809.201669.050-00 (Operating and Control Philosophy) PDF

Weir Minerals Netherlands b.v.
P.O. Box 249

NL – 5900 AE Venlo
Carmen Copper - 201669
Document title: Operating and Control Philosophy
Purchaser :
Carmen Copper Corporation
Vendor :
Project no. : 201669
Project name : Carmen Copper
Location : Philippines
Purchaser order no. : L-0017/17
00 23-03-2018 Initial issue RBR ETV

Checked by /
Rev. Date Description Made by / prepared
approved
Document title Doc. No. Rev. No. Page

Operating and Control Philosophy 809.201669.050 00 1 of 23
Copyright © Weir Minerals Netherlands b.v. Weir Minerals Netherlands b.v. is the owner of the copyright subsisting in these drawings and designs. They must not be used, reproduced or
copied in whole or in part, in any form or by any means, nor may the information therein contained, which is confidential to Weir Minerals Netherlands b.v. be disclosed to any person
without the prior written permission of Weir Minerals Netherlands b.v.. The drawing and designs has been delivered and received on the express condition that it may be used only for the
specific purpose for which it has been provided and may not be used in any way which may injure or cause loss directly or indirectly to Weir Minerals Netherlands b.v. or any related
corporation and will be returned to Weir Minerals Netherlands b.v. immediately on completion of the task for which it has been provided or on demand.
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Content
1 Abbreviations 3
2 Introduction 4
3 Associated documents Error! Bookmark not defined.
4 System operation and control 5
4.1 General 11
4.2 System start up 11
4.3 Suction pressure monitoring 12
4.4 Mainline PD pump operation 13
4.4.1 Local/remote mode 13
4.5 Pipeline operation 14
4.5.1 Introduction 14
4.6 Slurry dilution sequence 16
4.7 Normal System Stop 17
4.8 Emergency System Stop 17
4.9 De-blocking 18
5 System control procedures Error! Bookmark not defined.
5.1 Automatic system start up Error! Bookmark not defined.
5.2 Automatic system stop Error! Bookmark not defined.
5.3 Slurry clearing standalone Error! Bookmark not defined.
5.4 Loop controls and interlocks Error! Bookmark not defined.
5.4.1 Interlocks Error! Bookmark not defined.

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1 Abbreviations
WMNL : Weir Minerals Netherlands b.v.
DCS : Distributed Control System
TTSS : Thickened Tailings Slurry System
DP : Differential Pressure
PD : Positive Displacement
PLC : Programmable Logic Controller
VFD : Variable Frequency Drive
MPLC : Main system PLC
NPSH : Net Positive Suction Head

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2 Introduction
This project comprises of a Thickened Tailings Slurry System (TTSS) for a copper mine. The mine
produces waste materials which are transported to a high density thickener. In the thickener the
waste materials are thickened by flocculants converting the tailings stream to a non-settling slurry. For
removal of the copper tailings, a copper tailings transportation system will be erected.
The TTSS system will comprise of six mainline GEHO® piston diaphragm pumps and three main
discharge pipelines to the disposal area. Six pumps will be operating; two pumps will operate as one
unit for each pipeline.
The intention of this document is to serve as a basis for the system design.

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3 Associated documents
This document must be read in conjunction with:
• Basic System P&ID, document number 809.201669.200, generated by WMNL
• Design basis, document number 809.201669.051, generated by WMNL
• P&ID of GEHO® pump, document number 814.201669.03, generated by WMNL
• Control description of GEHO® pump; document number 814.201669.20, generated by WMNL

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4 System description
4.1 General
Waste materials are produced by crushing the rock and by extracting the ore minerals from the crushed
rocks. The waste materials are transported to high density thickeners where the waste materials are
thickened by flocculants converting the tailings stream to non-settling slurry. The non-settling slurry from all
thickeners is collected in a thickened copper tailings sump pit.
The high-density copper tailings are taken from the thickened copper tailings sump pit and fed through a
feed pump to the connected mainline PD pumps for transportation to the disposal area.
The proposed high-density copper tailings system can be divided into two major sections.
Firstly the copper tailings preparation system:

Waste materials are converted to a high density non-settling slurry by flocculation in thickeners.
Secondly the copper tailings transportation system:

Feed pumps
GEHO® piston diaphragm pumps
Main discharge pipelines
Disposal area for storing high concentrated copper tailings
In general the system will comprise of following main components:

High density thickeners with thickened copper tailings sump pit
Four copper tailings feed pumps, three in operation and one common stand-by
Six mainline GEHO® piston diaphragm slurry pumps
Three copper tailings transport pipelines with distribution system on the storage area
The description of the thickeners and controls is not incorporated in this document since the thickeners
are not part of WMNL scope of supply.

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4.2 Feed pumps

The feed pumps take suction directly from the bottom of the thickened copper tailings sump pit and
will feed and provide suction pressure to the mainline PD pumps. The suction line to the feed pump
has to be as short as possible. The feed pumps will operate at variable capacity/speed, generating
sufficient suction pressure and flow for the mainline pumps. The thickened copper tailings sump pit
will be equipped with four feed pumps, three operating and one common standby.
The feed pump will be equipped with a gland type seal which requires seal water for gland cooling.
The required seal water pressure should be 0.3 bar above the maximum head as generated by the
feed pump. However, it should be monitored that not too much water is passing through the gland
seal and thus diluting the copper tailings.
An automatic actuated slurry dilution valve will be provided in the suction of the feed pump. This will
enable the system or operator to quickly respond in the event of a sudden pressure raise in the
discharge line. It will also be used as flush water inlet for priming and preparing the system and
mainline PD pump for a stop or for maintenance purposes after running on slurry.
In the discharge line of each feed pump a pressure transmitter is installed. Combined with a pressure
transmitter on the suction air vessel of the PD pump the pressure loss over the suction pipelines to
the mainline PD pumps can be monitored.

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4.3 GEHO® pumps

As mainline PD pumps six GEHO® triplex single acting crankshaft driven piston diaphragm pumps size
TZPM 1200 are installed. Six pumps will be in operation on three main discharge pipelines. Two pumps
will be operating as a set on each pipeline and a synchronize unit will control the speed of each pump for
minimizing the pressure fluctuations in each pipeline. Each pump is rated for an effective maximum flow
of 581 m³/h against a maximum operating pressure of 61 bar. Each GEHO® pump is provided with one
air over slurry type air vessel on the suction side of the pump and three nitrogen charged pulsation
dampers at the discharge side of the pump. The air vessel provides for a pulsation free and optimal
operation for the suction side, the discharge damper serves to reduce the pressure pulsations in the
discharge line. All diaphragm chambers are protected against over pressurisation by an integral pressure
relief valve.
4.3.1 Air vessel, suction

One air over slurry type suction air vessel is provided at the suction manifold of each mainline PD pump
to protect the feed pump from the pulsating flow characteristics of the mainline PD pump. The air vessel
doesn’t require level control.
The air vessel will be equipped with:

• Pressure gauge
• Pressure transmitter
• Emergency air supply connection (not to be permanently connected to the compressed air grid)
A suction air vessel functions on the basis of having a confined air volume inside a vessel. When the
pressure increases, the air volume will decrease and vice versa. In this way it serves as a buffer opposite
to the pulsating flow characteristic generated by the mainline PD pump on the suction side.
The air supply connection at the top of the air vessel allows for hand operated filling of compressed air, in
order to allow lowering the copper tailings level if air were lost.
The pressure transmitter enables continuous monitoring of the suction pressure through the pump PLC.
Low suction pressure will trigger an alarm but the pump will continue to operate.

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4.3.2 Pulsation damper, discharge

Three pulsation dampeners are provided at the discharge manifold of each pump to balance the
pulsating flow characteristics generated by the GEHO® pump.
The pulsation dampeners will have the following equipment:

• High-pressure nitrogen connection
• Pressure gauge
• Pressure transmitter
The nitrogen supply connection at the top of the damper allows for hand operated pre-charging of
nitrogen.
A pulsation damper functions in general on the same basis as a suction air vessel with these differences
that in this case nitrogen is used as gas, it is pre-charged and there is a rubber diaphragm separating the
nitrogen from the copper tailings.
The pressure transmitter will enable continuous monitoring of the discharge pressure through the pump
PLC. High discharge pressure (61 bar) will trigger an alarm. Too high discharge pressure (67.1 bar) will
cause an automatic shutdown of the electric motor of the GEHO® pump.
Nitrogen will have to be pre-charged at 60-70% of the expected operating pressure. In case it is
expected that the system operating pressure will change, for example due to a change in discharge
point, the pre-charge pressure needs to be adapted on basis of the expected operating pressure. This
can only be done before the system and mainline PD pump is started. During commissioning the pre-
charge level will be determined.

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4.4 Main discharge pipeline

The discharge pipeline can carry the full flow generated by the mainline PD pump. The proposed line has
an 18 inch nominal diameter and has a minimum design pressure of 70.2 bar, this being equal to the
GEHO® pump relief valve set pressure.
Three pumps are in operation, two pumps a set for each main discharge pipeline.
In each pump discharge line a pipeline isolation valve will be installed. Also a drain valve will be installed,
just upstream the isolation valve. This drain valve will be used to check water outflow during priming of
the mainline PD pump and to drain the system from water or slurry, prior to maintenance.
The maximum allowable time at which the slurry can remain idle inside the pipeline will be depending
on the homogeneity of the slurry. Hands on experience will dictate the maximum period allowable for
the pipeline to be in idle mode on slurry. The pipeline has to be completely flushed with clean water if the
time of standstill of the pipeline will exceed the maximum allowable time. After flushing, the mainline PD
pump will be stopped and there will be no pressure left in the pipeline, except for the static head.
Whenever the pipeline at the disposal area will have to split into two directions, the use of spool
pieces is required in order to avoid dead pockets which can be blocked by settled or solidified slurry.

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System operation and control
5.1 General
As already indicated in the introduction, this section is intended to function as a basis for the system
design, development of system control software and for the creation of required operator manuals.
The system is designed to operate semi-automatic by controlling the equipment and devices from the
control room. Conditions that might cause a major system shutdown are automated.
The mainline PD pumps are of such complexity that they require dedicated controls. Therefore each
mainline PD pump will be controlled by a dedicated PLC. Relevant signals and data will be made
available to the main system PLC (MPLC). The MPLC will monitor, control and execute all relevant
actions. It will also generate all information required for the operator to run the system adequately, by
means of a graphical user interface. System component status, system settings and system alarms can
be derived from this screen.
It is required to install the GEHO® PLC and GEHO® HMI touch screen as close to the pump as possible,
preferably at the same side and near to the location of the auxiliary motors and propelling liquid filling and
relief valves. This will facilitate pump maintenance and pump diagnosis in case of problems.
GEHO® pump signals can be transferred to the MPLC through hard wired signals.
5.2 System start up

When initially starting up or when the system is not filled with water after maintenance, the piping
system up to and including the GEHO® pump discharge manifold has to be filled with water. Filling
proceeds through opening the slurry dilution valve in the booster pump suction while the isolation
valve in the outlet line of the thickened copper tailings sump pit and main pipeline isolation valve are
closed. The system is fully filled if an air free water flow is drained from the drain valve in the
discharge of the mainline PD pump. After the system is properly filled the main pipeline drain valve
and the slurry dilution valve are closed.
For a normal start-up after the system has been operated and stopped previously, the entire
discharge line will either be filled with slurry or with water. When a GEHO® pump is stopped after
running on slurry, at least the system up to and including the pump discharge header will have to be
flushed with water. Slurry can remain idle inside the main pipeline, depending on the time at which it
can still be restarted without operational problems.

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Before staring the system, a predetermined speed set-point for one set of GEHO® pumps will be set
in the MPLC. The MPLC will transmit the set speed to the GEHO® PLC’s and synchronizing unit of
the set.
The mainline PD pumps have to be set in “remote mode”. The ‘Pre-Start Sequence’ will be starting
after a route has been set and the operator has activated ‘Start pumping’ through the MPLC panel.
The GEHO® pumps will be given a pre-start signal by the MPLC, the auxiliary motors are started and
the mainline PD pump will give a signal “ready to run”.
When the thickened copper tailings sump pit is sufficiently filled, the isolation valve in the outlet of the
sump pit is opened automatically after which the feed pump can start. While the feed pump is building
up suction pressure the GEHO® pumps will automatically start upon sufficient available suction
pressure and will ramp-up according a pre-set time to the set stroke speed. The ramp-up time of each
mainline PD pump can be adjusted in the VFD to meet pipeline response. The ramp up time will be
determined during commissioning based on actual pipeline response.
5.3 Suction pressure monitoring

The feed pump located near the thickened copper tailings sump pit will feed the slurry at sufficient
pressure to the mainline PD pumps. The suction pressure transmitter will signal the suction air vessel
actual pressure. The suction air vessel of the GEHO® pump ensures that acceleration losses are
avoided, as this provides for an air / tailings buffer and provides for an improvement on the required
NPSH.
Monitoring of suction pressure is started upon activation of following two signals:

Running feed pump
Suction pressure ≥ 3.11 bar
GEHO® motor running
During normal operation the suction pressure is monitored and reported. When this pressure will
become too low, the GEHO® PLC will generate an alarm but system will continue to operate. The
operator is advised to find the cause of the alarm.

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5.4 Mainline PD pump operation
5.4.1 Local/remote mode

The pipeline system flow is a function of and proportional to the mainline PD pump stroke rate. The
mainline PD pump drive motor speed and hence the stroke rate and flow rate are controlled with an input
signal to the mainline PD pump VSD. In other words, the required capacity of the system will determine
the nominal stroke speed setting for the mainline PD pump.
The operating systems have facilities to adjust and maintain a pre-set minimum speed, a pre-set
maximum speed (i.e. normal operating range) and the ramp up time.
The pump control panels are provided with a key operated local / remote operating selector switch. In
local mode the operator can control the GEHO® pump manually and can control for example the pump
speed and acceleration time. In remote mode the pump speed and acceleration will be controlled by the
MPLC through the synchronizing unit if the synchronizing unit is active either in manual or automatic
mode. The maximum acceleration will be subject to the maximum discharge pressure of the system. At
maximum stroke speed neither the system on automatic, nor the operator can further increase the speed
Relevant pump signals are available to the MPLC through hard wiring.
5.4.2 Overpressure protection

The discharge pressure transmitter, located at the pulsation damper is monitoring the pump
discharge/pipeline entrance pressure continuously. The system will start diluting the copper tailings at
a pre-set discharge pressure. The maximum continuous operating pressure of the pump is 61 bar.
The pump controls will generate an alarm at 64.1 bar and an automatic shutdown of the pump main
motor at a pressure of 67.1 bar.
If the pressure would still increase, for instance immediately after shutdown, due to the mass inertia of
the unit, the pump internal safety relief valve will open at 70.2 bar. National or local regulations could
urge for the use of an additional pressure relief valve on the discharge line. Since the pipeline will
have an open connection to the mainline PD pump it is expected that there is no such requirement.

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5.4.3 Mainline pump tripping

The mainline PD pump will trip if during normal operation a trip signal is received from any of the
following:
• An emergency push button (local regulations prevail)
• A trip signal from the motor or drive protection systems
• The MPLC, based on programmed scenarios
Further trip conditions for the GEHO® pump are given in WMNL document 814.201669.20. Depending
on the type of stop, the same mainline PD pump may be available for restart and slurry clearing
procedures.
5.5 Pipeline operation
5.5.1 Introduction
The mainline PD pump is designed for normal operating conditions between a minimum and maximum
discharge pressure, based on slurry density and rheology limits. The GEHO® pump is however capable
of generating a higher pressure than required for normal operation. A margin shall be preserved for any
emergency, which could cause the main discharge pipeline friction to increase beyond the maximum
specified levels.
The mainline PD pump discharge pressure would increase typically in the following cases:
• increase of solids concentration
• restart of a slurry filled pipeline
• increased scaling, the effective pipeline diameter will decrease and tailings velocity will increase
• changes in the characteristics of the dry material and corresponding tailings rheology changes
• change of discharge point at the disposal area

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5.5.2 Monitoring pump discharge pressure

The safe operating condition of the pipeline has to be verified continuously and can be derived from
the GEHO® pump discharge pressure. The pump discharge pressure is monitored, by using the
pressure transmitter located on the pulsation damper and the first pressure transmitter installed on
the pipeline closest to the pump. The pressure transmitter located on the pulsation damper has a
number of functions.
Prime function is to indicate actual pump discharge pressure, which is equal to the main pipeline inlet
pressure. It is advised to log this pressure against a time scale continuously. When the pump is
operating at constant conditions and the pressure increases slowly over time, this is an indication that
certain parameters of the copper tailings or the system are deviating or changing.
5.5.3 Main pipeline differential pressure monitoring

The safe operating condition of the pipeline has to be verified continuously and can be derived from
two pressure transmitters which will be installed on the pipeline. The pressure transmitters are located
at a distance of approximately 500 m from each other, whereby the first pressure transmitter is
located just downstream the outlet of the GEHO® pump. Both pressure transmitters will signal the
actual pipeline pressure but at different locations. The difference between the two readings depends
on the slurry viscosity and other operating conditions and therefor friction loss in the 500 m piping
section. This differential pressure can be logged against time and used to monitor safe pipeline
conditions as well.
Based on actual operating conditions two pipeline operating pressures can be defined: a pre-alarm
pressure which indicates a pressure that is higher than normal expected operating pressure and a
slurry dilution pressure, which will initiate automatic slurry dilution. Both pressure settings will have to
be tuned during commissioning. When the pressure reaches the pre-alarm pressure, the system will
give a pre-alarm for increased discharge pressure. From this point on the system operation has to be
monitored very closely in order to prevent an automatic slurry dilution sequence. At the next set point
of slurry dilution pressure an automatic slurry dilution sequence is started. The amount of water
added is to be maximized and is not designed to correct to a certain minimum solids concentration.
The maximum amount of water which can enter the system will be used to dilute the slurry. This
provision is merely incorporated to prevent that the pipeline will be blocked by wrongly prepared
slurry.

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5.6 Slurry dilution sequence

This feature will be the final action for the system to avoid an automatic shutdown due to exceeding
maximum continuous pressure and/or discharge pressure of the main pump. Programmed stages are:
• pre alarm at 42.7 bar
• start dilution at 48.8 bar
• maximum operating pressure at 61 bar
• discharge pressure high alarm at of 64.1 bar
• automatic shutdown of main motor at 67.1bar
The discharge pressure is measured by the pressure transmitter on the pulsation dampener of the
pump as well as the first pressure transmitter installed on the pipeline closest to the pump. However,
the pressure transmitter on the pulsation dampener is measuring the pre-charged nitrogen pressure
so actual discharge pressure below the pre-charge pressure cannot be measured. For this reason the
pressure transmitter installed on the pipeline closest to the pump is used for the slurry dilution
sequence.
When the average system operating pressure is exceeding 48.8 bar, it is assumed that the system is
heading towards maximum discharge pressure. This would be the moment to introduce an automatic
slurry dilution sequence in order to avoid an automatic system shutdown with the complete system
filled with wrongly conditioned slurry. The automatic slurry dilution has to take place in the suction line
of the feed pump. The mainline PD pump will receive the diluted slurry rather quickly, which will lead
to a stop in discharge pressure increase and provisionally in a descending discharge pressure. When
the pressure in the pipeline has decreased to 31 bar the slurry dilution is terminated and the system is
stopped. Whether or not the cause for this situation is known, the operator can consider a restart “on
the fly”. The system could be restarted, avoiding the need for a complete system slurry clearing
sequence. This sequence, however, should only be executed if the cause for activating the slurry
dilution is absolutely clear, and that it is verified that a system restart is safe.

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5.7 Normal System Stop

Each time a subsequently system stop is executed, the isolation valve at the outlet of the thickened
copper tailings sump pit is closed and an automatic clearing sequence is started.
The time relating characteristics of the slurry require that each time the system will be stopped for a
prolonged period, the complete system from feed pump suction line until the spigots of the discharge
pipelines are cleared with water, by starting a system clearing sequence. The slurry isolation valve of
the sump pit is closed and the slurry dilution valve in the suction line of the feed pump is opened. The
feed pump is started and the mainline PD pumps will ramp up according a programmed ramp-up
schedule to maximum capacity. The mainline PD pumps will stop after which the feed pump will stop
and the slurry dilution valve is closed after approximately 32 minutes whereby the quantity of flush
water volume should be sufficient for one pipeline flush.
The slurry clearance cycle can be initiated by selecting ‘Start Slurry Clearing’ on the MPLC when
there is a scheduled system stop.
5.8 Emergency System Stop

An automatic emergency system stop can be generated when one of the components in the system
will suddenly stop operating or an instrument will give a signal which will initiate an emergency stop.
When it is expected that the system stop will last for several hours the operator is advised to clear the
line of slurry.
Depending on the nature of the emergency system stop, two different situations are defined:
• The mainline PD pumps and feed pump are operational
• The mainline PD pumps or feed pump are not operational
When the mainline PD pumps and the feed pump are still operational a possible slurry clearing
sequence can be initiated using these system components.
When one of the two mainline PD pumps is not operational, the clearing of the pipeline should be
done by the other GEHO® pump of the same set.
When the feed pump is not operational, the clearing of the pipeline should be done by the stand-by
feed pump.
The mainline PD pump which is not operational should be flushed by opening the slurry dilution valve
and the drain valve of the discharge pipeline.
The feed pump which is not operational should be flushed by opening the slurry dilution valve and the
drain valve in the suction line of the mainline PD pump.

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5.9 De-blocking
The mainline PD pumps are capable of de-blocking the pipeline (within its maximum pressure rating).
De-blocking proceeds with pumping of water, which is entering the pipe system at the suction of the feed
pump.
De-blocking sequence will always be in manual mode. One of the mainline PD pumps of a pump set, will
be manually controlled while observing the pump discharge pressure and ensuring that this pressure will
not exceed 61 bar. The mainline PD pump and its drive do allow operating, for a limited time, at
maximum discharge pressure for the whole speed range of the unit, from ›0% to 100%. Often a blocked
pipeline can become operational again by applying full pressure loading at low volume delivered.
A partially blocked pipeline can be de-blocked by pumping a maximum available water volume through
the partially blocked pipeline in an attempt to flush the blockage away. At high pressure and sufficient
flow this procedure is a proven field method unique to a PD pump.

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6 System control procedures
6.1 Automatic system start up

• It is ensured that sufficient bed level is available in the thickened copper tailings sump pit
• It is ensured that mainline PD pumps are primed, drain valves are closed, main isolation valves in
discharge line are opened and the actuated knife gate valve in the discharge of the feed pump is
open
• Is it ensured that the entire system is ready to run from mechanical and electrical point of view
and everything is “safe”
• GEHO® PLC’s are set in remote mode
• It is ensured that all PLC signals of the MPLC are healthy and no errors are appearing in the MPLC
screen
• Speed set-point and other relevant parameters have been set in the MPLC. The MPLC will transmit
the speed to the synchronizer of the mainline PD pump set
• The route is selected for the specific pump line(s) in the MPLC
• GEHO® pump is given a pre start signal
• ‘Start pumping’ button on the MPLC HMI is activated
• GEHO® pump will give ready to run signal as feedback
• The actuated knife gate valve in the outlet of the thickened copper tailings sump pit is opened and a
limit switch will signal the open position
• The feed pump will start
• Upon reaching sufficient suction pressure the GEHO® pumps will start automatically and ramp up
until the set speed according to the ramp up time programmed in the VSD
• GEHO® pump will operate at the set synchronized speed set at the MPLC
• Any time the automatic start sequence has been interrupted, the system should be able to restart
again through the MPLC ‘reset alarms’ and ‘start pumping’. The ‘start pumping’ selection button
should light up to signal to the operator that the system is in automatic system start-up mode
• At any time when the sequence needs to be stopped in case of emergency, the ‘Quick stop’
selection through the MPLC must be selected to stop the system and put the system in a non-
operational safe state

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6.2 Automatic system stop

• The MPLC will be given a ‘stop pumping’ command
• The actuated slurry dilution valve in the suction of the feed pump is opened and the piping system
up to and including the mainline PD pumps discharge headers is cleared of slurry
• The actuated knife gate valve in the outlet line of the thickened copper tailings sump pit will be
closed and a limit switch will signal the close position
• The GEHO® pumps are stopped
• The feed pump is stopped
• The actuated slurry dilution valve in the suction of the feed pump is closed
• If the transport of slurry through the pipeline is stopped for a prolonged period of time than the
slurry clearance procedure must be carried out
• Any time the automatic stop sequence has been interrupted, the system should be able to restart
again through the MPLC ‘reset alarms’ and ‘stop pumping’. The ‘stop pumping’ selection button
should light up to signal to the operator that the system is in automatic system stop mode
operational safe state

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6.3 Slurry clearing

After the system has been given a “stop pumping” command, depending on the time it is allowed to leave
the pipeline filled with slurry, the system can be given a “start slurry clearing” command.
• GEHO® pumps speed for slurry clearing of the pipeline and time for tailings clearing have been
entered in the MPLC
• The MPLC will be given an “slurry clearance” command
• It is ensured that GEHO® pumps are primed, drain valves are closed, main isolation valves in
discharge line are opened and drain valves are closed and the actuated knife gate valve in the
discharge of the feed pump is open
• Is it ensured that entire system is ready to run from mechanical and electrical point of view and
everything is “safe”
• GEHO® PLC’s are in remote mode
• It is ensured that all PLC signals of MPLC are healthy and no errors are appearing on the HMI screen
of the MPLC
• The route is selected for the specific pump line(s) in the MPLC
• GEHO® pump is given a pre start signal
• ‘Start Slurry Clearing’ button on the MPLC HMI is activated
• GEHO® pump will give ready to run signal as feedback
• The slurry dilution valve in the suction of the feed pump will be opened and a limit switch will signal
the open position
• The feed pump will start
• Upon reaching sufficient suction pressure the GEHO® pump will start automatically and ramp up
until the set speed according to the ramp up time programmed in the VFD as well as a ramp up
time programmed in the MPLC
• GEHO® pump will operate at the set clearing speed
• GEHO® pump will operate until pipeline is cleared of slurry
• GEHO® pump is stopped
• The feed pump is stopped
• The slurry dilution valve in the suction of the feed pump will be closed and a limit switch will signal the
close position
• All valves of the pump line will be closed
• Any time the automatic slurry clearance has been interrupted, the system should be able to restart
again through the MPLC ‘reset alarms’ and ‘Start Slurry Clearing’. The ‘Start Slurry Clearing’
selection button should light up to signal that the system is in slurry clearance mode
operational safe state.
Note: The ‘start slurry clearing command’ should normally be selected when the system is in slurry
pumping state if it is already determined that the system will be stopped for a prolonged period.

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6.4 Loop controls and interlocks

Following device modes are defined:
AUTO : operated and controlled automatically by MPLC

MANU : operated by MPLC but with manual control
LOC : local operation from field, locked by a key at GEHO® pump PLC
REMOTE : remote operation of GEHO® pump PLC, controlled by MPLC
There are three types of interlocks:
IA, operating interlock : valid in auto mode only

IP, operating interlock : valid in auto and manual mode
IB, blocking interlock : valid in auto and manual mode
6.4.1 Interlocks
No. Action Condition
IA1 Slurry dilution valve open Feed pump is running
and
main discharge line PT116, PT126 or PT136 >
dilution activation pressure
or
Slurry clearing mode
or
Stop pumping activated
IA2 Slurry dilution valve close mainline PD pump pressure < dilution
deactivation pressure
or
Start pumping activated
IP1 Feed pump start Isolation valve in outlet of sump pit is open
or
Slurry dilution valve open
IB1 Feed pump stop Feed pump is running
and
Isolation valve in outlet of sump pit is not
open
or
Slurry dilution valve closed

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7 Human machine interface

The following information and options will be available on the HMI;
• Alarm list (separate list for customer and manufacturer).
• Event list (separate list for customer and manufacturer).
• Operation visualization. Specific coloured lines indicating slurry flow. Idle clearing time
indication (blinking lines indicating slurry is in stagnation in that part for specific time).
• Warning and alarm indication of GEHO® pump PLC’s
• Remote access HMI.
• Various log-in levels. Log-in required. When starting up HMI shows log-in screen first.
• State of components indication. To indicate whether valves are opened or closed.
• Export data;
o Print screen USB
o Trends USB
o Alarms / events USB
• Separate screens;
o Log-in screen
o Parameter screen (Fill of operational parameters)
o Complete system on main screen including mode description and stage indication.
o Separate pump lines with Pumps (GEHO® pump and feed pump) and discharge
valves part of the system
o Mode selection
o Parameters (including running hours)
• WMNL logo on log-in screen and in upper left corners of other screens.


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Weir Minerals Netherlands b.v.

P.O. Box 249

Carmen Copper - 201669

Document title: Operating and Control Philosophy

Carmen Copper Corporation

Weir Minerals Netherlands b.v.

Project no. : 201669

Project name : Carmen Copper

Purchaser order no. : L-0017/17

00 23-03-2018 Initial issue RBR ETV

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Firstly the copper tailings preparation system:

Secondly the copper tailings transportation system:

In general the system will comprise of following main components:

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4.2 Feed pumps

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4.3 GEHO® pumps

4.3.1 Air vessel, suction

The air vessel will be equipped with:

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4.3.2 Pulsation damper, discharge

The pulsation dampeners will have the following equipment:

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4.4 Main discharge pipeline

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System operation and control

5.2 System start up

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5.3 Suction pressure monitoring

Monitoring of suction pressure is started upon activation of following two signals:

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5.4 Mainline PD pump operation

5.4.1 Local/remote mode

5.4.2 Overpressure protection

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5.4.3 Mainline pump tripping

5.5 Pipeline operation

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5.5.2 Monitoring pump discharge pressure