Site Acceptance Test Plan African Industries - Rev02

Minerals
Weir Minerals Netherlands b.v.

Egtenrayseweg 9, 5928 PH Venlo
The Netherlands
P.O. Box 249, 5900 AE Venlo
The Netherlands
Site Acceptance Test Plan
A Haroske
Weir Netherlands b.v.
12/3/2022
1
Release History
Date Version Released by Reason for release / changed chapters

13-11-2022 001 A. Haroske Start Optimization
2
Table of Content
Release History 2
Table of Content 3
Objective of this document 7
Glossary of terminology 8
Reference documents 9
Document Survey 10
1. Project information 11
2. Overview 12
2.1 Purpose 12
2.2 Scope of SAT 12
2.3 Output 12
2.4 Stakeholders 13
2.5 Witness 13
3. Testing 14
3.1 General approach 14
3.2 Responsibilities 14
3.3 Test Results 14
4. General Safety Tests 15
4.1 Power tests 15
4.1.1 Main power 15
4.1.2 Test results 15
4.1.3 Control voltage 15
4.2 Emergency Stop circuit tests 16
4.2.1 Internal Emergency Stop circuit 16
4.2.2 Test result 16
4.2.3 External Emergency Stop circuit 16
4.3 Pressure release test 17
4.3.1 Emergency stop Pressure release test 17
4.3.2 Fast stop Pressure release test 17
4.4 Warning signs 18
4.4.1 Warning Sign checks 18
5. Equipment tests 19
5.1 Main motors 19
5.1.1 MRT 19
5.1.2 Speed Sensors 19
5.1.3 Motor Heater 19
5.1.4 PTC 19
3
5.1.5 Emergency stop 19
5.1.6 Main motors Acceleration 19
5.1.7 Main motors Deceleration 19
5.1.8 Temperature Sensors 20
5.2 Cardan shafts 21
5.2.1 Cardan shaft test description 21
5.3 Safeset 22
5.3.1 Safeset test description 22
5.4 Gearboxes 23
5.4.1 Temperature Sensor oil MR 23
5.4.2 Temperature Sensor bearing MR 23
5.4.3 Temperature Sensor oil FR 23
5.4.4 Temperature Sensor bearing FR 23
5.4.5 MRT Cooler MR 23
5.4.6 MRT Cooler FR 23
5.4.7 Filter sensor MR 23
5.4.8 Filter sensor FR 24
5.5 Grease system 25
5.5.1 Pipe flushing 25
5.5.2 MRT 25
5.5.3 Barrel heater 25
5.5.4 Heat Trace 25
5.5.5 Sensors 25
5.5.6 Grease system functionality 26
5.6 Hydraulic system 27
5.6.1 Pipe flushing 27
5.6.2 MRT 27
5.6.3 Program Temperature controller 27
5.6.4 Temperature sensor 27
5.6.5 Heater 27
5.6.6 Sensors 27
5.6.7 Valve 27
5.6.8 Main cylinders 27
5.6.9 Retraction cylinders 28
5.7 Water cooling system 29
5.7.1 Water flow 29
5.8 Bearing Sensors 30
5.8.1 Temperature sensors 30
5.8.2 Bearing distance sensors 30
5.8.3 Bearing end limit switches 30
5.8.4 Vibration sensor 30
5.9 Auxiliary drive 31
5.9.1 MRT 31
5.9.2 Functionality 31
6. Mechanical 32
4
6.1 Zero Gap 32
6.2 Lateral walls 32
6.3 Water cooling 33
6.4 Tyre measurement 34
6.4.1 Fixed Roller 34
6.4.2 Movable Roller 34
7. Interface tests 35
7.1 Interlock tests 35
7.1.1 Plant Emergency Stop 35
7.1.2 Interlocking water supply 35
7.1.3 Interlocking Gearbox Cooler Systems 35
7.1.4 Interlocking Air Compressor 35
7.1.5 Interlocking Grease Lubrication 35
7.1.6 Interlock Material Feed Supply 36
7.1.7 Interlock test discharge 36
7.2 SCADA 37
7.2.1 SCADA Interface 37
7.2.2 SCADA Layout 37
7.2.3 SCADA Reboot 39
7.3 Diagnostic Box 40
7.3.1 Interface test 40
7.3.2 Data 40
7.3.3 USB 40
7.3.4 Diagnostics Box Reboot 40
7.4 PLC 41
7.4.1 PLC SD Card 41
7.4.2 Software backup 41
7.4.3 PLC Reboot 41
8. Training 42
8.1 Operator training 42
8.1.1 Scope of training 42
8.1.2 Participants 42
8.2 Mechanical training 43
8.3 Electrical training 44
9. Process 45
9.1 Process initial settings 45
9.2 Grinding size reduction 46
9.2.1 Measuring feed size 46
5
9.2.2 Measuring discharge size 46
10. Acceptance certificate 47
6
Objective of this document
The objective of this Site Acceptance Plan is to describe and record all tests that are conducted.
This document describes functional tests and process tests which have to be performed by the
commissioning engineer during the SAT testing period on site.
If a test is successful, the commissioning/test engineer places his or her initials and fills in the
appropriate code.
Some tests require product. This document assumes that all necessary requirements are
available. If not the commissioning/test engineer should report this so that the necessary
requirements can be arranged.
Some tests are described as a guideline to commission a module, eg. Grease system, Water
cooling. However, this document is not intended to be used as a working scheme. As long as all
tests are done, it is up to the commissioning/test engineer to determine in what order he or she
does the commissioning/testing.
Also this document is used a beneficial take-over when signed, from Weir Minerals to their
customer.
In this document the language which is used will be in English. The messages appearing
on SCADA or HMI are assumed to be in the English language. If on site the messages
appear in the native language, a translation will be made and a remark will recorded.
This document is only to be used by people with knowledge of the project, and/or the
communication applications stated in this document.
7
Glossary of terminology
HPGR High Pressure Grinding Rolls
RP Roller Press, abbreviation for HPGR used in different industries
FR Fixed Roller, the roller that is not movable hydraulically
MR Movable Roller, the roller that is hydraulically movable
Safeset Mechanical safety coupling between cardan shaft and gearbox
MRT Motor running test, to check running direction and mechanical check
ROLCOX Rolcox is the name of the HPGR control system
DS Drive side, this is the side where the motors are located
NDS Non Drive Side, this is the opposite side of the DS
HMI Human Machine Interface
MCC Main Control Cabinet
PLC Programmable Logic Controller
SCADA Supervisory Control and Data Acquisition
8
Reference documents
The following documents are used as a reference:
As build documentation will be delivered after commissioning is done and all corrections in
the documentation are made.
Document number Document description Author Date
9
Document Survey
This document consists of 6 main chapters, which are the consecutive steps in the Site
Acceptance Test plan.
Chapter 1: Project information
Chapter 2: Overview of SAT plan, explains what is the purpose and Scope of the SAT Plan
Chapter 3: Testing, explains the approach of testing
Chapter 4: General Safety tests, this chapter describes the safety features that have to be
tested before other tests can be conducted
Chapter 5: Equipment tests, the chapter describes the tests to be conducted on the equipment
all related to the HPGR and within Scope of Weir delivery
Chapter 6: Mechanical, this chapter describes the mechanical checks just before production
and after a while running
Chapter 7: Interface tests, this chapter describes the tests to be conducted on interlocks with
third party equipment.eg. Conveyors, pre-bunker load cells
Chapter 8: Training, describes which trainings are given to operators and maintenance
engineers
Chapter 9: Process tests, describes which process tests have to be conducted and values are
being evaluated
Chapter 10: Acceptance Certificate, when all tests are conducted and are signed of as
successful this document is marked as an official Acceptance Certificate of the
HPGR
10
1. Project information
Project information
Project African Industries
Purchase order no. AFDMCC/19/IN/ANRML/008559
Equipment type High Pressure Grinding Rolls (HPGR)
Equipment Name(s) RPM24-240/220
Quantity required 1
Equipment no. 205200028/1
Serial number Weir 205200028/1
Feed
Material Magnetite Quartzite Ore
Fresh feed (Design / max.) Recirc. Load: 192%
Specific throughput 1231t/h – 1308t/h (wet)
HPGR configuration
Diameter of rolls 2400mm
With of rolls 2200mm
Tyre diameter surface
Studs
protection
Tyre edge protection Lateral studs
Operating Speed 8,7 – 17,5rpm
Operating peripheral
1,1 – 2,2m/s
speed
Specific Power 4,19 kWh/t
Specific Pressure 3,5 N/mm2
11
2. Overview
2.1 Purpose
The purpose of this document is to:
 Describe the strategy for Site Acceptance Testing for the project to verify compliance with
requirements as specified in the supplier contract
 Ensure all requirements for Site Acceptance Testing of the HPGR System are appropriately
assessed and planned within the overall Project Plan
 Demonstrate to all stakeholders that the testing processes to be undertaken will be
appropriately managed and controlled.
2.2 Scope of SAT

The scope of this Site Acceptance Test Plan is:
 Describe which equipment is tested

 Describes which tests are conducted
 Results of tests are recorded
 Register stakeholders
 Confirm if contractual requirements are accomplished
2.3 Output
Outputs to be produced as a result of this Site Acceptance Test are:
 Test results
 Trained resources
 Acceptance Certificate
12
2.4 Stakeholders
All stakeholders of the project team which are involved / conducted tests should register below
Name : Alexander Haroske

Job title/function : Sr. Commissioning & Training Engineer
Company : Weir Minerals Netherlands b.v.
Reason of participation : Commissioning Engineer HPGR
Date : week 45-49 2022
Name :
Job title/function :
Company :
Reason of participation :
Date :
Name : ………………………………………………………
Job title/function : ………………………………………………………
Company : ………………………………………………………
Reason of participation : ………………………………………………………
Date :
Name : ………………………………………………………
Company : ………………………………………………………
Date : ………………………………………………………
2.5 Witness
All stakeholders of the project team which are witnessed tests should be registered below
Name :
Job title/function :
Company :
Reason of participation :
Date :
Name : ………………………………………………………
Company : ………………………………………………………
Date : ………………………………………………………
Name : ………………………………………………………
Company : ………………………………………………………
Date : ………………………………………………………
13
3. Testing
3.1 General approach
The general approach for the Site Acceptance Testing of the HPGR is as follows:
 Safety Testing
 Functional unit testing
 Interface testing
 Interlock testing
 System testing
 Acceptance testing
3.2 Responsibilities
The commissioning / test engineer is responsible that the tests are conducted according test
description.
Customer responsibility is that that the test environment en required test material is available.
Supplier Project management is responsible to review test cases and results and to supply the
SAT certificate.
3.3 Test Results

Test results will be documented by the Commissioning / test engineer.
The following codes will be given to the conducted tests
Code Description
N Not Tested
A Accepted
F Complete failure Remark required
P Partial failure (test completed) Remark required
NA Not applicable
14
4. General Safety Tests
4.1 Power tests
The power on test is to confirm that requested power supply is according specifications
4.1.1 Main power
With main power is meant the power supply from the customer MCC to the Rolcox cabinet.
4.1.1.1 Main power test description
Check the following:

 Cabling to cabinet according required standards
 If applicable glands are correctly tightened
 Fuse protection to Rolcox cabinet at specified
 Measure voltage before switching on main switch
4.1.2 Test results
The results of conducted tests above are recorded in the list below:
Test description Value Name Code

Cabling N.A. A. Haroske A
Glands N.A. A. Haroske A
Fuse protection A
Measured voltage 400VAC A. Haroske A
Remark:
No Glands installed correctly
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
4.1.3 Control voltage
With control voltage is meant the internal control voltage power supply of the HPGR Rolcox.
4.1.3.1 Control voltage test description

 Measure voltage supply of the control voltage
 Switch on fuse to control voltage supply
 Measure voltage of the control voltage
 Switch on fuse to controls system
4.1.4 Test results

Supply voltage 220VAC A. Haroske A
Control voltage 24VDC A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
15
…………………………………………………………………………………………………………………..
4.2 Emergency Stop circuit tests
The emergency stop circuit tests are divided into two tests. First test is the internal emergency stop
system of the HPGR Rolcox itself. The second is to check the correct integration of the HPGR
Rolcox internal emergency system with the plant emergency system.
4.2.1 Internal Emergency Stop circuit
The internal emergency stop system is checked by 1 emergency stop which is mounted on the
door of the HPGR Rolcox panel.
4.2.1.1 Internal Emergency Stop test description

 Emergency relay inside C01 indicates both channels are okay
 Press emergency stop S7
 Emergency relay indicates both channels are not okay
 Reset the pressed Emergency stop in original state
 Emergency stop relay indicates both channels are okay
4.2.2 Test result
Test description Name Code

Internal emergency circuit tests A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
4.2.3 External Emergency Stop circuit
The external emergency stop system has to be tested to confirm that the interlocking with the plant
emergency stop system is integrated with the HPGR Rolcox system correctly.
4.2.3.1 External Emergency Stop test description

 Emergency relay inside C01 indicates both channels are okay
 Press emergency stop which is in the plant emergency stop circuit
 Emergency relay indicates both channels are not okay
 Reset the pressed Emergency stop in original state
 Emergency stop relay indicates both channels are okay
4.2.4 Test result

External emergency circuit tests A. Haroske A
Remark:
No Emergency interlocking with other systems
…………………………………………………………………………………………………………………..
16
4.3 Pressure release test
The hydraulic pressure has to be released of the HPGR hydraulic system as soon as an
emergency stop is pressed.
4.3.1 Emergency stop Pressure release test
The pressure release or emergency pressure release valve is V08. This valve is wired fail safe and
is to prevent the HPGR Hydraulic system to be pressurized when an emergency system stop or a
system fast stop is done.
4.3.1.1 Emergency stop test description
For the tests below the HPGR Hydraulic system doesn’t have to be operational.

 Emergency relay indicates healthy
 Valve V08 is energized
 Press an emergency stop which is integrated into the HPGR Rolcox emergency circuit
 Valve V08 is not energized
 Reset the pressed emergency button
4.3.2 Fast stop Pressure release test
The pressure release or emergency pressure release valve is V08. This valve is wired fail safe and
is to prevent the HPGR Hydraulic system to be pressurized when a system fast stop is requested.
4.3.2.1 Fast Stop test description
For the tests below the HPGR Hydraulic system has to be operational.

 Emergency relay indicates healthy
 Hydraulic system is operational
 Pressurize hydraulic system until 40 bar is reached on both sides
 Trigger the end limed switch on one side of the HPGR
 Valve V08 is not energized
 Reset the pressed emergency button
4.3.3 Test result

Emergency stop pressure release test A. Haroske A
Fast stop pressure release test A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
17
4.4 Warning signs
On the HPGR several warning signs can be mounted, this differs per type.
Check if all required warning signs are mounted on the HPGR.
4.4.1 Warning Sign checks

 Warning signs “do not open doors….”
4.4.2 Test result

Warning signs A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
18
5. Equipment tests
The equipment tests to be conducted are all tests which are within the scope of the HPGR
functionality.
5.1 Main motors

The following tests have to be conducted for the main motors of the HPGR.
5.1.1 MRT
Test the following:

 Motor running test, check running directions.
5.1.2 Speed Sensors
Test the following:

 Check the signal of the speed sensor MR
 Adjust the position of the speed sensor MR
 Adjust the depth of the speed sensor MR
 Check the signal of the speed sensor FR
 Adjust the position of the speed sensor FR
 Adjust the depth of the speed sensor FR
5.1.3 Motor Heater
Test the following:

 Check wiring, make sure that the gland and isolation of wiring is accurate installed
 Check functionality
5.1.4 PTC
Test the following:

 Check connections
 Check functionality
5.1.5 Emergency stop
Test the following:

 Check the functionality
 Check the interlocking between the HPGR and the VFD
5.1.6 Main motors Acceleration
Test the following:

 Check the settings in the VFD
 Measure the time during acceleration
5.1.7 Main motors Deceleration
Test the following:

 Check the settings in the VFD
 Measure the time during acceleration
19
5.1.8 Temperature Sensors
Test the following:

5.1.9 Test result

MRT N.A. A. Haroske A
Speed sensor MR N.A A. Haroske A
Speed sensor FR N.A A. Haroske A
Motor Heater N.A. A. Haroske A
PTC N.A. A. Haroske A
Emergency stop N.A. A. Haroske A
Main motors Acceleration MR A. Haroske A
Main motors Deceleration MR A. Haroske A
Main motors Acceleration FR A. Haroske A
Main motors Deceleration FR A. Haroske A
Temperature sensors windings MR A. Haroske A
Temperature sensors bearings MR A. Haroske A
Temperature sensors windings FR A. Haroske A
Temperature sensors bearings FR A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
20
5.2 Cardan shafts
The cardan shafts a have a few critical points to be checked. The alignment of the cardan shaft is
very important to prevent vibrations in the motor and gearbox bearings. Grease points need to be
checked.
5.2.1 Cardan shaft test description

 Grease nipples are installed
 Grease is applied according manual
 Bolts correctly torqued
5.2.2 Test result

Cardan shaft MR grease nipple A. Haroske A
Cardan shaft FR grease nipple A. Haroske A
Cardan shaft MR grease applied A. Haroske A
Cardan shaft FR grease applied A. Haroske A
Cardan shaft MR motor side bolts torqued A. Haroske A
Cardan shaft MR gearbox side bolts torqued A. Haroske A
Cardan shaft FR motor side bolts torqued A. Haroske A
Cardan shaft FR gearbox side bolts torqued A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
21
5.3 Safeset
The safeset is the mechanical safety for the HPGR. If a too high torque is requested the sheer pen
has to break to prevent further damage. Every safeset is individually factory tested and is supplied
with a diagram for the correct setting.
5.3.1 Safeset test description

 Diagram Safeset MR filled in
 Safeset setting MR
 Diagram Safeset FR filled in
 Safeset setting FR
5.3.2 Test result

Diagram safeset MR filled in N.A. A. Haroske A
Safeset Setting MR 80MPA A. Haroske A
Diagram safeset FR filled in N.A. A. Haroske A
Safeset Setting FR 80MPA A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
22
5.4 Gearboxes
The following tests are related to all the equipment that is related to the gearboxes.
5.4.1 Temperature Sensor oil MR
The sensor that measures the oil temperature in the gearbox of the movable roller.
Test the following:

 Check functionality by checking in the PLC if the signal is working
 Check if the reading is correct in the PLC
5.4.2 Temperature Sensor bearing MR
The sensor that measures the bearing temperature in the gearbox of the movable roller.
Test the following:

5.4.3 Temperature Sensor oil FR
The sensor that measures the oil temperature in the gearbox of the movable roller.
Test the following:

5.4.4 Temperature Sensor bearing FR
The sensor that measures the bearing temperature in the gearbox of the movable roller.
Test the following:

5.4.5 MRT Cooler MR
Test the following:

 Motor running test, check running directions
5.4.6 MRT Cooler FR
Test the following:

 Motor running test, check running directions
5.4.7 Filter sensor MR
Test the following:

23
 Check interlocking
5.4.8 Filter sensor FR
Test the following:

 Check interlocking
5.4.9 Test result

Temperature sensor oil MR 12 A. Haroske A
Temperature sensors bearing MR 11 A. Haroske A
Temperature sensor oil FR 12 A. Haroske A
Temperature sensors bearing FR 11 A. Haroske A
MRT cooler MR N.A. A. Haroske A
MRT cooler FR N.A. A. Haroske A
Filter sensor MR N.A. A. Haroske A
Filter sensor FR N.A. A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
24
5.5 Grease system
The following tests have to be conducted on the grease system of the HPGR.
5.5.1 Pipe flushing
Test the following:

 Verify if piping is correctly flushed
5.5.2 MRT
Test the following:

5.5.3 Barrel heater
Test the following:

 Set the temperature
5.5.4 Heat Trace
Test the following:

5.5.5 Sensors
Test the following:

 Adjust sensors
25
5.5.6 Grease system functionality
Test the following:

 Open the air bleed plug on top of the pump
 Disconnect the hose coming from the pump
 Switch the pump on
 After pump has been bleed switch the pump off and connect the hose
 Disconnect the first connection to the first progressive valve
 After the piping has been bleed switch the pump off and connect the piping
 Disconnect the connection to the second stage progressive valves
 After the piping and the first stage has been bleed switch the pump off and connect the
piping
 Disconnect the connection to the second stage progressive valves
 After the piping and the first stage valve has been bleed switch the pump off and connect
the piping
 Disconnect the connection to the bearing housings and put bags or bottles to contaminate
the grease.
 After the piping and the second stage valves has been bleed switch the pump off and
connect the piping
 Check the volume in the bags or bottles.
During these action, check the over pressure valve at the grease pump regularly.
Grease may come out the pressure valve has to adjusted or there is a blockage in
the piping and/
or progressive valves.
5.5.7 Test result

Pipe flushing N.A. A. Haroske P
Barrel heater 70 A. Haroske A
Heat Trace N.A. A. Haroske
Grease Pulse sensor DS N.A. A. Haroske A
Grease Pulse sensor NDS N.A. A. Haroske A
Pressure sensor Pump N.A. A. Haroske A
Grease system functionality N.A. A. Haroske A
Remark:
Piping not flushed as requested, just pressurized/flushed with air 6 bar.
……………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
26
5.6 Hydraulic system
The hydraulic system is for moving the movable roller and to keep pressure on the movable roller
during production.
5.6.1 Pipe flushing
Test the following:

 Verify if piping is correctly flushed
5.6.2 MRT
Test the following:

5.6.3 Program Temperature controller
Test the following:

 Program the temperature controller
 Check the functionality of the temperature controller
5.6.4 Temperature sensor
Test the following:

 Check the functionality of the temperature sensors
5.6.5 Heater
Test the following:

 Check the functionality of the heater
5.6.6 Sensors
Test the following:

 Check the functionality of the sensors
5.6.7 Valve
Test the following:

 Check the functionality of all the valves individually
5.6.8 Main cylinders
Test the following:

 Bleed the air from the main cylinders by connecting a bleed hose to the bleed valves of the
main cylinders
 Add pressure to drain/bleed all the air in the main cylinder
 Repeat previous steps for the other cylinders
27
5.6.9 Retraction cylinders
Test the following:

 Bleed the air from the retraction cylinders by connecting a bleed hose to the bleed valves of
the main cylinders
 Add pressure to drain/bleed all the air in the retraction cylinder
 Repeat previous steps for the other retraction cylinder
5.6.10 Test result

Pipe flushing N.A. A. Haroske P
Program Temperature controller N.A. A. Haroske A
Temperature sensor N.A. A. Haroske A
Heater N.A. A. Haroske A
Level Switch N.A. A. Haroske A
Filter Sensor N.A. A. Haroske A
Proportional valve V01/V02 N.A. A. Haroske A
Proportional valve V03/V04 N.A. A. Haroske A
Valve V05 N.A. A. Haroske A
Main cylinders N.A. A. Haroske A
Retraction cylinders N.A. A. Haroske A
Remark:
Piping not flushed as requested, just pressurized/flushed with air 6 bar.
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
28
5.7 Water cooling system
The bearings and the rollers have water cooling. The water cooling is installed to prevent the shaft
and/or the bearings getting too hot.
5.7.1 Water flow
Test the following:

 Check the functionality of all water flow valves
5.7.2 Test result

Water flow MR DS N.A. A. Haroske A
Water flow MR NDS N.A. A. Haroske A
Water flow FR DS N.A. A. Haroske A
Water flow FR NDS N.A. A. Haroske A
Water flow Roller MR N.A. A. Haroske A
Water flow Roller FR N.A. A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
29
5.8 Bearing Sensors
On the bearing housings several sensors are mounted. The sensors are there to guard the
temperature and measure the vibration.
5.8.1 Temperature sensors
Test the following:

5.8.2 Bearing distance sensors
Test the following:

5.8.3 Bearing end limit switches
Test the following:

5.8.4 Vibration sensor
Test the following:

5.8.5 Test result

Temperature sensor MR DS 10 A. Haroske A
Temperature sensor MR NDS 10 A. Haroske A
Temperature sensor FR DS 10 A. Haroske A
Temperature sensor FR NDS 9 A. Haroske A
Bearing distance sensor DS N.A. A. Haroske A
Bearing distance sensor NDS N.A. A. Haroske A
Vibration sensor N.A. A. Haroske P
Remark:
Cable missing between V19 and C02
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
30
5.9 Auxiliary drive
The Auxiliary drive is used for checking the roller surface. A chain has to be mounted between the
auxiliary drive and the gearbox chain sprocket wheel.
Lockout the main motors before installing the chain.
5.9.1 MRT
Test the following:

 Motor running test, check running directions and speed setting
5.9.2 Functionality
Test the following:

 Check with the chain
5.9.3 Test result

Functionality N.A. A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
31
6. Mechanical
During commissioning mechanical adjustments have to be made. The mechanical adjustments are
described in this chapter.
6.1 Zero Gap

The Zero Gap of the machine has to be set by removing or adding shims. After setting the zero
gap correct the bearing distance sensor have to set correctly
Test the following:

 Check the distance between the rollers after installation
 Check the difference of the space between the rollers and mechanical en-stops
 Add or remove shims if required
 Pressurize the HPGR with 40 bar on the mechanical end stops
 Measure the roller distance and note in the test results
 If correct move the bearing distance sensors in the correct position so that zero is indicated
6.1.1 Test result

Zero Gap adjustment 10mm A. Haroske A
Bearing distance sensor DS N.A. A. Haroske A
Bearing distance sensor NDS N.A. A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
6.2 Lateral walls
The lateral walls are installed to contain the feed material inside the machine. The walls are set to
a certain pressure with different springs. The springs have to be set according the adjustment
specification in the manual.
Test the following:

 Check the height of the
 Measure the fixed roller surface
6.2.1 Test results

Adjust Lateral wall DS N.A. A. Haroske A
Adjust Lateral wall NDS N.A. A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
32
…………………………………………………………………………………………………………………..
6.3 Water cooling
Adjust the water cooling to the bearing housing after a while running.
6.3.1 Test result

Adjust water cooling MR DS Max A. Haroske N.A.
Adjust water cooling MR NDS Max A. Haroske N.A.
Adjust water cooling FR DS Max A. Haroske N.A.
Adjust water cooling FR NDS Max A. Haroske N.A.
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
33
6.4 Tyre measurement
The initial tyre measurement is done after approximately 10 hours of production. This is the initial
measurement. This measurement is being used a reference point.
6.4.1 Fixed Roller
Test the following:

 Check the surface of the fixed roller for damaged or broken studs
 Check the
 Mark the bolts which are in the holes where the measurement pins are installed
6.4.2 Movable Roller
Test the following:

 Check the surface of the fixed roller for damaged or broken studs
 Mark the bolts which are in the holes where the measurement pins are installed
6.4.3 Test result

Surface check fixed roller N.A. A. Haroske A
Surface check movable roller N.A. A. Haroske A
Initial wear measurement FR N.A.
Initial wear measurement MR N.A.
Bolts marked FR N.A.
Bolts marked MR N.A.
Measuring results Fixed Roller:
(Insert screenshot of measurement)
Measuring results Movable Roller:
(Insert screenshot of measurement)
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
34
7. Interface tests
In this chapter all the interfaces between the HPGR and its components are described and also the
interlocks between the other plant equipment.
7.1 Interlock tests
The HPGR is interlocked with several other equipment in the plant to prevent unexpected/expected
starting and/or stopping. All the interlocks should be tested individually.
All the consumers are started via the plant PLC. The Plant PLC is responsible to report back to
Rolcox if the consumer is running after being started.
7.1.1 Plant Emergency Stop
Test the following:

 Check by pressing an emergency stop button, which is not connected directly to the rolcox
cabinet, if the expected result is achieved
7.1.2 Interlocking water supply
Test the following:

 Check by starting and stopping the water supply to the HPGR if the expected result is
achieved
 Create an error on the water supply and check if the expected result is achieved
7.1.3 Interlocking Gearbox Cooler Systems
Test the following:

 Check by starting and stopping the gearbox cooler systems of the HPGR if the expected
result is achieved
 Create an error in the gearbox cooler system(s) and check if the expected result is
achieved
7.1.4 Interlocking Air Compressor
Test the following:

 Check by starting and stopping the air compressor of the HPGR if the expected result is
achieved
 Create an error on the air compressor and check if the expected result is achieved
7.1.5 Interlocking Grease Lubrication
Test the following:

 Check by starting and stopping the grease lubrication system of the HPGR if the expected
result achieved
 Create an error on the grease lubrication system and check if the expected result is
achieved
35
7.1.6 Interlock Material Feed Supply
Test the following:

 Check by starting and stopping the material feed supply of the HPGR if the expected result
achieved
 Create an error on the material feed supply and check if the expected result is achieved
 Create an error on the HPGR and check if the material feed supply is responding as
expected
7.1.7 Interlock test discharge
Test the following:

 Check by starting and stopping the material discharge system of the HPGR if the expected
result achieved
 Create an error on the material discharge system and check if the expected result is
achieved
7.1.8 Test results

Plant Emergency Stop N.A. N.A.
Interlock Water Supply N.A. N.A.
Interlock Gearbox Cooler Systems N.A. A. Haroske A
Interlock Air Compressor N.A. N.A.
Interlock Grease Lubrication N.A. A. Haroske A
Interlock Material Feed Supply N.A. A. Haroske A
Interlock Material Discharge N.A. A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
36
7.2 SCADA
In this chapter are the test described which will be conducted on the SCADA system.
7.2.1 SCADA Interface
Test the following:

 Connection between SCADA and the Rolcox PLC are established
 Check if some tags are communicated
7.2.2 SCADA Layout
The SCADA system contains two pages for the HPGR. The first and main page shows all the main
topics of the HPGR. The second page displays all the alarms.
7.2.2.1 Main Page
37
7.2.2.2 Alarm Page
38
7.2.3 SCADA Reboot
Test the following:

 Reboot the SCADA system
 Check if the connection is being build up again between the Rolcox PLC and the Plant PLC
7.2.4 Test result

SCADA interface N.A. A. Haroske A
SCADA Completion N.A. A. Haroske A
SCADA Functionality N.A. A. Haroske A
SCADA Reboot N.A. A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
39
7.3 Diagnostic Box
The Diagnostics Box is a part of the Rolcox control system. The Diagnostic box is to store data of
the HPGR. The data that is stored contains all the changes in settings, all signal changes and all
the measured values.
7.3.1 Interface test
Test the following:

 Connection between the Diagnostics Box and the Rolcox PLC is established
 Check if data is created
7.3.2 Data
Test the following:

 Check if the correct folders are created and stored on the Diagnostics Box
 All the required data is created and stored on the Diagnostics Box
7.3.3 USB
Test the following:

 Check if the correct and all data is copied to USB stick after inserting it into Diagnostics Box
 Check if the warning lights on the Rolcox cabinet are indicating as expected
7.3.4 Diagnostics Box Reboot
Test the following:

 Check if the connection is being build up again between the Rolcox PLC
7.3.5 Test results

PLC/Diagnostics Box Interface N.A. A. Haroske A
Data check N.A. A. Haroske A
USB copy function test N.A. A. Haroske A
Diagnostics Box Reboot N.A. A. Haroske A
Remark:
SYNERTREX is not setup and not commissioned (not necessary due to Barry Cootjans
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
40
7.4 PLC
The functionality of PLC software is tested during several tests. The following chapter is to assure
backups are made and a reboot test is conducted.
7.4.1 PLC SD Card
If applicable create a backup on the PLC SD card.
7.4.2 Software backup
Create a backup of the software.
7.4.3 PLC Reboot
Test the following:

 Check if the connection is being build up again between SCADA, Diagnostics Box and the
plant PLC
7.4.4 Test result

PLC SD card N.A. W. Matheij / A. Haroske A
Software backup N.A. W. Matheij / A. Haroske A
PLC Reboot N.A. W. Matheij / A. Haroske A
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
41
8. Training
In this chapter the different trainings are described.
8.1 Operator training
The operator training is given for field and control room operators that are operating the HPGR.
8.1.1 Scope of training
Scope of operator training is to train the following:
 Safety training of the HPGR

 Lock-out procedures
 Safety features
 Functional training HPGR
 How does the HPGR work
 Parts of the HPGR
 Settings and operating of the HPGR
 Settings
 Operating
8.1.2 Participants
All participants should be registered below:
See separate list.
Name : ………………………………………………………
Company : ………………………………………………………
Date : ………………………………………………………
42
8.2 Mechanical training
The Mechanical training is given for mechanical/maintenance engineers that are performing
mechanical and/or maintenance on the HPGR.
Scope of Mechanical training is to train the following:

 Safety features
 Maintenance
 Manual explanation
 Oil and Grease systems training
 Hydraulic system training
 Set Safeset
 Adjust Lateral Walls
8.2.2 Participants
See separate list.
Name : ………………………………………………………
Company : ………………………………………………………
Date : ………………………………………………………
43
8.3 Electrical training
The Electrical training is given for electrical/maintenance engineers that are performing Electrical
and/or maintenance on the HPGR.
Scope of Electrical training is to train the following:

 Safety features
 Electrical
 Manual explanation
 Electrical schematic training
 Fault finding
 Sub system training
8.3.2 Participants
See separate list.
Name : ………………………………………………………
Company : ………………………………………………………
Date : ………………………………………………………
44
9. Process
In this chapter process values are noted and process tests are
9.1 Process initial settings
This table describes the initial settings of the HPGR.
Operation Pressure Bar 140

Pressure Increase Max Bar 20
Pressure Ratio Bar/mm 0
Pressure Tolerance Bar 10
Pressure Difference Max Bar 30
Pressure Correction Factor K3 % 0
Pressure Max (Bypass Open) Bar 185!!!
Pressure Min (Accumulator) Bar 112
Pressure Increase Delay Time sec 1
Proportional Valves Pressure Increase % 100
Proportional Valves Pressure Decrease Low Point % 60
Proportional Valves Pressure Decrease High Point % 80
Bearing Distance Lmin mm 5
Bearing Distance L2 mm 20
Bearing Distance L2 increase mm 20
Bearing Distance Difference Max mm 10
Roller Distance Min (L/R) mm 30
Grease Pulse Rate pulses/h 50
Oil Heaters ON °C 42
Oil Heaters OFF °C 47
Feding Bin Level Max % 60
Feeding Bin Level Min % 20
Feed Regulating Gate Setpoint % 90
Feed Regulating Gate Hysteresis % 2
Main Drives Current Operation A 720
Main Drives Current Max A 850
Main Drives Current Difference Max A 150
Nitrogen Pressure big accumulators (2.13.1-4): 110bar (decreased on 24.11.2022 from appr. 145bar)
Nitrogen Pressure big accumulators (2.13.1-4): 120bar (increased on 02.12.2022 from appr. 95bar left and
100 bar right)
Nitrogen Pressure small accumulators (2.12.1-2): 150bar
Speed always 12rpm. Changed on 02.12.2022 to 10rpm due to not enough infeed material
available.
Remark:
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
45
46
9.2 Grinding size reduction
The grinding size reduction is determined by measuring the reduction in material size. A compare
must be made in feed material size and discharge material.
9.2.1 Measuring feed size
Test the following:

 Measure a sample of feed size material
9.2.2 Measuring discharge size
Test the following:

 Measure a sample of discharge size material
9.2.3 Test results

Measuring feed size
Measuring discharge size
Remark:
Done by customer – ongoing.
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
…………………………………………………………………………………………………………………..
47
10.Acceptance certificate
The acceptance certificate is signed when both parties agree that all tests successful conducted
and the system is ready for production.
Buyer / Customer : African Industries

Project Name : African Indutries / ARNML
Project Number : PO1605293
Machine serial number : 205200028/1
Description of Equipment : HPGR RPM24-240/220
Place of Commissioning : Kagarko, Kaduna, Nigeria

Commissioning Period
Installation of Equipment YES / NO

Completed equipment according
Manufacturer’s specifications
All tests in this SAT plan are conducted YES / NO

and passed, according manufacturer’s
specifications
Statement
The buyer hereby declares that the equipment supplied and commissioned now for 500tph infeed
(fresh feed to circuit) is accepted.
Subsequent acceptance certificates for 800tph and 1200tph will be signed in the period of January
to March 2023 as indicated by buyer.
All tests have been conducted satisfactorily and the goods are performing in accordance with
contract stipulations.
By signing this document it does not dismiss any open issues. Open issues should be
noted in a punch list or in other means of communication. Acceptance of the goods does
not have any influence on the contractually agreed warrantee clauses.
Commissioning Engineer for proper Commissioning
Name : A. Haroske
Job title/function : Senior Commissioning and Training Engineer / ZAFAS
Company : Weir Minerals Netherlands b.v.
Date :
Signature :
Customer for Acceptance
Name : ………………………………………………………
Company : ………………………………………………………
Date : ………………………………………………………
Signature : ………………………………………………………
Remark
Part of this acceptance test is, that for at least the next 6 months regularly visits needs to be done,
48
to increase the performance of the machine (acc. infeed material and so on).
Customer will place POs for these visits – or there will be a service contract between WEIR and
African Industries / ARNML .
49

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Weir Minerals Netherlands b.v.

Site Acceptance Test Plan

Date Version Released by Reason for release / changed chapters

10. Acceptance certificate 47

HPGR High Pressure Grinding Rolls

RP Roller Press, abbreviation for HPGR used in different industries

FR Fixed Roller, the roller that is not movable hydraulically

MR Movable Roller, the roller that is hydraulically movable

Safeset Mechanical safety coupling between cardan shaft and gearbox

ROLCOX Rolcox is the name of the HPGR control system

NDS Non Drive Side, this is the opposite side of the DS

HMI Human Machine Interface

MCC Main Control Cabinet

PLC Programmable Logic Controller

SCADA Supervisory Control and Data Acquisition

Document number Document description Author Date

Chapter 1: Project information

Chapter 3: Testing, explains the approach of testing

2.2 Scope of SAT

 Describe which equipment is tested

Name : Alexander Haroske

3.3 Test Results

The following codes will be given to the conducted tests

4.1.1 Main power

4.1.1.1 Main power test description

Check the following:

4.1.2 Test results

Test description Value Name Code

4.1.3 Control voltage

4.1.3.1 Control voltage test description

Check the following:

4.1.4 Test results

Test description Value Name Code

4.2.1 Internal Emergency Stop circuit

4.2.1.1 Internal Emergency Stop test description

Check the following:

4.2.2 Test result

Test description Name Code

4.2.3 External Emergency Stop circuit

4.2.3.1 External Emergency Stop test description

Check the following:

4.2.4 Test result

Test description Name Code

4.3.1 Emergency stop Pressure release test

4.3.1.1 Emergency stop test description

Check the following:

4.3.2 Fast stop Pressure release test

4.3.2.1 Fast Stop test description

Check the following:

4.3.3 Test result

Test description Name Code

4.4.1 Warning Sign checks

Check the following:

4.4.2 Test result

Test description Name Code

5.1 Main motors

Test the following:

5.1.2 Speed Sensors

Test the following:

5.1.3 Motor Heater

Test the following:

Test the following: