SAFE OPERATING PROCEDURE:

PAN OPERATIONS

1.

Purpose
To set a standard for safe operating and use of pans.

2.

Scope
This Procedure governs the safe use of a pan plant in the mining industry

3.

Reference Documents
Baseline Risk Assessment
Pan Operation Training Manual

4.

Definitions
Viscous :

Thick, sticky or not flowing easily

Inertia :

Resistance in change of movement

Proportional :

Influence in change

Inverse :

Describes relation between two things in such a way that when one
thing increases the other decreases.

Saturation :

Reaching a maximum capacity

Solute :

Solid

Solvent :

Liquid

Tailings :

Unwanted materials

Concentrate :

Wanted materials

Porrol :

Also known as puddle is a thick slurry mixture of water and soil

Attrition :

Effect of wear mechanism on the surface of the material.

Apertures :

Openings of the screen mash/ sized openings of the screen panel.

Abbreviations
HIRA :

Hazard Identification Risk Assessment

SOP :

Safe Operation Procedures

MSDS :

Material Safety Data Sheet

PLC :

Programmable Logic Controller

SAFE OPERATING PROCEDURE:

PAN OPERATIONS

SCADA :

Supervisory control and data acquisition

BIF :

Banded iron formation

5. Procedure
5.1. Operation of pan
5.1.1. Operation variables
5.1.1.1. Feed rate
Monitor feed rate from the pan feed conveyor, 50tons per hour maximum feed rate.
Ensure continuous feed rate to the pan.
5.1.1.2. Tappers
Clean tappers every 30 minutes.
Ensure continuous tapping at 100% (observe SCADA).
Make sure that the tappers are open and discharging onto the concentrate conveyor.
Ensure that the tapper flites are not worn-out and thus causing a gap between the auger and
the tapper.
5.1.1.3. Extractor
Inspect the back of the extractor that its not warn-out or damaged.
Ensure the extractor is replaced every 3 months.
3.1.1.4. Pan overflow weir
Regularly inspect overflow tails opening 110m from the floor
Inspect that the teeth are 50m from the pan floor
Regularly inspect that the pan teeth are changed within 7days
3.1.1.5. Pan density
Take pan density every 1 hour during the shift and record results.
Ensure density of 1.36kg/m3-1.42kg/m3
3.1.1.6. AMPS of the pan
Observe from PLC pan 1 & 2 amps at 56 amps
Observe from PLC pan 4 & 4 amps at 44 amps

3.1.1.7. Pan noise

SAFE OPERATING PROCEDURE:

PAN OPERATIONS

Flat pan tire(s): Inspect for any damage on the tires

Wet tire(s) : Caused by operator cleaning on top of the pan, water spills on tires
Density drop: Adding too much water.
Pan over feeding: Too much volume or weight material fed to the pans
Pan full of BIF: Material full of magnetics, normally material from old screen
Pan full of concentrate: over fed pans
Blocked tapper: neglecting to clean tapper every 30 minutes during shift run.
3.1.1.8. Pan operation variables
Puddle density
Optimum required pan density is between 1.36kg/m 3 and 1.42kg/m3, density slightly higher or
less than the required values is still acceptable, but too high densities will lead to heavy
contents of the pan which will cause pan drive motor AMPs to increase and over heat, either
damage will be caused on the motor or it will trap causing electrical faults. Pan density is
monitored and recorded each and every hour during production using a density cup and a
balance scale method. A density drop will cause belt spillages. The supervisor will check the
density by opening the soaker box inspection lid. This lid must be closed, and the grit secured
at all times as it forms part of the walkway leading to the power distribution boxes of each
individual pan.
Feed rate
Feed rates is dependent on volume and weight of the material mined, to focus on one variable
the feed rate at pan plant is dependent on weight. The scrubber feed rate varies but the pan
feed rate is at 50 tons per hour, maximum of 50 tons to be fed. The feed rate of the pans
should not exceed 50tons per hour, such results will cause overfeeding of the pan and may
cause serious problems with the pan drive getting damaged or overflowing of the pan may
occur. If the pan feed rate monitoring weight -meter read 50 tons is fed but pan is overflowing or
noises are heard on the wheels, it is important to do a Metallurgical test work with belt cult to
calculate amount fed to the pans, also to monitor amount BIF in the feed
The tapper
Tappers are very important equipment and part of the pan, malfunctioning of the tapper can
occur due to:
a.
b.
c.
d.
e.

Worn-out spiral extractor

Spiral extractor flites been short to allow for normal tap rate
Malfunctioning of the motor
Chain drive off
Blocked extractor entrance

All of the above could result into:

a. Lose of concentrate
b. Overheating of pan motor drives due to un released /delay of material fed into the pan
causing the pan to be heavy

SAFE OPERATING PROCEDURE:

PAN OPERATIONS

c. Wearing out of pan teeth

3.2. House keeping

Housekeeping refers to keeping working area clean at all times, placing everything in its rightful
place. It ensures ones safety, prevents further injuries and saves time. Adhering to the
procedures and good housekeeping prevents injuries and damage to equipment. Good
housekeeping is extremely important when working at the pan plant, all spillages must be
cleaned and foreign substance removed (glass, metal pieces, welding rods etc.).
3.2.1. Area of focus
Spillages around main feed bin and within the guards of the feed bin.
Spillages around the scrubber area, tranches and sumps.
Spillages at most bottom pulleys of the conveyors.
Build ups under the concentrate and tails conveyor
Washing of porrel tanks, screens and exterior surface of the pans
Spillage under the pans.
Spillage under green area conveyors and chutes.
Cleaning of porrel spillages at the porrel system tanks.
Removal of foreign substances around the plant (plastics, papers, metal pieces, etc.).
.

6. Responsibility
Supervisor, area responsible person, safety representative, Engineer, Mine Manager.
Deviations must be reported to the area responsible person who must rectify the deviation as soon as
possible.
7. Records

The Safety officer must keep the

Risk Assessment and Safe Operating Procedures on file.

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SHE OFFICER

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MANAGER