Instruction Manual

Grease Spray

Zangezur Copper Molybdenum Combine CJSC

Kajaran, Armenia

Prepared by

Ver 2.0 12-Dec-2023 MANAR MANAR KSR For Reference

FLSmidth Private Limited Ver 1.0 28-Nov-2023 MANAR MANAR KSR For Reference
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Date
34, Rajiv Gandhi road, Egatoor, NONE Drawn Chkd. Appr.
Kelambakkam (Chennai), Tamil Nadu 603 103 Zangezur Copper Molybdenum Combine CJSC
Tel : +91 44 4748 3000 / 2741 3000 Armenia
Fax : +91 44 2747 0301 / 302 2872277059
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Instruction Manual for Grease Spray Operation

Introduction

Grease Spray for SAG Mill, Ball Mill-1 and Ball Mill-2 is integrated into main PLC after reconnection of
instruments and relays from Local Panel.
Below explained are control philosophy, ECS mimics and brief program description.

Physical Connectivity between New IO/HMI Panel and old Grease Spray Panel
Interconnection Drawings indicating the connectivity is shown below, full document can be referenced for
details. As indicated, multicore cable is laid between individual IO/HMI for SAG, BM-1 and BM-2 to old
Grease Spray Panels. Cables between Instruments and Grease Spray Panel are reused.
FLS had recommended to lay individual cable to each instrument to remove old panel completely. Since
Relays from old panel are re-used, it was decided to continue using the old panel. Although it is
recommended in the future upgrades to completely remove old panel to reduce number of Junction points,
thus reduces source of faults.
Control Philosophy – SAG Mill
SAG Mill Grease Lubrication is composed of one Pneumatic Pump (Q01) for Pumping Grease. In addition,
there are two set of Atomizing Panels (one each for Mill Clockwise and Counterclockwise Direction), which
have a Lub Valve (Q03 & Q05), Atomizing Air Valve (Q02 & Q04), and a Distributor Panel.
Distributor Block has a sensor to detect Grease Flow.
There are three Pressure Transmitters one each for
• Grease Line which is mounted after Pneumatic Pump (Q01) - This Pressure signal is used to control
Pump ON and OFF based on Lub Pressure Limits set from Faceplate in ECS. Alarms for Low
pressure is enabled after Q01 is open.
• Atomizing Air Pressure Transmitter– This is used to detect Atomizing Compressed Air Pressure.
These sensors are mounted after Atomizing Air Valves (Q02 & Q04). Alarms for Low pressure is
enabled after Q02/Q04 is open.

Setpoints & Status

• Spray Count – Number of Spray Pulses required in single cycle. Operator can Set the same.
• Air Purge Time – Time in seconds for Cleaning the line with Air after completion of each spray cycle.
Operator can Set the same.
• Pause Time – Time in Minutes where Spray is on hold after completion of each spray cycle.
Operator can Set the same.
 • Mill Shutdown Time – Time for Mill Shutdown in case of any Fault\Alarm in Grease Spray System.
This can be set from “UNIT FAULT -MILL WILL TRIP” Alarm and “GREASE SPRAY READY
ALARM” by Authorized Automation Engineers.

Operation Steps

• Start Pinion Grease Spray Group G05.

• Direction of Grease Spray is linked to Mill Direction Selection.
• Once Mill Starts, first Spray cycle will start irrespective of Pause Time and Pause Timer will reset
once spray cycle completes.
• Considering Forward/Clockwise Direction – Q02 & Q03 will open. Air Pressure Transmitter value will
be read to detect Low Air Pressure after Q02 opens. In case, pressure is less than LL value
(currently set at 2 Bar), alarm will generate Grease Spray Ready Signal will generate warning and
start counting down Mill Shutdown Timer.
• In case of no fault, the spray will continue until Distributor Block Sensor, records 0 ->1 transitions
equal to Spray Count SP.
• Q01 which is connected to Pneumatic Pump is starting and stopping at ON and OFF Value Setting
of Lub pressure which are currently set as Less than 60 Bar start pump and stop at 80 Bar.
• After Spray Cycle is completed Q03 will close immediately and Q02 will remain open for time set in
Purge Air time SP.
• For Counter Clock/ Reverse Direction Q04 and Q05 will operate in place of Q02 and Q03
respectively.
• In case of any Fault/Alarm or Spray Cycle not completing or Mill Running but Grease Spray Stopped,
then Mill Shutdown Timer will start counting down, but Spray system will keep trying to Spray. In
case timer runs down, Mill will Trip on Grease Spray Running Interlock.
• Issue needs to diagnose in the field physically and after issue is found and resolved, Run the Group
G05 in case it was not running, then use Manual Reset Selection to Force Start Spraying. When
Manual Start is Selected, the Pause Time is fixed 20 secs.
• If forced spraying succeeds and a spray cycle successfully completes then Alarm will Reset and
Manual Reset Selection will deselect automatically.
• Manual Reset Selection can also be used to force faster cycles or run Grease Spray without running
the Mill, but Manual Reset Selection must be deselected by operator in case it was selected by
operator without a fault.
• NOTE: Alarm will not reset without running the Grease Spray with Manual Reset Selection and
having one Successful Spray Cycle.

Grease Drum Replacement

• Safe replacement of Grease Drum must be done in Grease Spray Group Stopped Condition. If group
is still running, then Pump will start after Pause Time is elapsed. This is a safety safety hazard and
may develop issues in the pump.
• Before changing the Drum Operator to stop the Group 05. This will have no immediate impact on Mill
Running.
• Mill Trip Warning will be released, and mill trip timer will start for 30 minutes.
• Once group is off, drum can be changed at site.
• After drum is changed and getting clearance from site, operator can restart Group05.
• Upon restart, after pause time is elapsed the grease spray will start and upon a successful Spray
Count, the mill trip warning can be acknowledged by operator and timer will reset to 30 minutes.

Control & Alarm Limits - All Limits are based on Site Inputs. Operation must be observed regularly for
correct operation of the mill. Parameters can be adjusted upon consultation.

• Air Pressure –
o Instrument range 0-10 Bar
o LL Alarm Limit – 2 Bar
o L Warning Limit – 3 Bar
• Lub Pressure –
o Instrument range 0-100 Bar
o LL Alarm Limit – 20 Bar
o L Warning Limit – 30 Bar
o Operation Range of Pump
▪ ON – 60 Bar
▪ OFF – 80 Bar
• Spray Count SP – 3 to complete within 5 minutes.
• Pause Time – 7 mins normal Operation. 20 secs for Manual Reset
• Air Purge Time – 15 secs
• Mill Trip Time – 30 Minutes (Set in Alarm Point 400SM100_GSP_X01 and 400SM100_GSP_X02).
When changing update timings in both Alarm points.
Control Philosophy – Ball Mill-1
Ball Mill-1 Grease Lubrication is composed of one Pneumatic Pump (Q01) for Pumping Grease. In addition,
there is a set of Atomizing Panel, which has a Lub Valve Q03, Atomizing Air Valve Q02, and a Distributor
Panel.
Distributor Block has a sensor to detect Grease Flow.
There are two Pressure Transmitters one each for
• Grease Line which is mounted after Pneumatic Pump (Q01) - This Pressure signal is used to control
Pump ON and OFF based on Lub Pressure Limits set from Faceplate in ECS. Alarms for Low
pressure is enabled after Q01 is open.
• Atomizing Air Pressure Transmitter– This is used to detect Atomizing Compressed Air Pressure.
This sensor is mounted after Atomizing Air Valve (Q02). Alarms for Low pressure is enabled after
Q02 is open.

Setpoints & Status

• Spray Count – Number of Spray Pulses required in single cycle. Operator can Set the same.
• Air Purge Time – Time in seconds for Cleaning the line with Air after completion of each spray cycle.
Operator can Set the same.
• Pause Time – Time in Minutes where Spray is on hold after completion of each spray cycle.
Operator can Set the same.
• Mill Shutdown Time – Time for Mill Shutdown in case of any Fault\Alarm in Grease Spray System.
This can be set from “UNIT FAULT -MILL WILL TRIP” Alarm and “GREASE SPRAY READY
ALARM” by Authorized Automation Engineers.

Operation Steps

• Start Pinion Grease Spray Group G05.

• Once Mill Starts, first Spray cycle will start irrespective of Pause Time and Pause Timer will reset
once spray cycle completes.
• Q02 & Q03 will open. Air Pressure Transmitter value will be read to detect Low Air Pressure after
Q02 opens. In case, pressure is less than LL value (currently set at 2 Bar), alarm will generate
Grease Spray Ready Signal will generate warning and start counting down Mill Shutdown Timer.
 • In case of no fault, the spray will continue until Distributor Block Sensor, records 0 ->1 transitions
equal to Spray Count SP.
• Q01 which is connected to Pneumatic Pump is starting and stopping at ON and OFF Value Setting
of Lub pressure which are currently set as Less than 60 Bar start pump and stop at 80 Bar.
• After Spray Cycle is completed Q03 will close immediately and Q02 will remain open for time set in
Purge Air time SP.
• In case of any Fault/Alarm or Spray Cycle not completing or Mill Running but Grease Spray Stopped,
then Mill Shutdown Timer will start counting down, but Spray system will keep trying to Spray. In
case timer runs down, Mill will Trip on Grease Spray Running Interlock.
• Issue needs to diagnose in the field physically and after issue is found and resolved, Run the Group
G05 in case it was not running, then use Manual Reset Selection to Force Start Spraying. When
Manual Start is Selected, the Pause Time is fixed 20 secs.
• If forced spraying succeeds and a spray cycle successfully completes then Alarm will Reset and
Manual Reset Selection will deselect automatically.
• Manual Reset Selection can also be used to force faster cycles or run Grease Spray without running
the Mill, but Manual Reset Selection must be deselected by operator in case it was selected by
operator without a fault.
• NOTE: Alarm will not reset without running the Grease Spray with Manual Reset Selection and
having one Successful Spray Cycle.

Grease Drum Replacement

• Safe replacement of Grease Drum must be done in Grease Spray Group Stopped Condition. If group
is still running, then Pump will start after Pause Time is elapsed. This is a safety safety hazard and
may develop issues in the pump.
• Before changing the Drum Operator to stop the Group 05. This will have no immediate impact on Mill
Running.
• Mill Trip Warning will be released, and mill trip timer will start for 30 minutes.
• Once group is off, drum can be changed at site.
• After drum is changed and getting clearance from site, operator can restart Group05.
• Upon restart, after pause time is elapsed the grease spray will start and upon a successful Spray
Count, the mill trip warning can be acknowledged by operator and timer will reset to 30 minutes.

Control & Alarm Limits – All Limits are based on Site Inputs. Operation must be observed regularly for
correct operation of the mill. Parameters can be adjusted upon consultation.

• Air Pressure –
o Instrument range 0-10 Bar
o LL Alarm Limit – 2 Bar
o L Warning Limit – 3 Bar
• Lub Pressure –
o Instrument range 0-100 Bar
o LL Alarm Limit – 20 Bar
o L Warning Limit – 30 Bar
o Operation Range of Pump
▪ ON – 60 Bar
▪ OFF – 80 Bar
• Spray Count SP – 3 to complete within 5 minutes.
• Pause Time – 7 mins normal Operation. 20 secs for Manual Reset
• Air Purge Time – 15 secs
• Mill Trip Time (Mill Motor will Run Clutch Motor is Interlocked) – 30 Minutes (Set in Alarm Point
300BM100_GSP_X01 and 300BM100_GSP_X02). When changing update timings in both Alarm
points.
Control Philosophy – Ball Mill-2
Ball Mill-2 Grease Lubrication is composed of one Pneumatic Pump (Q01) for Pumping Grease. In addition,
there is an Atomizing Air Valve Q02, and a Distributor Panel.
Distributor Block has a sensor to detect Grease Flow.
There are two Pressure Transmitters one each for
• Grease Line which is mounted after Pneumatic Pump (Q01) - This Pressure signal is used to Monitor
Lub Pressure. Alarms for Low pressure is enabled after Q01 is open.
• Atomizing Air Pressure Transmitter– This is used to detect Atomizing Compressed Air Pressure.
This sensor is mounted after Atomizing Air Valve (Q02). Alarms for Low pressure is enabled after
Q02 is open.

Setpoints & Status

• Spray Count – Number of Spray Pulses required in single cycle. Operator can Set the same.
• Air Purge Time – Time in seconds for Cleaning the line with Air after completion of each spray cycle.
Operator can Set the same.
• Pause Time – Time in Minutes where Spray is on hold after completion of each spray cycle.
Operator can Set the same.
• Mill Shutdown Time – Time for Mill Shutdown in case of any Fault\Alarm in Grease Spray System.
This can be set from “UNIT FAULT -MILL WILL TRIP” Alarm and “GREASE SPRAY READY
ALARM” by Authorized Automation Engineers.

Operation Steps

• Start Pinion Grease Spray Group G05.

• Once Mill Starts, first Spray cycle will start irrespective of Pause Time and Pause Timer will reset
once spray cycle completes.
• Q01 & Q02 will open. Air Pressure Transmitter value will be read to detect Low Air Pressure after
Q02 opens and Lub Pressure Transmitter value will be read to detect Low Lub Pressure after Q01
opens. In case, pressure is less than LL value (currently set at 2 Bar for Air Pressure and 20 Bar for
Lub Pressure), alarm from Grease Spray Ready Signal will generate warning and start counting
down Mill Shutdown Timer.
 • In case of no fault, the spray will continue until Distributor Block Sensor, records 0 ->1 transitions
equal to Spray Count SP.
• After Spray Cycle is completed Q01 will close immediately and Q02 will remain open for time set in
Purge Air time SP.
• In case of any Fault/Alarm or Spray Cycle not completing or Mill Running but Grease Spray Stopped,
then Mill Shutdown Timer will start counting down, but Spray system will keep trying to Spray. In
case timer runs down, Mill will Trip on Grease Spray Running Interlock.
• Issue needs to diagnose in the field physically and after issue is found and resolved, Run the Group
G05 in case it was not running, then use Manual Reset Selection to Force Start Spraying. When
Manual Start is Selected, the Pause Time is fixed 20 secs.
• If forced spraying succeeds and a spray cycle successfully completes then Alarm will Reset and
Manual Reset Selection will deselect automatically.
• Manual Reset Selection can also be used to force faster cycles or run Grease Spray without running
the Mill, but Manual Reset Selection must be deselected by operator in case it was selected by
operator without a fault.
• NOTE: Alarm will not reset without running the Grease Spray with Manual Reset Selection and
having one Successful Spray Cycle.

Grease Drum Replacement

• This Grease Spray System is provided with option to change the drum without stopping the group,
since there is a Level signal and Elevator System.
• Upon detecting L2 Grease Level, Grease Pump will stop operating.
• Mill Trip Warning will be released, and mill trip timer will start for 30 minutes.
• From old panel Elevator Switch must be changed to lift position (with Grease Pump in Off condition)
to change the drum. When Button is in lift position and Grease Pump is off, Elevator Valve will
energize and lift the Lid.
• Grease drum can be changed in this condition and after Drum is changed, change the switch
position back to Lower Position, this will bring the lid down.
• Level Signal should become healthy upon sensing sufficient grease level in the drum.
• Once Alarm is acknowledged, after pause time is elapsed the grease spray will start and upon a
successful Spray Count, the mill trip warning can be acknowledged by operator and timer will reset
to 30 minutes.

Control & Alarm Limits - All Limits are based on Site Inputs. Operation must be observed regularly for
correct operation of the mill. Parameters can be adjusted upon consultation.

• Air Pressure –
o Instrument range 0-7 Bar
o LL Alarm Limit – 2 Bar
o L Warning Limit – 3 Bar
• Lub Pressure –
o Instrument range 0-200 Bar
o LL Alarm Limit – 20 Bar
o L Warning Limit – 30 Bar
• Spray Count SP – 3 to complete within 5 minutes.
• Pause Time – 7 mins normal Operation. 20 secs for Manual Reset
• Air Purge Time – 15 secs
• Mill Trip Time (Mill Motor will Run Clutch Motor is Interlocked) – 30 Minutes (Set in Alarm Point
200LU11BM_X01 and 200LU11BM_X02). When changing update timings in both Alarm points.