Control Philosophy: Ø 99m Tailings Thickener Tag 2610-TH-004

DQ160086 – SPENCE GROWTH OPTION (SGO) PROJECT
Control Philosophy
Ø 99m Tailings Thickener
Tag 2610-TH-004
3 Rodbor 27.08.18 - - Rodbor 27.08.18 Issued for Approval

2 Rodbor 06.06.18 - - Rodbor 20.06.18 Issued for Approval
1 jossal 27.03.18 RodBor 13.04.18 RodBor 13.04.18 Issued for Approval – English Version
0 jossal 05.09.16 ivacon 05.09.16 jossal 05.09.16 Certificate
D jossal 18.08.16 ivacon 18.08.16 jossal 18.08.16 Issued for Approval
Name Date Name Date Name Date Revision Text
Rev
Prepared Checked Released
Status: Original Size:
Issued for Approval
Customer: Project Phase: Site No.:
BHP / Spence / Fluor Detail Engineering
Project Name: Customer Document ID:
Spence Growth Option (SGO) Project 4-V2-2610-IC-IPC-113032

Replaced by: Replaces:
Document Title:
Control Philosophy
Ø99m Tailings Thickener
Tag 2610-TH-004
BHP Purchase Order No. 8500088818 / Fluor Salfa Purchase
Equipment No: Item No: Order No. B2SG-4-701-WP02-L/B2SG100043
G2280 T10
Project ID: Plant Code: Plant Unit Code: Document Type: Running No: Revision: Sheet of Sheets:
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The contents of this document are the sole property of Outotec Oyj. Any rights not expressly granted herein are reserved. Outotec Document ID:
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prohibited. DQ160086-E30-000-
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Control Philosophy
DQ160086 – Spence Growth Option (SGO) Project
Ø99m Tailing Thickener; Tag 2610-TH-004
INDEX Page
1 SCOPE .............................................................................................................................. 4
2 OBJECTIVE ....................................................................................................................... 5
3 REFFERENCES AND ANNEXES ...................................................................................... 6
4 CONTROL PHILOSOPHY (P&ID DQ160086-G2280-T10-0250)........................................ 7
4.1 OPERATION PRINCIPLE ..........................................................................................7
4.2 FEEDWELL................................................................................................................8
4.2.1 TURBODIL ............................................................................................................9
4.3 CONTROL STRATEGY .............................................................................................9
4.3.1 HYDRAULIC DRIVE MOVEMENT .........................................................................9
4.3.2 RAKE LIFTING ACTUATION ...............................................................................12
4.3.3 SELF-LEVELLING DRIVE SYSTEM ....................................................................13
4.4 INTERFACE MEASUREMENT ................................................................................13
4.5 BED MASS MEASUREMENT ..................................................................................13
5 CONTROL TACTICS ....................................................................................................... 14
5.1 START/STOP ROTATION OF RAKES.....................................................................14
5.2 DIRECTION OF RAKE ROTATION..........................................................................14
5.3 AUTOMATIC RAKE LIFTING. ..................................................................................14
5.4 MANUAL RAKE LIFT ...............................................................................................16
5.5 LOW HYDRAULIC OIL LEVEL AT THE RESERVOIR .............................................16
5.6 LOW-LOW HYDRAULIC OIL LEVEL AT THE RESERVOIR ....................................16
5.7 LOW HYDRAULIC OIL LEVEL AT THE GEARBOX .................................................17
5.8 HIGH-HIGH TEMPERATURE HYDRAULIC UNIT OIL .............................................17
5.9 RAKE TORQUE TRIP (at 95% of the Maximum Torque)..........................................17
5.10 INTERFACE OR BED LEVEL MEASUREMENT. .....................................................17
5.11 BED MASS MEASUREMENT ..................................................................................17
5.12 TURBIDITY MEASUREMENT ..................................................................................18
5.13 TURBODIL ...............................................................................................................18
6 CONTROL PANEL........................................................................................................... 19
7 INTERLOCKING AND TRIPS .......................................................................................... 20
7.1 SAFETY TRIPS........................................................................................................20
8 CONTROL LOOPS .......................................................................................................... 21
8.1 FLOCCULANT ADDITION PUMP VELOCITY CONTROL........................................21
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8.2 UNDERFLOW DISCHARGE PUMP VELOCITY CONTROL ....................................21

9 PROCESS OPERATION ................................................................................................. 22
9.1 LOCATIONS ............................................................................................................22
9.2 SCENARIOS ............................................................................................................22
9.2.1 NORMAL START-UP (EMPTY) ...........................................................................22
9.3 START-UP OR QUICK START (WITH LOAD) .........................................................23
9.4 SHUTDOWN (NORMAL THICKENER SHUTDOWN) ..............................................23
9.5 MAINTENANCE SHUTDOWN (EMPTY THICKENER SHUTDOWN).......................24
10 CONTROL PANEL I/O SIGNALS .................................................................................. 25
10.1 INSTRUMENTS .......................................................................................................25
10.2 SOLENOID VALVES ................................................................................................25
10.3 INPUTS/OUTPUTS OF THE MCC ...........................................................................26
11 PLANT DCS I/O SIGNALS ............................................................................................ 27
12 ALARM LIST ................................................................................................................. 27
13 APPENDIX A ................................................................................................................ 28
13.1 AUTOMATIC RAKE LIFT & LOWER FLOW CHART................................................28
13.2 MANUAL RAKE LIFT & LOWER FLOW CHART......................................................29
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Control Philosophy
1 SCOPE
This document describes the Control Philosophy for the HRT Ø99m Thickener; Tag
2610-TH-004 developed for BHP - Spence Growth Option (SGO) Project; which shall
process Copper Tailings.
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2 OBJECTIVE
The main objective of a tailings thickener is to recover water from the tailings slurry
and to provide thickened tailings for deposition to tailings storage. Once the tailing is
in the Thickener, flocculant is added to the slurry in order of settling the solids and
achieving the separation of water particles and in this way, they are settled down by
gravity at the bottom of the thickener. The surface of the settled pulp bed forms a
well-defined interface, which has a layer of cleared liquid above it; this liquid is
recovered by overflow and generally is stored in a recovery tank for its later use in
other processes.
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3 REFFERENCES AND ANNEXES
Document No. Description
HRT Ø99m Thickener – Tailing Thickener

DQ160086-G2280-T10-0250
No. 1; P&ID
DQ160086-E30-000-IN-LI-0001 Instrument List
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4 CONTROL PHILOSOPHY (P&ID DQ160086-G2280-T10-0250)
4.1 OPERATION PRINCIPLE

Outotec® High Rate Thickener (HRT) is designed for thickening ore slurries at a high
consistency and simultaneously delivering a clarified liquid suitable for being reused
as process water.
Feeding slurry is enters the Thickener through a feedpipe, and it is tangentially
discharged inside the Feedwell. The slurry is diluted with liquid (water) and chemical
agents (flocculants) added; the flocculant is attached to solid particles present in the
slurry making them settle faster towards the bottom of the tank by gravity. Flocculated
pulp deposits at the bottom of the thickener tank, form the bed surface identifying a
well-defined interface with the clear liquid over the flocculated bed.
For measuring the level of this interface, a level sensor / transmitter 2610-LE/LT-
06420 is used at the upper part of the Thickener, from the bridge.
The clarified liquid flows to a peripheral launder in the upper part of the Thickener
tank and it is discharged through the overflow box, which reaches the recovered
water pond to be reused later.
Thickener underflow is directed to a central cone at the base of the thickener by a
rake mechanism, and then is discharged and transported (by gravity or by the use of
pumps) to the next stage of the process according to the mass and the pressure
measurement by a pressure sensor / transmitter 2610-PIT-06422 installed in the
central cone.
The Outotec® HRT uses a proprietary Feedwell for ensuring an efficient flocculation,
and includes a rake design which improves permeability and releases water from the
sedimented bed.
The Thickener is equipped with rake arms provided with blades to sweep the entire
bottom once per revolution. The rakes move the solids to a lower cone at the centre
of the tank (Underflow Cone), helping also keeping the movement of the bed and
compacting the solids.
The Thickener processes the tailings coming from the concentrator plant using a
flocculant solution to produce:
Thickened tailings to be sent generally to the deposit or to the tailings tank

and
Clarified water to be reused.

The Thickener control is made by the Local Control Panel 2610-CO-10002 installed
in the thickener bridge.
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The Thickener mechanism can be started or stopped by the button pads and
selectors located in the frontal part of the local panel. Local panel displays all the
mechanical alarms as also the main process signals, such as the Torque, bed
interface level and the thickener bed mass (pressure).
4.2 FEEDWELL
The incoming pulp tangentially enters in the Feedwell producing mixing of the slurry,
dilution water and the flocculant, the Feedwell is designed in such way for producing
an optimal dilution which maximizes the solids sedimentation and water release.
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4.2.1 TURBODIL
Outotec Vane Feedwell can be equipped with one or more Turbodil®, which is a
forced dilution system which allows more flexibility and control over a great variation
in the feeding volume and the solid content conditions. For the particular case of the
2610-TH-004 thickener, inclusion of a (1) turbodil is considered.
4.3 CONTROL STRATEGY
The raking system includes a Hydraulic Power Pack connected to six (6) hydraulic
motors directly assembled in six (6) planetary gearboxes. These gearboxes actuate
a common ring gear, which supports the shaft of the thickener rakes.
The hydraulic unit is mounted at the central zone of the thickener bridge next to the
drive.
The Drive Unit includes three (3) lifting cylinders (Rake Lifting System) allowing a
maximum lifting of 600 mm.
The torque is directly measured by a pressure transducer 2610-OT-06401 installed
on the Hydraulic Power Pack together with the high torque switch 2610-OSH-06414
(95% of the Maximum Operating Torque (MOT) of 11.500.000 Nm). While the lifting
position of the rake is measured with the 2610-ZT-06400 position sensor and the
respective limit switches 2610-ZSH-06413 (upper position); 2610-ZSL-06413 (lower
position) mounted in the centre column of the thickener.
4.3.1 HYDRAULIC DRIVE MOVEMENT

The Hydraulic Drive Movement includes:
The selection of the mode Local or Remote only can be selected in the Client
DCS.
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In "Remote" mode, the control and monitoring are performed from the Client
DCS, using Ethernet IP communication. There are two options in Remote
mode: Remote/Auto and Remote/Manual to be explained later on.
In the “Local” mode, the drive commands of the rakes consider a JOG
Selector, which have to maintain activated in the position of the selected
direction, and when this JOG Selector is de-activated will come back to the
neutral position, this with the objective to always have a neutral condition in
the thickener when the “Remote” mode is activated and avoid operational
issues. The command of Lifting/lowering rakes is by a selector 2610-HS-
06412 and the change of direction clockwise/counter clockwise by a selector
2610-HS-06411; when some of these selectors is activated will be activated
the corresponding solenoid valves in the Hydraulic power pack in order to get
the desired movements.
The "Automatic” mode, considers controlling the lifting system in function of

the torque, lifting/lowering the rakes according the control logic installed in the
PLC. Monitoring can be done by both local control panel or DCS. In
“Automatic” operation mode, rake movements shall be commanded
according to the control logic described in point 5.0
The "Manual" mode means that the lifting system control logic in function of
the torque is disabled, only acting by commands from the console in the local
control panel or Client DCS, to lift/lower the rakes, as Local or Remote mode
respectively.
As summary:
- Remote/Auto (Normal Operation): Lifting/lowering movements are
commanded according the control logic installed in the PLC and DCS is
able to switch to local/remote mode.
- Remote/Manual: Lifting control logic of PLC is disabled; DCS controls
Lifting/lowering movements and also is able to switch to local/remote
mode. In this mode, movements cannot be commanded by control panel,
but it can be stopped by the emergency stop button 2610-HS-06410D.
- Local/Manual mode: Lifting control logic is disabled; Lifting/lowering rake
commands are available from local control panel only.
- Local/Autol: Doesn’t exist
Pressure switch 2610-OSH-06414 is incorporated in the drive circuit of the

hydraulic power unit for cutting the power to the electric motor when the
hydraulic oil pressure reaches proportional to 95% maximum operating
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torque. This signal is fed to the PLC where it is used to trip the high torque
alarm 2610-OAH-06414 on the panel door display and also fed to DCS to stop
the electric motor via a contactor in the MCC.
The oil reservoir low level switch on the hydraulic power unit (2610-LSL-
06405), once activated sends a signal to the PLC and turn on the alarm 2610-
LAL-06405. Also, the instrument has a low low-level switch (2610-LSLL-
06405) that once activated, the PLC sends a signal to DCS to cut the power
of the electric motor and trips the low-low oil level alarm 2610-LALL-06405.
There are six (6) low-level switches of gearboxes oil (2610-LSL-

06406A/B/C/D/E/F) that send a signal to the control panel and turn on the
alarm 2610-LAL-06406C.
Temperature transmitter 2610-TT-06407 will provide the measure of the oil

temperature in the reservoir of the power unit, this sensor will send a signal
to the control panel and from there a signal will be send to the cut-off valve
2610-ZY-06412G, which is normally closed. If the temperature is above 70°C
the solenoid will be energised and will open this valve (oil flows to fan motor
– cooling is on). When temperature is below 50° C, the solenoid valve will be
de-energised then oil bypasses the fan motor and cooling stops.
The same temperature transmitter 2610-TT-06407 will send a signal to the

control panel and from there a signal will be send to the Client DCS to activate
or de-activate the oil heater. This will be activated when the temperature is
down below 5°C and will stop when the temperature is over 15°C.
Torque Measurement: Drive unit hydraulic pressure (Rake Torque) is

displayed in the panel door display with a range of 0 – 100% (0 –11.500.000
Nm) at the Local Panel. This pressure is measured with the pressure
transducer 2610-OT-06401.
A mechanical protection against the torque is set in the hydraulic axial piston
pump, when torque reaches 100% of MOT (11.500.000 Nm) the pump
compensator goes to 0° and de-strokes the pistons, it means no oil pumped
to hydraulic motors, so the rakes stops.
Another mechanical protection against the high torque shall be the use of a
pressure relief valve manually adjusted to 12.075.000 Nm (105% of MOT),
which acts as control protection backup, eliminating the possibility of
overloading the drive system. When torque reaches 105% then the relief
valve sends the oil to the reservoir by-passing the hydraulic motors.
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Torque Value (%) Torque Value (Nm) Pressure Value (bar)

approx. approx.
25 % MOT 2.875.000 51
40 % MOT 4.600.000 82
45% MOT 5.175.000 92
50% MOT 5.750.000 102
95% MOT 10.925.000 194
100% MOT 11.500.000 204
105% MOT 12.075.000 214
Summary Table of Torque at the Thickeners (referential)
4.3.2 RAKE LIFTING ACTUATION

There is a rake lifting hydraulic system for controlling the rake torque (Automatic
Control Mode). If the torque level reaches or overpasses 50% of the total torque load
the rake is automatically lifted and if the torque is lower than 40% the hydraulic
system must lower the rake. For actuating the lifting or lowering of the rake, refer to
point 4.3.3 where is described the self-levelling system.
For measuring the position of the rake, the following instruments are used:
Rake elevation position shall be measured by the Position Sensor 2610-ZT-

06400 sending this signal to the local panel PLC and to the DCS, where this
value can be displayed.
Additionally, there is an upper position switch 2610-ZSH-06413 and a lower

position switch 2610-ZSL-06413 to determine the upper and lower run limits
of the rake respectively, taking immediate movement detention action.
The hydraulic unit has a hydraulic oil filter which indicate when it is needed to replace
the oil, activating the Hydraulic Oil Filter Blocked 2610-PDSH-06408, the signal from
this instrument is send to the PLC in the local control panel and to client DCS; where
will be displayed the alarm of “Oil Filter Blocked”
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4.3.3 SELF-LEVELLING DRIVE SYSTEM

The Rake Lift system, consists of 3 hydraulic cylinders, symmetrically arranged on a
Rake lift mechanism. Its primary function is to lift/lower the Rakes when Rake drive
torque exceeds a set point value.
In the Self Levelling Drive System, the pressure compensated piston pump sends the
oil to the directional valve which enable the lift system (2610-XV-06412). Each
cylinder is individually controlled by its own proportional valve (2610-VP/ST-
06412A/B/C) and a separate cut-off valve (2610-XV-06412A/B/C).
Each cylinder will have position feedback via linear position sensor (string-pot) (2610-
ZT-06412E/F/G). These are 4-20mA devices for feedback by the controller.
Additionally, separate pressure transducers for each cylinder pressure monitoring are
provided (2610-PT-06412A/B/C); and one additional pressure transducer is provided
for the main feed lifting system pressure monitoring (2610-PT-06412D).
The concept is to provide ‘Position Control’ for each cylinder maintaining a set
tolerance. The rake lift stroke is 600 mm, with 1-2mm stroke deviation between each
of the cylinders.
The ideal control philosophy would be a master and slave set-up. The Rake Lift speed
is slow (approx. 150 mm/minute) and typically does not require a fast response or
opening of proportional valves.
4.4 INTERFACE MEASUREMENT

Interface level measurement shall be delivered by the level transmitter 2610-LT-
06420, which gives an analogue signal of 4-20 mA corresponding to clear water
phase. This signal shall be sent to the Control Panel with PLC and Ethernet IP to the
control system (Plant DCS).
4.5 BED MASS MEASUREMENT

For the measuring of the bed mass a pressure transmitter is used with extended
diaphragm sealing 2610-PIT-06422, located in the side wall of the discharge cone,
which gives a signal which represents the 0 to 100% of the bed mass.
The Foundation Fieldbus digital signal given by the pressure transmitter represents
the solid inventory, and it is sent to the client’s DCS and from here to the control panel
of the thickener where is displayed in the panel door display.
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5 CONTROL TACTICS
5.1 START/STOP ROTATION OF RAKES.

When the command “Hydraulic Unit Start” is given, it shall be stopped only if:
A High Torque Trip signal is detected (95% of MOT of 11.500.000 Nm).
There is a failure of the hydraulic unit motor in the MCC.
There is an Emergency Shutdown (hard interlock to the motor, MCC).

To start the hydraulic unit no alarm must be displayed in panel door.
5.2 DIRECTION OF RAKE ROTATION

The change of rake direction shall be commanded only in Manual Mode from the
Control Panel by a JOG type switch (2610-HS-06411). This command includes three
positions: Counter Clockwise / Neutral / Clockwise, being “Neutral” the normal
command position (clockwise is looking at the rakes from the bridge); for moving the
rake the command must be kept in the desired direction, a PLC logic shall determine
the transition times from one mode to another, basically when changing the direction
with the hydraulic unit working, is necessary to pause at least 5-10 seconds in
“Neutral” position, this is for preventing the unit from damages.
The rake direction in “Counter Clockwise” direction must only be used in
Local/Manual mode, which indicates the operation corresponds to an emergency
condition.
When selecting “Clockwise” the “Clockwise Solenoid” (2610-HY-06411A) shall be
energized, in the same way if the “Counter Clockwise” is selected the “Counter
Clockwise Solenoid” (2610-HY-06411B) shall be energized. Both are de-energized
when the “Neutral” mode is selected.
The rotation direction change is made by the same configuration of the hydraulic unit,
without the need for stopping the electric motor, and only acting over the solenoids
of the directional valves present in the hydraulic circuit.
5.3 AUTOMATIC RAKE LIFTING.

Pressure transducer 2610-OT-06401 of the rake hydraulic unit (Torque) gives a
signal of 4 – 20 mA corresponding to the 0-100% (0 – 11.500.000 Nm) of the rake
torque; this signal is wired to the Control Panel (PLC) where it is used for the Rake-
Lifting control. In Appendix A, a flow diagram of the Rake-Lifting control logic is
shown.
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The rake is automatically lifted – with speed of 150 mm/minute – by energizing its
respective solenoids (2610-XV-06412 & 2610-VP/ST-06412A/B/C & 2610-XV-
06412A/B/C) when:
The torque (2610-OT-06401) overpasses the 50% of the maximum torque, this is
5.750.000 Nm, and
Rake Upper Position Limit Switch (2610-ZSH-06413) is not activated and
While the operation mode is automatic for the control panel

Until:
The torque (2610-OT-06401) is equal or lower than 45% of the maximum torque,
this is 5.175.000 Nm, or
Rake Upper Position Limit Switch (2610-ZSH-06413) is activated.
The rake is automatically lowered energizing its respective solenoid (2610-XV-06412

& 2610-VP/ST-06412A/B/C & 2610-XV-06412A/B/C) when:
The torque (2610-OT-06401) is lower than 40% of the maximum torque, this is
4.600.000 Nm, and
Rake Lower Position Limit Switch (2610-ZSL-06413) is not activated and
While the operation mode is automatic in the control panel
Rake direction is clockwise

Until:
The torque (2610-OT-06401) rises above 45% of the maximum torque of

5.175.000 Nm , or
Rake Lower Position Limit Switch (2610-ZSL-06413) is activated
The rake direction is set to neutral or counter clockwise
Automatic sequence for lowering the rake consists in a timer which energizes the
corresponding solenoid valves (2610-XV-06412 & 2610-VP/ST-06412A/B/C & 2610-
XV-06412A/B/C) to lower the rakes for 12 seconds and then de-energizes them for
660 seconds. It means, rakes shall lower in 30 mm steps every 660 seconds.
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When the rake reaches its lowest position the Lower Limit Switch (N.C.):
Starts-up the Fully Low Rake position indicator (2610-ZAL-06413).
De-energizes the lowering rake solenoids (2610-XV-06412 & 2610-VP/ST-

06412A/B/C & 2610-XV-06412A/B/C) and
Disables the Lower Rake button (2610-HS-06412)

When the rake reaches its highest position, the Upper Limit Switch (N.C):
Starts-up the Fully Up Rake position indicator (2610-ZAH-06413).
De-energizes the lifting rake solenoid (2610-XV-06412 & 2610-VP/ST-

06412A/B/C & 2610-XV-06412A/B/C) and
Disables the Lift Rake button (2610-HS-06412)
5.4 MANUAL RAKE LIFT

Turning the 2610-HS-06412 selector for Lifting the Rake shall energize the
corresponding solenoid (2610-XV-06412 & 2610-VP/ST-06412A/B/C & 2610-XV-
06412A/B/C) while the upper limit switch (2610-ZSH-06413) is not activated.
Turning the 2610-HS-06412 selector for Lowering the Rake shall energize the
corresponding solenoid while the lower limit switch (2610-ZSL-06413) is not activated
nor the torque is higher than 50%.
5.5 LOW HYDRAULIC OIL LEVEL AT THE RESERVOIR

The Oil Low Level Switch of Hydraulic Unit (N.O.) 2610-LSL-06405 displays the alarm
(2610-LAL-06405) in the panel door display and then a signal is sent to DCS.
5.6 LOW-LOW HYDRAULIC OIL LEVEL AT THE RESERVOIR

The Oil Low Low-Level Switch of Hydraulic Unit (N.O.) 2610-LSLL-06405 sends a
signal to the PLC to trip the low-low oil level alarm 2610-LALL-06405 which is
displayed in the panel door. At the same time, a digital signal from PLC is fed to DCS
to cut the power to the electric motor via contactor in the MCC.
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5.7 LOW HYDRAULIC OIL LEVEL AT THE GEARBOX

Low Level Switches 2610-LSL-06406A/B/C/D/E/F (N.O.) on each of the six (6)
gearboxes, if any of these switches is activated; they shall display the alarm (2610-
LAL-06406C) in the panel door display and then a signal is sent to DCS.
5.8 HIGH-HIGH TEMPERATURE HYDRAULIC UNIT OIL

A digital signal from the PLC is fed to DCS to stop the Hydraulic power unit electric
motor via a contactor in the MCC when hydraulic oil temperature (2610-TT-06407),
rises above a pre-defined temperature setpoint of 85°C to protect the hydraulic pump
seals.
5.9 RAKE TORQUE TRIP (at 95% of the Maximum Torque)

On torque trip condition of the rake by the activation of the high torque pressure
switch (N.C.) of the hydraulic unit 2610-OSH-06414, high torque trip 2610-OAH-
06414 is displayed in the panel door display and from PLC a digital signal is fed to
DCS to cut the power to the electric motor via contactor in the MCC.
5.10 INTERFACE OR BED LEVEL MEASUREMENT.

The Interface Level measurement is given by the Level Transmitter 2610-LT-06420
mounted in the Thickener bridge; gives an analogue signal of 4-20 mA. This signal
represents the clear water phase. This signal shall be sent to the Control Panel with
PLC and from the panel by Ethernet IP to the control system (Plant DCS).
5.11 BED MASS MEASUREMENT

The Pressure transmitter 2610-PIT-06422, located at the side wall of the discharge
cone generates a Foundation Fieldbus digital signal which represents the 0 to 100%
of the bed mass. This analogue signal is sent to the DCS, and it is normally used to
control the extraction of the discharge or Underflow pump. From the DCS the reading
is returned to the control panel of the thickener to be deployed as information in the
panel door display.
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5.12 TURBIDITY MEASUREMENT

The turbidity transmitter 2610-AIT-06421 (supplied by Outotec), which is installed
hanging from the bridge by the client, sends a signal to the PLC and then is sent to
the DCS as information via communication.
5.13 TURBODIL
The Turbodil® is equipped with a level switch 2610-LSL-06424 which trips the
turbodil motor in case overtflow liquid level is low, sends a signal to the PLC and
displays an alarm (2610-XL-06515B) in control panel door.
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6 CONTROL PANEL
Thickener Control Panel includes an Allen Bradley Control Logix PLC control unit
with a processor, Ethernet IP Communication and analogue and digital I/O modules,
all incorporated inside a NEMA 4X cabinet with access for operations and
maintenance.
At the frontal door of the cabinet there are components as panel door display to
visualize the process variables, status lights and alarms, button pads and selectors
for performing the Thickener operation.
The available commands are as follow:
JOG Selector Counter Clock-wise/Neutral/Clock-wise direction of rotation of rakes
JOG Selector Lift/Neutral/Lower Rakes
Hydraulic Unit Motor Start Button
Hydraulic Unit Motor Stop Button
Emergency Stop Button (Maintained Mushroom type)
Turbodil Motor Start Button
Turbodil Motor Stop Button

Indications, alarms and status shall be available in panel door display.
Note:
1) Refer to drawings DQ160086-G2280-T10-0200 and DQ160086-G2280-T10-

0210 (sheet 1 to 11) for more details of the control panel and scope of the
considered supply.
2) Beacon and Siren are delivered loose in order to customer can decide better
location for operation.
[-----] [-----] [-----] [-----] 3 19 (29)

IN-IN-0001
Control Philosophy
7 INTERLOCKING AND TRIPS
7.1 SAFETY TRIPS

Hydraulic unit motor can keep the operation until the following conditions occur:
Low low hydraulic unit oil level (2610-LSLL-06405).
High High temperature hydraulic unit oil (2610-TT-06407) at 85°C,
High torque trip (2610-OSH-06414) at 95% MOT
Electrical motor failure
Emergency shutdown button activated (2610-HS-06410D)
Turbodil motor can keep the operation until the following conditions occur:
Low water level switch of Turbodil (2610-LSL-06424)
Electrical motor failure
Emergency shutdown button activated (2610-HS-06410D)
[-----] [-----] [-----] [-----] 3 20 (29)

IN-IN-0001
Control Philosophy
8 CONTROL LOOPS
The following are the control loops recommended for a correct operation of the
thickener, these loops are recommended to be considered in the control of the client.
8.1 FLOCCULANT ADDITION PUMP VELOCITY CONTROL

The flocculant must be added based on g/t (grams per tonnes). The flocculant
addition pump velocity must be increased as the interface level increases and
decrease if the interface decreases.
8.2 UNDERFLOW DISCHARGE PUMP VELOCITY CONTROL

In case there is a pump, the discharge pump velocity must be regulated so the mass
flow allows keeping the level of the bed inside the thickener. A Feed Forward signal
must be used for improving the dynamic answer of this control link or flow loop, which
means, the tonnage feeding signal must be considered in the control link or level loop
of the bed. A control link or mass flow loop must be executed as slave to the control
link of bed level loop to reject the work disturbances in the pipes or the pumping. In
case there are no pumps, the same logic must be used for controlling the underflow
discharge velocity.
[-----] [-----] [-----] [-----] 3 21 (29)

IN-IN-0001
Control Philosophy
9 PROCESS OPERATION
9.1 LOCATIONS
The Local Control Panel gives the indication of the status of alarms, rake manual
control button pads, and analogue indications. Control logic and monitoring shall be
made through the Local Control Panel. Start-up and maintenance operation must
always be made through the local control panel; during normal operation it can be
monitored and/or operated from the operation station in the central control room.
9.2 SCENARIOS
Operation scenarios for the Thickener are the following:
9.2.1 NORMAL START-UP (EMPTY)

Normal start-up is defined as the starting of the thickener filled with water with
minimum solid content.
Before the start-up the plant operator must check:
Rake direction is set to Neutral
There are no alarms in the system
Flocculant feeding system is operational
Thickener discharge system is operational
Start-up Procedure:
1. Start-up the hydraulic unit from the Local Control Panel.

2. Start-up the rakes drive system of the thickener from the Local Control Panel.
The rake rotation must be in clock-wise direction when it is seen from above.
3. Check the lifting system of the rakes is operational and Automatic
4. Check the rake torque is normal. When the thickener is filled only with water,
the rake torque must be minimum, << 25-30%, which is the operation torque
for normal work conditions.
5. Immediately before the first pulp is introduced, is important to ensure the
flocculation level at the Feedwell is correct.
[-----] [-----] [-----] [-----] 3 22 (29)

IN-IN-0001
Control Philosophy
9.3 START-UP OR QUICK START (WITH LOAD)

Quick start is defined as the Thickener start-up fully filled with water with a solid bed
present (Bed with solid content percentage of approximately 34% and the start-up
torque must not exceed normal operation conditions).
Before the start-up the plant operator must check that:
Rake direction is set to Neutral
There are no alarms in the system
Flocculant feeding system is operational
Thickener discharge system is operational
Start-up Procedure:
1. Start-up the hydraulic unit from the Local Control Panel.

2. Start-up the rakes drive system of the thickener from the Local Control Panel.
The rake rotation must be in clock-wise direction when it is seen from above.
3. Check the selector is in Automatic
4. Check the torque of the rake is normal (25-30%). Depending on the shutdown
time of the thickener with load inside, the torque might overpass the normal
operation torque value of 25-30%. The torque of the equipment must be
monitored and discharge the underflow of the thickener if necessary even
without feeding with new pulp until the torque is stabilized and the rakes are
in their lowest location.
5. Activate pulp feeding making sure that the Feedwell flocculation level is
correct, according to the IOM manual.
6. If the torque is still high (> 40%) or goes up again, it is recommended to cancel
the feeding and maintain the underflow load until the torque value decreases
again (<30%) before feeding back pulp to the thickener.
9.4 SHUTDOWN (NORMAL THICKENER SHUTDOWN)

This is a programmed or normal shutdown of the thickener during a normal operation
time (thickener filled with water and with minimum solid content).
Before stopping the thickener, the equipment operator must check that:
[-----] [-----] [-----] [-----] 3 23 (29)

IN-IN-0001
Control Philosophy
Remaining solids in the thickener are the minimum and they shall not cause
torque problems during the later start-up. This is confirmed checking the
torque of the rakes and the density of the discharge is low.
There is no solid content in the feeding to the thickener.
Shutdown procedure:
1. Stop the rotation of the rakes from the local control panel.
2. Check the feeding of pulp and flocculant or dilution water have been stopped
9.5 MAINTENANCE SHUTDOWN (EMPTY THICKENER SHUTDOWN)

A maintenance shutdown follows the same procedure described for a normal
shutdown, followed by the drainage of the thickener through the underflow discharge
and the cleaning up or sweeping of wastes and slurry by hoses and water if
necessary.
Before stopping the thickener the equipment operator must check that:
Remaining solids in the thickener are the minimum and they shall not cause
torque problems during the later start-up. This is confirmed checking the
torque of the rakes and the density of the discharge is low.
There is no solid content in the feeding to the thickener.
Shutdown procedure:
1. Stop the rotation of the rakes from the local control panel.
2. Check the feeding of pulp and flocculant or dilution water has been stopped.
3. Drain the thickener through the discharge pumps of the underflow and clean
up or sweep the wastes and slurry by hoses or water if necessary.
4. Before start-up again, fill with water the thickener to perform the start-up
according to the instructions described for a normal cold start-up.
5. Lower the rakes until the mechanical stoppage level to eliminate potential
energy of the automatic levelling system of the rakes.
[-----] [-----] [-----] [-----] 3 24 (29)

IN-IN-0001
Control Philosophy
10 CONTROL PANEL I/O SIGNALS
10.1 INSTRUMENTS
Digital input from instruments:
Hydraulic Unit Filter Saturation 2610-PDSH-06408
Low Level Hydraulic Unit Oil 2610-LSL-06405
Low-Low Level Hydraulic Unit Oil 2610-LSLL-06405
Rake Lower Position 2610-ZSL-06413
Rake Upper Position 2610-ZSH-06413
High Torque trip (torque 95%) 2610-OSH-06414
Low Level Gearbox oil (serial connection of logical 2610-LSL-06406A @ 2610-LSL-
signals) 06406F
Turbodil level switch 2610-LSL-06424
Analogue Inputs / F.F. from instruments: Tag

Torque 2610-OT-06401
Hydraulic oil temperature 2610-TT-06407
Rake Position 2610-ZT-06400
Bed Mass (F.F.) 2610-PIT-06422
Bed Level 2610-LT-06420
Turbidity 2610-AIT-06421
Position Transducer of Cylinders 2610-ZT-06412A @ ZT-06412E
Pressure Transducer of Cylinders 2610-PT-06412A @ PT-06412D
10.2 SOLENOID VALVES

Digital Outputs to the solenoids: Tag
Rake Rotation Clockwise 2610-HY-06411A
Rake Rotation Counter Clockwise 2610-HY-06411B
Enable Lifting & Lowering System of Cylinder 2610-XV-06412A @ XV-06412C
Enable Main Feed Lifting & Lowering System 2610-XV-06412
Hydraulic Unit Oil Cooler 2610-ZY-06412G
Analogue Outputs to the solenoids: Tag

2610-VP/ST-06482A @ VP/ST-
Lifting & Lowering System / Self Levelling of Cylinders
06482C
[-----] [-----] [-----] [-----] 3 25 (29)

IN-IN-0001
Control Philosophy
10.3 INPUTS/OUTPUTS OF THE MCC

Digital inputs from the motor MCC Tag
Hydraulic unit motor failure 2610-XL-06410C
Hydraulic unit motor running 2610-XL-06410B
Turbodil motor running 2610-XL-06415A
Turbodil motor failure 2610-XL-06415B
Digital Outputs to the MCC motor Tag

Thickener Actuation Emergency Stop 2610-HS-06410D
Command start hydraulic unit 2610-HS-06410B
Command stop hydraulic unit 2610-HS-06410C
Command start Turbodil 2610-HS-06415B
Command stop Turbodil 2610-HS-06415C
- Commands to MCC via Profibus DP
[-----] [-----] [-----] [-----] 3 26 (29)

IN-IN-0001
Control Philosophy
11 PLANT DCS I/O SIGNALS

Plant DCS signals are provided in Data Transfer table: BHP Document Number 4-V2-2610-IC-
LST-113001 (OT Document Number DQ160086-E30-000-IN-LI-010
12 ALARM LIST
Alarms are provided in Alarm List – All Thickeners: BHP Document Number 4-V2-2000-IC-LST-
113000 (OT Document Number DQ160086-E30-000-IN-LI-100)
[-----] [-----] [-----] [-----] 3 27 (29)

IN-IN-0001
Control Philosophy
13 APPENDIX A
13.1 AUTOMATIC RAKE LIFT & LOWER FLOW CHART

This flowchart applies when the rake lift is set to “Automatic”.
Start
Torque Torque
N Greater N
Less than
40% than 50%
Y Y
N Drive Set
to Forward
Lower Upper
Y Limit Limit Y
Switch Switch
Tripped Tripped
N N
Rake Lower Rake Raise

(intermittent) (constant)
Torque Torque
Greater N N
Less than
than 40% 45%
Y Y
Stop Rake Stop Rake

Lower Raise
[-----] [-----] [-----] [-----] 3 28 (29)

IN-IN-0001
Control Philosophy
13.2 MANUAL RAKE LIFT & LOWER FLOW CHART

This flowchart applies when the rake lift is set to “Manual”.
Start
Rake Rake
Lower PB N Raise PB N
Pressed Pressed
Y Y
Torque
Y Greater
than 50%
Lower Upper
Y Limit Limit Y
Switch Switch
Tripped Tripped
N N
Rake Lower Rake Raise

(constant) (constant)
Rake Rake
Lower PB Y Y Raise PB
Pressed Pressed
N N
Stop Rake Stop Rake

Lower Raise
[-----] [-----] [-----] [-----] 3 29 (29)

IN-IN-0001

Control Philosophy: Ø 99m Tailings Thickener Tag 2610-TH-004

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Control Philosophy: Ø 99m Tailings Thickener Tag 2610-TH-004

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DQ160086 – SPENCE GROWTH OPTION (SGO) PROJECT

3 Rodbor 27.08.18 - - Rodbor 27.08.18 Issued for Approval

Spence Growth Option (SGO) Project 4-V2-2610-IC-IPC-113032

[-----] [-----] [-----] [-----] 3 1 (29)

[-----] [-----] [-----] [-----] 3 2 (29)

8.2 UNDERFLOW DISCHARGE PUMP VELOCITY CONTROL ....................................21

[-----] [-----] [-----] [-----] 3 3 (29)

[-----] [-----] [-----] [-----] 3 4 (29)

[-----] [-----] [-----] [-----] 3 5 (29)

3 REFFERENCES AND ANNEXES

Document No. Description

HRT Ø99m Thickener – Tailing Thickener

DQ160086-E30-000-IN-LI-0001 Instrument List

[-----] [-----] [-----] [-----] 3 6 (29)

4 CONTROL PHILOSOPHY (P&ID DQ160086-G2280-T10-0250)

4.1 OPERATION PRINCIPLE

Thickened tailings to be sent generally to the deposit or to the tailings tank

Clarified water to be reused.

[-----] [-----] [-----] [-----] 3 7 (29)

[-----] [-----] [-----] [-----] 3 8 (29)

4.3 CONTROL STRATEGY

4.3.1 HYDRAULIC DRIVE MOVEMENT

[-----] [-----] [-----] [-----] 3 9 (29)

The "Automatic” mode, considers controlling the lifting system in function of

Pressure switch 2610-OSH-06414 is incorporated in the drive circuit of the

[-----] [-----] [-----] [-----] 3 10 (29)

There are six (6) low-level switches of gearboxes oil (2610-LSL-

Temperature transmitter 2610-TT-06407 will provide the measure of the oil

The same temperature transmitter 2610-TT-06407 will send a signal to the

Torque Measurement: Drive unit hydraulic pressure (Rake Torque) is

[-----] [-----] [-----] [-----] 3 11 (29)

Torque Value (%) Torque Value (Nm) Pressure Value (bar)

45% MOT 5.175.000 92

50% MOT 5.750.000 102

95% MOT 10.925.000 194

100% MOT 11.500.000 204

105% MOT 12.075.000 214

Summary Table of Torque at the Thickeners (referential)

4.3.2 RAKE LIFTING ACTUATION

Rake elevation position shall be measured by the Position Sensor 2610-ZT-

Additionally, there is an upper position switch 2610-ZSH-06413 and a lower

[-----] [-----] [-----] [-----] 3 12 (29)

4.3.3 SELF-LEVELLING DRIVE SYSTEM

4.4 INTERFACE MEASUREMENT

4.5 BED MASS MEASUREMENT

[-----] [-----] [-----] [-----] 3 13 (29)

5.1 START/STOP ROTATION OF RAKES.

A High Torque Trip signal is detected (95% of MOT of 11.500.000 Nm).

There is a failure of the hydraulic unit motor in the MCC.

There is an Emergency Shutdown (hard interlock to the motor, MCC).

5.2 DIRECTION OF RAKE ROTATION

5.3 AUTOMATIC RAKE LIFTING.

[-----] [-----] [-----] [-----] 3 14 (29)

Rake Upper Position Limit Switch (2610-ZSH-06413) is not activated and

While the operation mode is automatic for the control panel

Rake Upper Position Limit Switch (2610-ZSH-06413) is activated.

The rake is automatically lowered energizing its respective solenoid (2610-XV-06412

Rake Lower Position Limit Switch (2610-ZSL-06413) is not activated and

While the operation mode is automatic in the control panel

Rake direction is clockwise

The torque (2610-OT-06401) rises above 45% of the maximum torque of

Rake Lower Position Limit Switch (2610-ZSL-06413) is activated

The rake direction is set to neutral or counter clockwise