by relating the part number to t he descript ion on th e table that follow s the diagram.

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

E70415-32 DRY-END FASTENERS REGION

E70415 - 40 E70415 - 41 E70415 - 42 E70415 - 43 E70415 - 44 E70415 - 45 E70415 - 46 E70415 - 47 E70415 - 48

 A

MOTOR MOTOR TERMINAL BOX MOTOR TERMINAL BOX COVER MOTOR FAN COWL MOTOR FAN MOTOR DRIVE END SHIELD MOTOR NON-DRIVE END SHIELD MOTOR DRIVE END OIL SEAL MOTOR NON-DRIVE END OIL SEAL

E70415 - 72-01-05 NAME PLATE BRACKET

E70415 - 72-01-03 BASE PLATE

E70415 - 72-02-03 RUBBER LINED VOLUTE

E70415 - 50

GEARBOX & MOTOR ADAPTER

E70415 - 51 E70415 - 52

GEARBOX OPERATIONAL SPARES GEARBOX FILTER BREATHER

E70415 - 72-01-04 GEARBOX COUPLING

E70415 - 72-02-04 RUBBER LINED INTERFACE SEAL

E70415 - 72-04 PUMP IMPELLOR E70415 - 72-01-03 MOUNTING BASE

E70415 - 72-04-03 RUBBER LINED PBT

E70415 - 72-05 FIRST SHAFT ASSEMBLY

DETAIL A ( 1 : 20 )

E70415 - 72-05-06 PUMP MOUNTING FLANGE

E70415 - 72-03-02 HYDRAULIC LEG E70415-33 WET-END FASTENERS REGION B

E70415 - 72-03-01 CYLINDRICAL WEDGE WIRE SCREEN E70415 - 31 10m ROLL COMPRESSIBLE NEOPRENE STRIP GASKET (INSERTED BETWEEN WEDGE WIRE SCREEN, VOLUTE AND HYDRAULIC LEG)

E70415 - 72-06 RUBBER LINED ROTATING CAGE

E70415 - 72-03-00-01 DRAIN PLUG E70415 - 72-03-00-01 DRAIN SOCKET

E70415 - 72-06-07 RUBBER LINED PULSE BLADE

E70415 - 72-07 SECOND AGITATOR SHAFT

E70415 - 72-07-03 HYDROFOIL BLADE WITH STABILISER

DETAIL B ( 1 : 35 )

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Table 2 - AAC MPSP Interstage Screen Compl ete Parts Lis t

INTERSTAGE SCREENS: COMPLETE SPARE PARTS LIST REFERENCE DRAWING: PART DESCRIPTION Base plate Rubber lined volute & top structure assembly Rubber lined volute interface seal Rubber lined pumping impeller Rubber lined PBT (set) First shaft assembly Pump coupling Hydraulic leg Cylindrical wedge wire screen Rubber lined rotating cage Rubber lined pulse blades (set)

E70444-72 KEMIX PART NUMBER E70444 -72-01-03 E70444 -72-02-03 E70444 -72-02-04 E70444 -72-04 E70444 -72-04-03 E70444 -72-05 E70444 -72-05-06 E70444 -72-03-02 E70444 -72-03-01 E70444 -72-06 E70444 -72-06-07

EX WORKS LEAD TIME 8 Weeks 12 Weeks 4 Weeks 12 Weeks 6 Weeks 10 Weeks 4 Weeks 8 Weeks 8 Weeks 10 Weeks 4 Weeks

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Table 2 - AAC MPSP Interstage Screen Compl ete Parts Lis t

INTERSTAGE SCREENS: COMPLETE SPARE PARTS LIST REFERENCE DRAWING:

E70444-72

PART DESCRIPTION

KEMIX PART NUMBER

Base plate Rubber lined volute & top structure assembly Rubber lined volute interface seal Rubber lined pumping impeller Rubber lined PBT (set) First shaft assembly Pump coupling Hydraulic leg Cylindrical wedge wire screen Rubber lined rotating cage Rubber lined pulse blades (set) Second agitator shaft Hydrofoil blade with stabiliser Hook mounting support set (2 per set) Hold down clamp set (2 per set) Dry end fasteners Wet end fasteners Motor Motor terminal box Motor terminal box cover Motor fan cowl Motor fan Motor drive end shield Motor non-drive end shield Motor drive end oil seal Motor non-drive end oil seal Gearbox & motor adaptor Gearbox operational spares set Gearbox filter breather (6 month shelf life) Gearbox coupling 10m roll compressible neoprene strip gasket Hydraulic leg drain plug and socket set

E70444 -72-01-03 E70444 -72-02-03 E70444 -72-02-04 E70444 -72-04 E70444 -72-04-03 E70444 -72-05 E70444 -72-05-06 E70444 -72-03-02 E70444 -72-03-01 E70444 -72-06 E70444 -72-06-07 E70444 -72-07 E70444 -72-07-03 E70444 -26 E70444 -22 E70444 -32 E70444 -33 E70444 -40 E70444 -41 E70444 -42 E70444 -43 E70444 -44 E70444 -45 E70444 -46 E70444 -47 E70444 -48 E70444 -50 E70444 -51 E70444 -52 E70444 -72-01-04 E70444 -31 E70444 -72-03-00-01

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EX WORKS LEAD TIME 8 Weeks 12 Weeks 4 Weeks 12 Weeks 6 Weeks 10 Weeks 4 Weeks 8 Weeks 8 Weeks 10 Weeks 4 Weeks 10 Weeks 8 Weeks 8 Weeks 8 Weeks 4 Weeks 4 Weeks 16 Weeks 16 Weeks 16 Weeks 16 Weeks 16 Weeks 16 Weeks 16 Weeks 16 Weeks 16 Weeks 16 Weeks 10 Weeks 4 Weeks 8 Weeks 4 Weeks 4 Weeks

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

5

UNPACKING AND ASSEMBLY PROCEDURE AFTER TRANSPORTATION.

For shipping purposes the Kemix AAC Interstage Screen is equipped with various locking and support brackets to safe guard the Interstage Screen from damage during transit. The locking brackets are used to enable the rotating parts of the Interstage Screen to be locked in place forming one ridged assembly whereas the support brackets are used to support the Interstage Screen in the horizontal transport position. These locki ng and sup port b rackets are to be removed before the Interstage Screen is p laced into operation or before the Interstage screen is rotated. The location of the brackets and the procedure steps for removing the brackets are as follows: NOTE: THE BELOW PROCEDURE ORDER MUST BE FOLLOWED (i.e. START WITH STEP 1, THEN STEP 2, THEN STEP 3, THEN STEP 4 AND FINALLY STEP 5).

5.1

Step 1 - Removal of the Rotatin g Cage Suppor t A-Frame

Before any of the locking and support brackets are removed, the Kemix Interstage Screen needs to be placed inside the maintenance bay in a vertical position (refer section 7) using the provided four lifting lugs located inside the volute top structure (refer to figure 3). The first support bracket required to be removed is the rotating cage support A-frame (refer to figure 5) located at the bottom end of the Interstage Screen. The procedure for removal is as follows: 1. Whilst the Interstage Screen is in a vertical position situated inside the maintenance structure, nylon slings and chain blocks must be used to secure the rotating cage to the maintenance bay structure (refer to figure 4). 2. The fasteners connecting the A-frame arms to the bottom flange of the wedge wire screen need to be unbolted and removed (refer to figure 5). 3. Next the fasteners connecting the A-frame bracket to the rotating cage hub and shaft flange must be unbolted and removed. As per point 1 above, the rotating cage assembly is supported by nylon slings attached to the maintenance bay structure steelwork and there is therefore no risk of the rotating cage dropping due to removal of support brackets. 4. Once the A-frame has been detached from the Interstage Screen assembly and removed, the centre bolt located in the center of the rotating cage hub needs to be removed. The fasteners that were unbolted to remove the Aframe as well as the centre bolt located in the center of the rotating cage hub must not be re-inserted until completion of step 3.

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VOLUTE LIFITING LUG

Figure 3 – Provided Lifti ng Lugs for Hoist ing th e Interstage Screen Vertic ally

CHAIN BLOCK

NYLON SLINGS

Figure 4 – Supporting t he Rotating Cage using Nylon Slings and Chain Bl ocks

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

 A-FRAME  ARM

ROTATING CAGE HUB FASTENERS

 A-FRAME BOTTOM FLANGE OF WEDGE WIRE SCREEN

Figure 5 – Location of Rotating Cage Support A-Frame

Figure 6 – Center Bolt Located in Center of Rotating Cage Hub

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

5.2

Step 2 - Removal of the front 1st shaft Locking Brackets

This next step is to be completed after step 1 has been completed. The locking bracket located on top of the volute internal frame (refer figure 7) needs to be removed. The procedure for removal is as follows: 1. Unbolt and remove all the fastener nuts and threaded bars located between the top shaft flange and the channels which are bolted on the top of the volute internal frame. The shaft and pump assembly is supported by brackets located between the volute moat and pump assembly (see section 5.3) and there is therefore no risk of the shaft and pump assembly dropping due to no support. 2. Unbolt the channels from the top of the volute internal frame and remove.

THREADED BAR

CHANNEL BRACKETS ON VOLUTE INTERNAL FRAME

FASTENER NUTS

Figure 7 – Location of the front 1 st  shaft Locking Brackets

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

5.3

Step 3 - Remov al of the Pump Suppo rt Brackets .

This step is to be completed once step 2 has been completed. The pump assembly support brackets are located on the inside of the Interstage Screen volute as shown in figure 8. The procedure for removing the brackets is as follows: 1. Using the maintenance crane, lift the shaft and pump assembly using the pump lifting lugs on the top of the pump to a height that allows the easy removal of the four  pump support brackets from the volute moat (refer figure 8). Care should be taken when lifting the pump assembly not to damage the pump flange on the internal structure of the volute. 2. Inspect the circumference of the volute moat to ensure that allfour  of the pump support brackets have been identified and removed. 3. Using the maintenance crane still hoisting the shaft and pump assembly using the pump lifting lugs on the top of the pump, slowly (creep/inch function) lower the shaft and pump assembly until the bottom flange of the shaft comes in contact with the hub of the rotating cage. Special pre-cautions mus t be taken to ensure that the shaft and pump assembly is on ly low ered until the bottom flange of the shaft creates a gap of approxi mately 5mm from rotating cage hub. Lowering of the shaft and pump assembly to lo w might result in damage to the rotating c age. 4. The centre bolt located in the center of the rotating cage hub can now be inserted and the 5mm gap can be taken up by tightening the rotating cage hub center bolt (refer to figure 9). This will secure the rotating cage and shaft together. Ensure the bolts of the shaft flange and rotating cage hub are inserted before tightening of the center bolt of the rotating cage to ensure all the flange bolt holes for the rotating cage and shaft are aligned. Special attention must be given to ensure that shaft flange and rotating cage is correctly coupled together (refer section 6.9). Note: The weight of the shaft and pump assembly must remain supported by the maintenance crane until com pletion of step 4.

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PUMP LIFTING LUGS PUMP SUPPORT BRACKET

VOLUTE MOAT

Figure 8 – Location of Pump Support Br acket

5mm GAP

Figures 9 – Assembl e the 1st  shaft t o the Rotating Cage with 5mm Gap

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

5.4 Step 4 - Removal of the Rotating Cage Loc kin g Brack ets  After completion of step 3, with the shaft and pump assembly still being hoisted by the maintenance crane, the rotating cage locking brackets must now be removed. The rotating cage locking brackets are located between the t op of the rotating cage and the top flange of the screen (refer to figure 10). The procedure is as follows: 1. The clamping fasteners on the rotating cage locking brackets need to be unbolted (refer to figure 11). 2. The fasteners connecting the rotating cage locking brackets to the top flange of the wedge wire screen must then be unbolted (refer to figure 11). 3. The rotating cage locking brackets can now be removed and the fasteners removed from the top flange of the wedge wire screen must be reinserted and tightened (refer to section 12). 4. The shaft and pump assembly still being hoisted by the maintenance crane can now be slowly (creep/inch function) lowered until the pump assembly comes to rest on the volute moat.

ROTATING CAGE LOCKING BRACKET

Figure 10 – Location of Rotating Cage Locking Br ackets

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

SCREEN TOP FLANGE FASTENER

CLAMPING FASTENER

Figure 11 – Location of Rotating Cage Support Locking Bracket

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

5.5

Step 5 – Assembly of the Kemix Interstage Screen from the Transported State of Partial As sembly

This step involves the full assembly of the Kemix Interstage Screen for operation from the partial state of assembly in which the Interstage Screen was transported. The assembly activities required are as follows: 1. Install the gearbox and baseplate assembly as per section 6.6 and section 6.7. Ensure the oil, breathers and sight glass is installed. 2. The agitator blades and agitator shaft can now be assembled as per section 6.1.7. 3. After the agitator blades and shaft have been assembled, the agitator blades and shaft assembly must be bolted onto the underside of the rotating cage hub as per section 6.10. NOTE: Before the Interstage Screens are placed into operation, the inspections identified in Section 7.1 of this m anual must be performed.

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6

COMPLETE BREAKDOWN OF MECHANISM FOR  ASSEMBLY

The complete assembly of the mechanism from a completely dismantled state is detailed below. A list of tools required is given in section 13. All bolts should be torqued to the values specified in section 12. The next eight sections (sections 6.1.1 to 6.1.8) refer to pre-assembly activities that are required before the main assembly is assembled. The sections 6.2 to 6.10 refer to the main assembly of the Interstage Screen.

6.1

Pre-Assembly requir ements 1 to 8

6.1.1 Pre-Assemble 1: the Pulse Blades to the Rotating Cage The parts required for this procedure are: Pulse Blades   Rotating Cage 

E70444-72-06-07 E70444-72-06

The recommended assembly procedure is as follows: 1. The rotating cage has a leading drilling pattern as seen in figure 13. The pulse blade holes are not centered on the upright of the rotating cage and therefore the blades should be mounted in a specific orientation. 2. Assemble the pulse blades, with the provided stainless steel nuts, bolts and oversize washers, so that the inner edge of the pulse blade overlaps the upright angle of the rotating cage by +/- 10mm as shown in Figure 13. The pulse blades are sacrificial items. Their purpose is to protect the rotating cage uprights from wear during operation. Incorrect orientation of the pulse blades will result in premature wear of the rotating cage uprights – a much more costly replacement than a set of pulse blades.

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

PULSE

ROTATING

BLADE

CAGE

Figure 12 - Assembly of Pulse Blades

PULSE BLADE

DIRECTION OF ROTATION PLAN VIEW

Figure 13- Orientation of Pulse Blades

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.1.2 Pre-Assemble 2: the Hydraulic Leg to Screen The parts required for this procedure are:   

Hydraulic Leg Hydraulic leg drainage plug and socket set Wedge Wire Screen

E70444-72-03-02 E70444-72-03-00-01 E70444-72-03-01

The recommended assembly procedure is as follows: 1. Apply the 50mm wide neoprene strip to one side of the flange of the drainage socket. 2. Using a fairly sharp object to push holes through the neoprene rubber strip to coincide with the holes located on the flange of the drainage socket. 3. Assemble the hydraulic leg drainage port to the hydraulic leg using the provided stainless steel fasteners as shown in Figure 14. 4. Affix 50mm width neoprene rubber to the flange on the underside of the hydraulic leg disc. (This serves as a sealing gasket between the hydraulic leg and the wedge wire screen.) 5. Use a fairly sharp object to push holes through the neoprene rubber strip coinciding with the holes in the hydraulic leg. 6. Lower the hydraulic leg into the wedge wire screen. 7. Bolt the hydraulic leg to the screen using the given stainless steel fasteners as shown in Figure 15. 8. Check that the hydraulic leg pipe is concentric to the wedge wire screen at the top flange. 9. If the hydraulic leg is not concentric t o the screen, excessive wear will occur against the main shaft or pum p assembly during o peration.

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Figure 14 – Assembling the Hydraulic Leg Drainage Port

Figure 15 - Assembling the Hydraulic Leg to the Screen

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.1.3 Pre-Assemble 3: the Female Rigid Coupling to the Gearbox Output Shaft The parts required for this procedure are: Gearbox (c/w key)   Female Rigid Coupling (c/w keep plate)

 

E70444-50 E70444-72-01-04

The recommended assembly procedure, using Figure 16 as a reference, is as follows: 1. Insert the gearbox key into the gearbox output shaft. 2. Slide the female half of the rigid coupling over the output shaft and key. 3. Bolt the female rigid coupling keep plate into the recess in the coupling using the provided fasteners. Using the torque table in s ection 12, ensure the fasteners are correctly tightened. 4. Ensure the oil, breathers and sight glass is installed (refer section 18).

ELECTRIC MOTOR

NAMEPLATE BRACKET

GEARBOX

GEARBOX KEY

FEMALE RIGID COUPLING FEMALE RIGID COUPLING KEEP PLATE

Figure 16 – Assembling th e female half of the ri gid cou pling to the gearbox

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.1.4 Pre-Assemble 4: the Gearbox to Base Plate The parts required for this procedure are:  

Gearbox (c/w key) Gearbox Baseplate

E70444-50 E70444-72-01-03

The recommended assembly procedure, using Figure 17 and 18 as a reference, is as follows: 1. Place gearbox base plate on chocks as indicated in figure 17. 2. Place the Gearbox assembly onto the baseplate, making sure the holes on the underside of the gearbox locates correctly with the baseplate holes. Precautions should be taken to ensure that the lubricating pipe work on the gearbox is not damaged when placing the gearbox onto the base plate. 3. Using the provided fasteners, bolt the gearbox to the base plate. Using the torque table in section 12, ensure the fasteners are correctly tightened. Note: Once the gearbox and baseplate assembly is complete, ensure that the assembly is correctly supported. This is done by using the appropriate chocking to support two ends of the baseplate as seen in figure 19. This is to ensure a clearance is obtained between the gearbox output shaft and the ground and that the gearbox and baseplate are secured in a stable position.

Figure 17 – Positi oning of the Gearbox ont o th e Baseplate

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Figure 18 – Assembly of the Gearbox to Baseplate

Figure 19 – Correct su pportin g of the gearbox and baseplate assembly

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.1.5 Pre-Assembly 5: Assemble the pump The parts required for this procedure are:   

Pump Inner Cone Pump Outer Cone PBT Blades

E70444-72-04 E70444-72-04 E70444-72-04-03

The recommended assembly procedure is as follows: 1. Using the appropriate lifting equipment (nylon slings, chain blocks and overhead cranes), stand the pump inner cone upside down on the flange face. The pump inner cone may be manipulated using the lifting lugs on the top disc, as shown in Figure 21. 2. Lower the pump outer cone over the inner cone whilst being careful not to damage any of the rubber lining. 3. Locate the bolting tabs of the outer cone through the matching slots of the inner cone, as shown in Figure 21, whilst being careful not to damage the tabs when aligning the parts. 4. Bolt up the two cones using the appropriate stainless steel bolts. Using the torque table in section 12, ensure the fasteners are correctly tightened. 5. Turn the pump over so that the flange is now at the top and stand it on the pipe shaft whilst keeping it steady using the lifting equipment. Make sure that the protectiv e coating is protected from damage at all times. 6. Attach the PBT to the bottom of the pump using the stainless bolts as shown in Figure 22. Using the torque table in section 12, ensure the fasteners are correctly tightened.

Figure 20 – Exploded Pump Assembly

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

LIFTING LUGS PUMP INNER CONE TABS

PUMP OUTER CONE TABS

Figure 21 - Pump bolting tabs and lifting l ugs

Figure 22 - Bolting the PBT blades to the pump

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.1.6 Pre-Assembly 6 – Assemble the pump coupling to the first shaft The parts required for this procedure are:  

First Shaft Pump Coupling

E70444-72-05 E70444-72-05-06

The recommended assembly procedure is as follows: 1. Using eye-bolts in the two provided tapped holes on the pump coupling, position the two halves of the pump coupling to facilitate the attaching of the pump coupling halves onto the mid-flange of the shaft as shown in figure 23. 2. Using the supplied fasteners, bolt the pump coupling onto the shaft mid-flange. Using the torque table in section 12, ensure the fasteners are correctly tightened.

Figure 23 - Bolti ng the pump coup ling halves onto t he shaft

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.1.7 Pre-Assemble 7: Agitator Blades to agitator shaft The parts required for this procedure are:  

Agitator shaft Agitator blades

E70444-72-07 E70444-72-07-03

The recommended assembly procedure is as follows: 1. With the agitator shaft being held vertically, the agitator blades must be assembled to the agitator shaft using the provided fasteners. 2. The blades have an area free of rubber lining which must be mated with the underside of the corresponding spoke on the agitator shaft as shown in Figure 24. Using the torque table in section 12, ensure the fasteners are correctly tightened.

AGITATOR SHAFT

SPOKE

BLADE

Figure 24 - Fitti ng the agitator bl ade to the agitator shaft

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.1.8 Pre-Assemble 8: Volute Interface Seal to Volute The parts required for this procedure are:  

Volute Assembly (excluding internal frame) Volute Interface seal

E70444-72-02-03 E70444-72-02-04

The recommended assembly procedure is as follows: 1. With the volute being placed vertically up, the volute interface seal must be assembled to the volute using the provided fasteners (refer figure 25). 2. Once assembled ensure that the volute interface seal is completely flat against the volute opening face with no gaps evident. Using the torque table in section 12, ensure the fasteners are correctly tightened.

Figure 25 - Fitti ng th e Volut e Interface Seal to the Volut e

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.2

Position the Volute into the maintenance struc ture

The parts required for this procedure are: 

Volute Assembly (excluding internal frame)

E70444-72-02-03

The recommended assembly procedure is as follows: 1. Lift the Volute Assembly (excluding internal frame) using slings and shackles through the four provided lifting lugs inside the volute top structure. 2. Lower the volute into to mounting facility located on the top level of the maintenance bay, making sure that the rubber lining on the volute does not get damaged during the process.

Figure 26 – Positioning of Volute int o Maintenance Bay

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.3

Position the Pumping Impeller into the Volute

The parts required for this procedure are:  

Assembled pump as given in section 6.1.5 Mechanism as assembled in section 6.2

E70444-72-04

The recommended assembly procedure is as follows: 1. Lift the pump assembly using slings and shackles on the provided lifting lugs. 2. Lower the pump into the volute, making sure that the pump PBT blades do not get damaged during the process. The pump will come to rest on the volute moat.

Figure 27 – Positi oning of Pumping Impeller into the Volute

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Figure 28 – Positioning of Pumping Impeller int o the Volute

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.4

Ass emble the 1st  Shaft  Shaft i nto Pumping Impeller Impeller

The parts required for this procedure are:  

1st Shaft and pump coupling assembly (see section 6.1.6) Mechanism as assembled in section 6.3

The recommended assembly procedure is as follows: 1. With the use of nylon slings, attach slings around underside of 1st shaft top flange lift the shaft into position as shown in Figures 29 & 30. 2. Once the shaft is in position, bolt both the pump flange and the pump coupling (already coupled to the 1st  shaft flange, see section 6.1.6) together with the supplied fasteners. Using the torque table in section 12, ensure the fasteners are correctly tightened.

Figures 29 – Positi Positi oning of 1st Shaft Shaft i nto Pumping Impeller Impeller

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Figures 30 – Positi Positi oning of 1st Shaft Shaft in to Pumping Impeller Impeller

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.5

Posit ion the Internal Frame Into the Volut e

The parts required for this procedure are:  

Internal frame Mechanism as assembled in section 6.4

The recommended assembly procedure is as follows: 1. Lift the internal frame using slings into the volute. 2. Assemble the internal frame onto the volute using the given mild steel fasteners. Using the torque table in section 12, ensure the fasteners are correctly tightened. Note: The internal frame can only be inserted in one orientation. Make sure that the frame is orientated such that the shaft is central to the square opening in the internal frame.

Figures 31 – Positionin g of the Internal Internal Frame into the Volute

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Figures 32 – Positionin g of the Internal Frame into the Volute

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.6

Ass emble the Gearbox and Base Plate Ass embly onto the Internal Frame

The parts required for this procedure are:  

Gearbox (gearbox, motor and coupling) and baseplate assembly as per section 6.1.4. Mechanism as assembled as per section 6.5.

The recommended assembly procedure is as follows: 1. Place the gearbox and baseplate assembly onto the volute internal frame, making sure the holes on the underside of the baseplate locates correctly with the volute internal frame holes and that the motor end of the gearbox is facing the volute opening side of the volute. 2. Bolt the gearbox and baseplate assembly to the volute internal frame using the provided fasteners. Using the torque table in section 12, ensure the fasteners are correctly tightened.

Figures 33 – Assemble the Drive Unit onto the Base Plate

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Figures 34 – Assemble the Drive Unit onto the Base Plate

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.7

Assemble the Gearbox coupli ng onto the 1 st  Shaft

The parts required for this procedure are: 

Mechanism as assembled as per section 6.6.

The recommended assembly procedure is as follows: 1. Using the maintenance crane, slowly (creep/inch function) lift the shaft and pump assembly using the lifting lugs on the top of the pump to a height that allows the bolting of the gearbox coupling and 1st shaft flange to be coupled together as shown in figure 35 and 36. 2. Bolt the gearbox coupling to the 1st shaft top flange using the provided fasteners. Using the torque table in section 12, ensure the fasteners are correctly tightened. NOTE: Special attention must be given to ensure that the gearbox coupl ing and 1st  shaft f lange are correctly coupled t ogether, for example the two flange faces are in full contact.

Figures 35 – Positi oning of the 1st Shaft up to the Gearbox Coupli ng

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Figures 36 – Coupling t he 1st Shaft t o the Gearbox Coupli ng

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.8

Assemble the Hydraulic Leg and Screen Assembly to the Volute

The parts required for this procedure are:  

Hydraulic leg and Screen assembly per section 6.1.2 Mechanism as assembled as per section 6.7.

The recommended assembly procedure is as follows: 1. Apply a 50mm wide neoprene rubber to the top flange of the wedge wire screen as shown in Figure 39. 2. Use a fairly sharp object to push holes through the neoprene rubber strip coinciding with the holes in the screen flange. 3. Hoist the Hydraulic leg and Screen assembly up to the under side of the volute. 4. Bolt the screen top flange to the volute using the given stainless steel nuts, bolts and washers. Using the torque table in section 12, ensure the fasteners are correctly tightened.

Figures 37 – Positi oning of 1st Shaft i nto Pumping Impeller

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Figures 38 – Positioning o f 1st Shaft into Pumping Impeller

NEOPRENE RUBBER TO GO ON SCREEN TOP FLANGE

Figure 39 – Apply Neoprene rubber to screen top f lange and assemble to v olute flange.

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.9

Ass emble the Rotating Cage to the 1st  Shaft

The parts required for this procedure are:  

Rotating cage assembly as per section 6.1.1. Mechanism as assembled in section 6.8

The recommended assembly procedure is as follows: 1. Stand the rotating cage upright on a flat surface that will not inflict damage to the rubber lining. 2. Bring the rotating cage up to meet the bottom flange of the 1st shaft. Attach the rotating cage using only the center bolt/stud and washer supplied (refer figure 41).

Figures 40 – Ass emble the 1 st  shaft t o the Rotating Cage

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Figures 41 – Ass emble the 1 st  shaft t o the Rotating Cage

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

6.10 Assemble Agitator t o the Mechanism The parts required for this procedure are:  

Agitator shaft and blade assembly as per section 6.1.7 Mechanism as assembled to section 6.9

The recommended assembly procedure is as follows: 1. The agitator assembly should be positioned under the mechanism for assembly. 2. The agitator shaft flange, the rotating cage and the main shaft flange must then be bolted together using the required washers, nuts and bolts as shown in Figure 42. The centre bolt holdi ng the rotating cage onto the 1 st  shaft must remain in position. Using the torque table in section 12, ensure the fasteners are correctly tightened.

Note: At thi s stage, the assembly o f the mechanism is c omplete. Before the Interstage Screen is placed into operation, the inspections identified in Section 7.1 of this manual mus t be performed.

AGITATOR SHAFT

Figure 42 - Assembling t he agitator onto the mechanism

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7

CHECKING AND ADJUSTMENT OF THE MPSP INTERSTAGE SCREEN BEFORE OPERATION

Note: It is necessary to have a maintenance bay, as shown in Figure 43, in order to perform the following checks and adjustments. The Mechanism should be vertical and the rotating cage free to rotate. It is assumed from hereon that the Mechanism is located in such a structure.  A typical Kemix maintenance bay is shown in Figure 43. It has three or four levels in order to access the mechanism to adjust and clean all the required parts. The upper level allows access to the drive section and adjustment of the pump heights etc. The middle levels allows for high pressure washing of the wedge wire screen during cleaning and also inspection of the rotating cage. The lower level allows the screen and rotating cage to be lowered onto a trolley in order to facilitate assembly and disassembly. The trolley allows the components to be moved to a position that can be reached by an overhead crane. It also has an extra docking bay in order to facilitate speedy replacement of the mechanisms in the circuit.

EXTRA BAY FOR REPLACEMENT MACHINE

HOOKS

CLEANING PLATFORM

SCREEN REMOVAL PLATFORM

Figure 43 - Kemix m aintenance bay

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

7.1

Perform Align ment Checks on Shaft and Rotating Cage

When the mechanism is operating, there are two problems that may occur with respect to alignment of the shaft and rotating cage.   

The shaft may rotate off center. The shaft may not hang perfectly vertical. The rotating cage does not rotate with a uniform distance around the wedge wire screen.

To check whether either of the above is occurring, turn the mechanism manual (with out switching on the power) whilst the mechanism is located within the maintenance structure. While the mechanism is being manually rotated the following checks must be performed: 1. The clearance between the rotating cage and wedge wire screen must be uniform around the circumference and the length of the wedge wire screen (refer to figure 50). If the clearance between the rotating cage and wedge wire screen is not uniform, the most likely causes are as follows: i. The shaft has bent during transportation or handling. For minor bends in the shaft, the shaft can usually be straightened but if the shaft is severely distorted, a replacement shaft must be installed into the mechanism. ii. The rotating cause has distorted either through transportation or handling. If the distorting is minor, the rotating cage can usually be straightened but if the rotating cage is severely distorted, a replacement rotating cage must be installed onto the mechanism. iii. The pump coupling or gearbox coupling is not correctly fitted and properly engaged, refer to point 2 below. 2. The deflection of the shaft at the bottom of the mechanism (where the shaft couples to the rotating cage) must not be over 10mm. This is most likely caused due to the incorrect installation of the pump coupling. The shaft will deflect due to the unbalanced mass of the pumping impeller if the pump coupling is not correctly seated on the shaft and pump flange. This can be corrected by re-fitting the pump coupling correctly ensuring the pump coupling makes complete contact with both the shaft and pump flange. If the gearbox coupling is not correctly fitted and properly engaged, this will cause the shaft to deflect.

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8

INSTALLA TION AND REMOVAL OF AN AAC PUMPCELL INTERSTAGE SCREEN

The details of installing an AAC Pumpcell Interstage Screen into a tank of a Pumpcell plant are detailed in this section.

8.1

Installation

8.1.1 Open Hook Mounting Bracket and Hold Down Clamp 1. 2. 3. 4.

Pull out the hook mounting bracket arm retaining pin as shown in Figure 44. Retract the hook mounting bracket arm as shown in Figure 44. Remove the hold down clamp retaining pin as shown in Figure 45. Retract the hold down clamp arm as shown in Figure 45.

8.1.2 Lower And Position The Mechanism In The Tank 1. An overhead crane, with slings attached to the lifting lugs located on the inside of the volute top structure, is used to manipulate the mechanism. 2. Lower the mechanism into the centre of the port in the tank top structure so that there is clearance around the entire mechanism. 3. Care should be taken to avoid damage to the agitator, rotating cage and volute during lowering. 4. The mechanism should be lowered to a height where the mechanism hooks are slightly above the hook mounting bracket as shown in Figure 46. 5. Move the mechanism towards the launder interface until the launder and mechanism interfaces are in contact as shown in Figure 47 and 48.

8.1.3 Position And Secure The Mechanism 1. Lower the mechanism onto the hook mounting bracket so that the hooks engage with the hook pin. 2. Once the load of the entire mechanism has been taken up by the hook mounting bracket, a visual inspection of the seal between the interface of the volute opening and the launder should be made in order to establish whether an adequate seal has been achieved. 3. If there appears to be any visible gap between the interface of the volute opening and the launder, the hook mounting bracket is adjusted using the procedure indicated in section 8.1.4.

8.1.4 Adjusting the Hook Mounting bracket 1. Taking the weight of the Pumpcell Interstage screen off of the hook mounting bracket, by lifting the Interstage Screen slightly up, loosen the bolts fastening the hook mounting bracket to the top structure of the tank. The hook mounting bracket can then be moved forward or backward as required using the slotted holes provided on the hook mounting bracket.  Refer to figure 47 related to a gap being experienced at the bottom of the volute opening and launder interface. Refer to figure 48 related to a gap being experienced at the top of the  volute opening and launder interface

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual 2. Once the desired position has been achieved, the hook mounting bracket can then be secured by tightening the fastener bolts and the Interstage screen is repositioned as per section 8.1.3.

8.1.5 Tighten Hook Mounting Bracket and Hold Down Clamp 1. Return the hook mounting bracket arm in to a position over the hook of the Interstage Screen. 2. Replace the hook mounting bracket arm retaining pin. 3. Tighten the hook mounting bracket arm screw and locknut. 4. Return the hold down clamp arm in to a position over the top structure of the Interstage Screen. 5. Replace the hold down clamp arm retaining pin. 6. Tighten the hold down clamp arm screw and locknut.

Figure 44 – Hook Mount Lock ing Br acket

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HOLDING DOWN CLAMP ARM SCREW

HOLDING DOWN CLAMP ARM

HOLDING DOWN CLAMP ARM RETAINING PIN

Figure 45 - Holding dow n clamp

Figure 46 - Checking the position of the hook pi n lock ing device

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SLIDE HOOK MOUNTING BRACKET IN THIS DIRECTION

GAP AT BOTTOM

Figure 47 - Correcting a gap at the bottom of interface

SLIDE HOOK MOUNTING BRACKET IN THIS DIRECTION

GAP AT TOP

Figure 48 - Correcting a gap at the top of interface

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8.2

Removal

8.2.1 Open Hook Mounting Bracket and Hold Down Clamp 1. 2. 3. 4. 5. 6.

Loosen the hook mounting bracket arm screw and locknut as shown in 44. Pull out the hook mounting bracket arm retaining pin as shown in 44. Retract the hook mounting bracket arm as shown in 44. Loosen the hold down clamp arm screw and locknut as shown in Figure 45. Remove the hold down clamp retaining pin as shown in Figure 45. Retract the hold down clamp arm as shown in Figure 45.

8.2.2 Lift the Interstage Screen Out Of The Tank 1. An overhead crane, with slings attached to the lifting lugs, is used to manipulate the mechanism. 2. The seal between the interfaces must be broken by lifting the machine slightly. Care should be taken not to lift the Interstage Screen too far as this will damage the volute interface seal. 3. Once the seal has been broken, the Interstage screen must be moved away from the launder interface to a position where there is approximately the same clearance on all four sides of the volute top structure. 4. The Interstage screen must then be lifted slowly out of the tank. 5. Care should be taken to avoid damage to the agitator, rotating cage and volute during lifting.

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9

MAINTENANCE AND INSPECTION PROCEDURE

9.1

Maintenance and Inspection Procedure during normal operation

The followings Maintenance and Inspection procedure activities are related to the maintenance and inspection requirements during operation of the Kemix Interstage Screen:

9.1.1

Maintenance and Inspection of the Wedge Wire Screen

The wedge wire screen of each of the Kemix Interstage Screen should be washed and inspected once every two weeks. If the Kemix Interstage Screen is operated outside of the process specifications indicated on the Interstage Screen general arrangement drawing, the time frame between cleaning intervals could be shortened. The recommended cleaning procedure is as follows: 1. The Kemix Interstage Screen is taken out of operation and placed within a maintenance structure (refer to section 7). 2. The inspection ports located on the bottom of the hydraulic leg are then opened (using the provided drainage port wrench, see Figure 49) to facilitate the washing out any potential settled solids located within the wedge wire screen. 3. Using a high pressure washer, the entire surface area of the wedge wire screen is then washed to remove all embedded grit. 4. Any remaining grit still present after the high pressure wash will need to be removed with the aid of a wire brush being applied in a brushing action over the entire surface of the screen. 5. Once the wedge wire screen has been cleaned as described above, an inspection is then done of the screen to ensure that the aperture size is within size limitation of the carbon being used. The screen is inspected for any damage that may have occurred during operation and handling. 6. The gap between the wedge wire screen and rotating cage must be inspected to ensure that the gap is uniform around the circumference and length of the screen (as shown in figure 50).

Figure 49 – Opening o f th e Hydraulic Leg Drainage Port u sing the wrench to ol

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GAP

GAP

Figure 50 – Clearance gap inspection between screen and rotating cage

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

9.1.2 Maintenance and Inspection of the Drive Unit. The drive unit consists of the gearbox, gearbox motor adaptor and electric motor. The maintenance and inspection of the drive unit consists of monitoring the gearbox oil levels and lubrication of the bearing for the gearbox motor adaptor and electric motor every two weeks for each Interstage Screen in operation. For more information on the maintenance and inspection of the gearbox and motor adaptor refer to section 18 of this manual. More information related to the maintenance and inspection of the electric motor can be attained in section 11 of this manual. The specification of the oil can be attained from section 19 of this manual.

9.1.3 Maintenance and Inspection of the Protective coatings of Entire Interstage Screen Assembly. During the maintenance and inspection procedure of the wedge wire screen indicated in section 9.1.1, additional time should be taken for the inspection of the condition of the protective coatings that have been applied to the Interstage Screen. The recommended inspection procedure is as follows: 1. Using a high pressure washer, clean off all soiled areas of the entire Interstage Screen assembly. 2. A thorough inspection of all the rubber lined and painted surfaces should be conducted and any corroded/abraded areas should be repaired. This is done using a rubber lining repair kit or touch-up paint depending on the corrosion protected surface being repaired. 3. Before the damaged surface is repaired, actions should be taken to ensure that the repaired surfaces are clear of dust, moisture and surface rust.

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9.2

Maintenance and Inspect ion Procedur e dur ing Storage

Whilst the Kemix Interstage Screen is placed out of operation or in storage, the following procedures must be taken to protect the equipment:

9.2.1 Maintenance and Inspection of the Drive Unit during Storage The following storage procedures are in accordance with the gearbox and motor supplier recommendations: 1. Gearbox and motor assembly are required to be rotated past one complete revolution once every month. 2. Gearbox assembly are required to be stored away from direct sunlight to avoid any significant temperature increases in the oil and grease. 3. The motor and gearboxes are required to be stored away from any sources of vibration for example railway lines, forklifts, blasting etc.

9.2.2 Maintenance and Inspection of the Entire Interstage Screen Assembly during Storage The following storage procedures are to be implemented for the entire Interstage Screen assembly: 1. It is recommended that the Interstage Screen part assembly be stored indoors to avoid damage to the natural rubber lining caused from extensive exposure to UV direct sunlight. 2. The Interstage Screens should be stored in an area that is away from any grinding or welding activities to ensure that no weld splatter or grinding sparks contaminate the Interstage Screen protective coating.

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

10 SPARES REPLACEMENT PROCEDURES The most common of the spare parts that will require to be replaced is the replacement of the wedge wire screen. This under a good a maintenance schedule will be required to be replace between 9 and 12 months depending on the nature of the pulp being treated. The replacement procedure for the wedge wire screen is detailed below. A list of tools required is given in section 13. All bolts should be torqued to the values specified in section 12.

10.1 Wedge-Wire Screen Replacement The wedge wire screen may be replaced by the reverse procedure of assembling the Interstage Screen and must be performed in a maintenance bay as follows: 1. The Interstage Screen must first be mounted in a maintenance bay (refer to section 7). 2. The weight of the agitator (located at the bottom of the Interstage screen), must then be supported by using nylon slings and chain blocks which are used to secure the agitator to the maintenance bay structure (refer to figure 51). 3. Once it has been ensured that the agitator is well supported, remove the agitator by removing the bolts through the agitator flange, rotating cage hub and first shaft lower flange. The centre bolt located in the center of the rotating cage hub which secures the rotating cage and shaft together will prevent the rotating cage from dropping. 4. The agitator can now be lowered and removed. 5. The weight of the rotating cage must now be supported by using the nylon slings and chain blocks which are used to secure the rotating cage to the maintenance bay structure (refer to figure 52). Care should be taken not to damage the rotating cage during this procedure. 6. Once it has been ensured that the rotating cage is well supported, remove the centre bolt located in the center of the rotating cage hub which secures the rotating cage and shaft together. 7. The rotating cage can now be carefully lowered and removed, making sure not to damage any coatings. 8. A temporary bracket, similar to that shown in figure 53, must now be bolted to the 1st shaft lower flange to support the hydraulic leg. 9. The weight of the wedge wire screen and hydraulic leg must then be taken up by using slings and chain blocks which are used to secure the wedge wire screen and hydraulic leg to the maintenance bay structure (refer to figure 54). 10. Once it has been ensured that the wedge wire screen and hydraulic leg is well supported, remove the bolts in the wedge wire screen top flange. 11. Lower the wedge wire screen and hydraulic leg until the hydraulic leg rests on the temporary bracket attached to the shaft flange. 12. The weight of the wedge wire screen must then be taken up by using slings and chain blocks which are used to secure the wedge wire screen to the maintenance bay structure. 13. Once it has been ensured that the wedge wire screen is well supported, remove the fasteners in the wedge wire screen bottom flange and lower the wedge wire screen and remove. The hydraulic leg will remain behind supported on the temporary bracket attached to the shaft flange. 14. The new wedge wire screen can now be fitted in the reverse order to that of above.

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CHAIN BLOCK

NYLON SLINGS

Figure 51 51 – Supporting the Agitator usin g Nylon Slings and Chain Blocks

NYLON SLINGS CHAIN BLOCK

Figure 52 – Supporting th e Rotating Rotating Cage using Nylon Slings and Chain Chain Bloc ks

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Figure 53 - Hydraulic leg suppor t bracket

CHAIN BLOCK

NYLON SLINGS

Figure 54 – Supporti Supporti ng t he Wedge Wedge Wire Screen Screen and Hydraulic Leg using Nylon Slings and Chain Chain Blocks

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

11 INSTALL INSTAL L ATION AND MAINTENANCE MAINTENA NCE INSTRUCTIONS INSTRUCTIONS FOR ELECTRIC MOTORS 11.1 11.1 Receivi Receivi ng Check    

Check if any damage has occured during transportation. Check nameplate data. Remove shaft locking device (if any) before operating the motor. Turn the shaft with the hand to make make sure if it is turning freely.

11.2 Handling and Transportation

NOTE: NOTE:

MOTORS MUST NOT BE LIFTED BY THE SHAFT, BUT BY THE EYE BOLTS WHICH ARE PROPERLY DESIGNED TO SUPPORT THE MOTOR WEIGHT.

Lifting devices, when supplied, are designed only to support the motor. If the motor has two lifting devices then a double chain must be used to lift it. Lifting and lowering must be done gently without any shocks, otherwise the bearings can get damaged.

NOTE: NOTE:

DURING TRANSPORTATION, MOTORS FITTED WITH ROLLER OR  ANGULAR C  ANGULAR CONTACT ONTACT BEARINGS ARE PROTECTED AGAINST BEARING DAMAGES WITH A SHAFT LOCKING DEVICE.

NOTE: NOTE:

THIS LOCKING DEVICE MUST BE USED ON ANY FURTHER TRANSPORT OF THE MOTOR, EVEN WHEN THIS MEANS TO UNCOPULE THE MOTOR FROM THE DRIVEN MACHINE.

11.3 Storage If motors are not immediately installed, they must be stored in dry places, free of dust, vibrations, gases, corrosive smokes, under constant temperature and in normal position free from other objects. In case the motors are stored for more than two years, the bearings must be changed or the lubrication grease must be totally replaced after cleaning. Single phase motors when kept in stock for 2 years or more must have their capacitors replaced (if any). We recommend to turn the shaft (by hands) at least once a month, and to measure the insulation resistance before installing it, in in cases of motors stored for more than 6 months or when subject to high humidity areas. If motor is fitted with space heaters, these should be switched on.

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11.4 Insulation Resistance Check Measure the insulation resistance before operating the motor and/or when there is any sign of humidity in the winding. The resistance measured at 25°C (77°F) must be: Ri > (20 x U) / (1000 + 2P) [Mohm] d.c.); Where:

U = voltage P = power (kW)

(measured with a MEGGER at 500 V

(V)

If the insulation resistance is less than 2 megaohms, the winding must be dried according to the following: Warm it up inside an oven at a minimum temperature of 80°C (176 F) increasing 5°C (41 F) every hour until 105°C (221 F), remaining under this temperature for at least one hour. Check if the stator insulation resistance remains constant within the accepted values. If not, stator must be reimpregnated. o

o

o

11.5 Installation 11.5.1 Safety  All personnel involved with electrical installations, eit her handling, lifting, operation or maintenance must be well informed and up-to-dated concerning the safety standard and principles that govern the work and carefully follow them. We strongly recommend that these jobs are carried out by qualified personnel.

NOTE:

MAKE SURE THAT THE ELECTRIC MOTORS ARE SWITCHED OFF BEFORE STARTING ANY MAINTENANCE SERVICE.

Motors must be protected against accidental starts. When performing any maintenance service, disconnect the motor from the power supply. Make sure all accessories have been switched off and disconnected. Do not change the regulation of the protecting devices to avoid damaging.

NOTE:

LEAD CONNECTION IN SULATION INSIDE THE TERMINAL BOX MUST BE DONE WITH AN INSULATING MATERIAL COMPATIBLE WITH MOTOR THERMAL CLASS WHICH IS SHOWN ON THE MOTOR NAMEPLATE.

11.5.2 Operating Conditions Electric motors, in general, are designed for operation at an altitude of 1000m above sea level for an ambient temperature between 25°C (77°F) and 40°C (104°F). Any variation is stated on the nameplate.

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NOTE:

COMPARE THE CURRENT, VOLTAGE, FREQUENCY, SPEED, OUTPUT AND OTHER VALUES DEMANDED BY THE APPLICATION WITH THE DATA GIVEN ON THE NAMEPLATE.

Motors supplied for hazardous locations must be installed in areas that comply with that specified on the motor nameplate.

NOTE:

KEEP AIR INLET AND OUTLET FREE AND CLEAN. THE AIR BLOWN OUT BY THE MOTOR SHALL NOT ENTER AGAIN. THE DISTANCE BETWEEN THE AIR INLET AND THE WALL MUST BE AROUND ¼ OF THE INLET OPENING DIAMETER.

11.5.3 Foundation Motors provided with feet must be installed on though foundations to avoid excessive vibrations. The purchaser is fully responsible for the foundation. Metal parts must be painted to avoid corrosion. The foundation must be uniform and sufficiently tough to support any short circuit strengths. It must be designed in such a way to stop any vibration originated from resonance.

11.5.4 Drain Holes Make sure the drains are placed in the lower part of the motor when the mounting configuration differs from that specified on the motor purchase order.

11.5.5 Balancing

NOTE:

KEMIX MOTORS ARE DYNAMICALLY BALANCED, WITH HALF KEY  AT NO LOAD AND UNCOUPLED.

Transmission elements such as pulleys, couplings, etc must be dynamically balanced with half key before installation. Use always appropriate tools for installation and removal.

11.5.6 Alignment

NOTE:

 ALIGN THE SHAFT ENDS AND USE FLEXIBLE COUPLING, WHENEVER POSSIBLE.

Ensure that the motor mounting devices do not allow modifications on the alignment and further damages to the bearings. When assembling a half-coupling, be sure to use suitable equipment and tools to protect the bearings. Suitable assembly of half-coupling: check that clearance Y is less than 0.05mm and that the difference X1 to X2 is less than 0.05m as well. Note: The“X” dimension must be at least 3mm.

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Figure 55 - Suitable assembly of half-coupling

11.5.7 Belt Drive When using pulley or belt coupling the following must be observed: Belts must be tighten just enough to avoid slippage when running, according to the specifications stated on the belt supplier recommendation.

WARNING:

Excessive tension on the pulleys will damage the bearings and lead to a probable shaft rupture.

11.5.8 Connection

WARNING:

Voltage may be connected at standstill inside the terminal box for heating elements or direct winding heating.

WARNING:

The capacitor on single-phase motors can retain a charge which appears across the motor terminals, even when the motor has reached standstill.

NOTE:

 A WRONG CONNECTION CAN BURN THE MOTOR.

Voltage and connection are indicated on the nameplate. The acceptable voltage variation is ± 10%, the acceptable frequency variation is ± 5% and the total acceptable variation is ± 10%.

11.5.9 Starting Methods The motor is rather started through direct starting. All Kemix motors must be connected as shown on the motor nameplate, failure to follow the motor nameplate could lead to motor failure. In case this is not possible, use compatible methods to the motor load and voltage. 3 lead single voltage and 9 lead dual voltage motors can be started as follows:   

Full Voltage Direct On Line. Auto-Transformer Starting. Electronic Soft-Starting.

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual 

VFD Starting - subject to verification and application analysis.

6 lead single voltage motors and 12 lead dual voltage motors can be connected as follows:     

Full Voltage Direct On Line. WYE/DELTA Starting. Auto-Transformer Starting. Electronic Soft-Starting. VFD Starting - subject to verification and application analysis.

The rotation direction is clockwise if the motor is viewed from DE side and if the phases are connected according to the sequence L1, L2, L3. To change the rotation direction, interchange two of the connecting leads.

NOTE:

THE CONNECTION TO THE POWER SUPPLY MUST BE DONE BY QUALIFIED PERSONNEL AND WITH FULL ATTENTION TO ASSURE A SAFE AND PERMANENT CONNECTION. AFTER CONNECTING THE MOTOR, CHECK FOR ANY STRANGE BODY INSIDE THE TERMINAL BOX. THE CABLE INLETS NOT IN USE MUST BE CLOSED.

Make sure to use the correct cable dimension, based on the rated current stamped on the motor nameplate.

NOTE:

BEFORE ENERGIZING THE TERMINALS, CHECK IF THE EARTHING IS MADE ACCORDING TO THE ACTUAL STANDARDS. THIS IS ESSENTIAL AGAINST ACCIDENT RISKS.

When the motor is supplied with protective or monitor temperature device such as thermostats, thermistors, thermal protector, etc, connect their terminals to the corresponding devices on the control panel.

11.5.10

NOTE:

Start-Up THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING THE MOTOR.

a) The motor must start and operate smoothly. In case this does not occur, turn it off and check the connections and the mounting before starting it again. b) If there is excessive vibration, check if the fastening screws are correctly fastened. Check also if the vibration comes from a neighbour machine. Periodical vibration checks must be done. c) Run the motor under rated load for a short period of time and compare if the running current is equal to that stamped on the nameplate.

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11.6 Maintenance

WARNING:

SAFETY CHECK LIST.

11.6.1 General Inspection        

Check the motor periodically. Keep the motor clean and assure free air flow. Check the seals or V Ring and replace them, if required. Check the connections as well as supporting screws. Check the bearings and observe: Any excessive noise, bearing temperature and grease condition. When a changing, under normal conditions, is detected, check the motor and replace the required parts. The frequency of the inspections depends on the motor type and on the application conditions.

11.7 LUBRICATION

NOTE:

FOLLOW THE REGREASING INTERVALS. THIS IS FUNDAMENTAL FOR PROPER MOTOR OPERATION.

11.7.1 Machines without Grease Nipples Motors up to frame 324/6T are normally fitted without grease nipples. In these cases the regreasing shall be done at the preventive maintenance job observing the following aspects:    

Disassemble carefully the motors. Take all the grease out. Wash the bearing with querosene or diesel. Regrease the bearing immediately.

11.7.2 Machines Fitted with Grease Nipples It is strongly recommended to grease the machine while running. This allows the grease renewal in the bearing housing. When this is not possible due to turning parts by the grease device (pulleys, bushing, etc) that offer some risk to the physical integrity of the operator, proceed as follows:   

Clean the area near to the grease nipple. Put approximately half of the total grease and run the motor for 1 minute at full speed. Then turn off the motor and pump the rest of the grease. The injection of all the grease with the motor in standstill can make the grease penetrate into the motor, through the inner seal of the bearing housing.

When regreasing, use only special bearing grease with the following properties:

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

Table 3 - Relubr icati on Interv als Recommended - Polyrex® Em Grease (Esso/Exxo n)

Frame

 Amo un t o f Grease (g)

3600 rpm 3000 rpm 1800 rpm 1500 rp m 1200 rpm 1000 rpm

900 rp m

750 rpm

720 rp m

600 rpm

500 rpm

Relubrication intervals in hours - ball bearings 254/6T

13

15700

18100

20000

20000

20000

20000

20000

20000

20000

20000

20000

284/6T

18

11500

13700

20000

20000

20000

20000

20000

20000

20000

20000

20000

324/6T

21

9800

11900

20000

20000

20000

20000

20000

20000

20000

20000

20000

364/5T

27

3600

4500

9700

11600

14200

16400

17300

19700

20000

20000

20000

404/5TS

27

3600

4500

9700

11600

14200

16400

17300

19700

20000

20000

20000

444/5TS

27

3600

4500

9700

11600

14200

16400

17300

19700

20000

20000

20000

504/5TS

27

3600

4500

9700

11600

14200

16400

17300

19700

20000

20000

20000

586/7TS

27

3600

4500 9700 11600 14200 16400 17300 Relubrication intervals in hours - cylindrical roller bearings

19700

20000

20000

20000

324/5T

21

9800

11900

20000

20000

20000

20000

20000

20000

20000

20000

20000

364/5T

27

9700

11600

14200

16400

17300

19700

20000

20000

20000

404/5T

34

6000

7600

9500

11600

13800

15500

15500

17800

20000

444/5T

45

4700

6000

7600

9800

12200

13700

13700

15700

20000

447/5T

45

4700

6000

7600

9800

12200

13700

13700

15700

20000

504/5T

45

4700

6000

7600

9800

12200

13700

13700

15700

20000

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

WARNING:

The table above is specifically intended for relubrication with Polyrex® EM grease and bearing absolute operating temperature of: 70oC (158oF) for 254/6T to 324/6T frame motors; 85oC (185oF) for 364/5T to 586/7T frame motors.

For every 15 C (59 F) above these limits, relubrication interval must be reduced by half. Shielded bearing (ZZ) are lubricated for berings life as long as they operate under normal ambient conditions and temperature of 70°C(158F ). o

o

o

NOTE:

WE RECOMMEND TO USE BALL BEARINGS FOR MOTORS DIRECTLY COUPLED TO THE LOAD.

WARNING:

EXCESS OF GREASE CAN CAUSE BEARING OVERHEATING RESULTING IN COMPLETE DAMAGE.

 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

WARNING:

The table above is specifically intended for relubrication with Polyrex® EM grease and bearing absolute operating temperature of: 70oC (158oF) for 254/6T to 324/6T frame motors; 85oC (185oF) for 364/5T to 586/7T frame motors.

For every 15 C (59 F) above these limits, relubrication interval must be reduced by half. Shielded bearing (ZZ) are lubricated for berings life as long as they operate under normal ambient conditions and temperature of 70°C(158F ). o

o

o

NOTE:

WE RECOMMEND TO USE BALL BEARINGS FOR MOTORS DIRECTLY COUPLED TO THE LOAD.

WARNING:

EXCESS OF GREASE CAN CAUSE BEARING OVERHEATING RESULTING IN COMPLETE DAMAGE.

®

11.7.3 Compatibility of Polyrex EM grease with other types of grease ®

Containing polyurea thickener and mineral oil, the Polyrex EM grease is compatible with other types of grease that contain:  

Lithium base or complex of lithium or polyurea and highly refined mineral oil; Inhibitor additive against corrosion, rust and anti-oxidant additive.

Notes:   



Although Polyrex EM is compatible with the types of grease given above, we do no recommend to mix it with any other greases. If you intend to use a type of grease different than those recommended above, first contact Kemix. On applications (with high or low temperatures, speed variation, etc), the type of grease and relubrication interval are given on an additicional nameplate attached to the motor. Vertical mounted motors must have the relubrication intervals reduced by half.

NOTE:

®

THE USE OF STANDARD MOTORS IN SPECIFIC AREAS OR SPECIAL  APPLICATIONS MUST BE DONE BY CONSULT TO THE GREASE MANUFACTURER OR KEMIX.

11.8 ASSEMBLY AND DISASSEMBLY Disassembly and assembly must be done by qualified personnel using only suitable tools and appropriated methods. The stator grips must be applied over the side face of the inner ring to be disassembled or over and adjacent part.

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual It is essential that the bearings disassembly and assembly be done under cleanning conditions to ensure good operation and to avoid damages. New bearings shall only be taken out from their cases when assembling them. Before installing a new bearing it is required to check the shaft fitting for any sharp edge or strike signals. For bearing assembly, warm their inner parts with suitable equipment - inductive process - or use suitable tools.

11.9 SPARE PARTS When ordering spare parts, please specify the full type designation and product code as stated on the motor nameplate. Please also inform the motor serial number stated on the nameplate.

11.10 MOTORS FOR HAZA RDOUS LOCATIONS Besides the recommendations given previously, these ones must be also followed:

NOTE:

THE SPECIFICATION OF THE MOTOR INSTALLATION PLACE IS FOR CUSTOMER’S RESPONSIBILITY, WHO WILL ALSO DETERMINE THE ENVIRONMENT CHARACTERISTICS.

Motors for hazardous locations are manufactured according to specific standards for such environments and they are certified by worldwide certifying entities.

11.10.1

Installation

The complete installation must follow procedures given by the local legislation in effect.

NOTE:

11.10.2

THE INSTALLATION OF HAZARDOUS LOCATION MOTORS MUST BE CARRIED OUT BY SKILLED PEOPLE, AND THE THERMAL PROTECTION MUST BE ALWAYS INSTALLED, EITHER INSIDE OR OUTSIDE THE MOTOR, OPERATING AT THE RATED CURRENT.

Maintenance

Maintenance must be carried out by repair shops authorized by Kemix. Repair shops and people without Kemix’s authorization who will perform any service or hazardous location motors will be fully responsible for such service as well as for any consequential damage.

NOTE:

 ANY ELECTRICAL OR MECHANICAL MODIFICATION MADE ON HAZARDOUS LOCATION MOTORS WILL VOID THE CERTIFICATION.

When performing maintenance, installation or relubrication, follow these instructions:

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

     

Check if all components are free of edges, knocks or dirt. Make sure all parts are in perfect conditions. Lubricate the surfaces of the endshield fittings with protective oil to make the assembly easier. Use only rubber hammer to fit the parts. Check for correct bolts tightening. Use clearance calibrator for correct T-box fitting (smaller than 0.05mm).

NOTE:

DO NOT REUSE DAMAGED OR WORN PARTS. REPLACE THEM BY NEW ONES SUPPLIED BY THE FACTORY.

11.11 MOTORS DRIVEN BY VFD  Applications using VFD´s without filter can affect motor pe rformance as follows:       

Lower efficiency. Higher vibration. Higher noise level. Higher rated current. Higher temperature rise. Reduced motor insulation. Reduced bearing life.

11.11.1   

Voltages lower than 440V do not require filter. Voltages equal or higher than 440V or lower than 575V require filter for motor power supply cables longer than 20 meters. Voltages equal or higher than 575V require filter for any size of power supply cables.

NOTE:

11.11.2  

Standard Motors

IF SUCH RECOMMENDATIONS ARE NOT FOLLOWED  ACCORDINGLY, MOTOR WARRANTY WILL BE VOID.

Inverter Duty Motors

Check power supply voltage of the forced cooling set. Filters are not required.

11.12 WARRANTY TERMS - SERIES AND ENGINEERING PRODUCTS Kemix warrants its products against defects in workmanship and materials for 18 months from the invoice date issued by the factory, authorized distributor or agent limited to 24 months from manufacturing date independent of installation date as long as the following items are fulfilled accordingly:

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Proper transportation, handling and storage; Correct installation based on the specified ambient conditions and free of corrosive gases; Operation under motor capacity limits; Observation of the periodical maintenance services; Repair and/or replacement effected only by personnel duly authorized in writing by Kemix; The failed product be available to the supplier and/or repair shop for a required period to detect the cause of the failure and corresponding repair; Immediate notice by the purchaser about failures occured and that these are accepted by Kemix as manufacturing defects.

This warranty does not include disassembly services at the purchaser facilities, transportation costs with product, tickets, accomodation and meals for technical personnel when requested by the customer. The warranty service will be only carried out at Kemix Authorized Repair Shops or at Kemix´s facilities. Components whose useful life, under normal use, is shorter than the warranty period are not covered by these warranty terms. The repair and/or replacement of parts or components, when effected by Kemix and/or any Kemix Authorized Repair Shop, will not give warranty extension. This constitutes Kemix´s only warranty in connection with this sale and the company will have no obligation or liability whatsoever to people, third parties, other equipment or installations, including without limitation, any claims for consequential damages or labor costs.

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 Kemix Pty Ltd AAC Pumpcell Plant Operating Manual

12 BOLT TORQUE TABLE  All the bolts on the AAC Pumpcell mechanism should be torq ue to the values specified in Table 4. Table 4 - Steel B olt Torque Table (Nm) Grade Size 12 16 20 24 30 36

4.6 38 95 185 320 600 -

8.8 68 185 360 620 1225 2343

Table 5 – 304 Stainless Steel Bolt Torque Table (Nm) Size 12 16 20 24 30 36

Torque (Nm) 38 95 185 320 600 1115

13 TOOLS REQUIREMENT 

Full set of metric spanners. (Sizes 10 – 60)

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14 TECHNICAL DRAWINGS 1 – G.A OF AA C PUMPCELL PLANT Figure 56 - G.A. of AA C Pumpcell Plant

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15 TECHNICAL DRAWINGS 1 – G.A OF AA C PUMPCELL MECHANISM Figure 57 - G.A. of A AC Pumpcell Mechanism

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16 TECHNICAL DRAWINGS 3 – P & ID AND PFD Figure 58 – P & ID and PFD of A AC Pumpc ell Plant

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18 GEARBOX OPERATING INSTRUCTIONS  A.1 Gearbox tec hnic al operati ng in st ru ct io ns

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