TIERRA AMERILLA BALL MILL

CONTROL PHILOSOPHY

1.0 GENERAL

The Ball Mill as supplied by Bradken Mineral Processing consists of the Mill, the Mill Drive
Train, Barring Drive and associated ancillary drives.

The mill motor is a 3650 kW, 4160 volt wound rotor motor, started by means of a secondary
liquid resistance starter.

The primary starter for the mill, including the Motor Protection Unit, the mills associated drives,
(cooling fans, lube oil pumps etc.) and anti condensation heater starters and contactors are the
responsibility of the client.

The following forms the major items of the mill package.

 Mill motor
 Liquid resistance starter
 Gearbox complete with cooling system
 Barring drive
 Pinion bearing lubrication system
 Trunnion bearing lubrication system
 Girth gear spray system
 Mill control Panel

All instrumentation associated with the Mill is wired back to the Mill Control Panel which
controls the prerequisites and interlocking for the drives via a P.L.C.

The Control Panel contains Stop/Start buttons for the associated drives while the control
philosophy adopts a manual sequence or auto start with remote control facilities.

All starters associated with the Mill Drives are part of the main MCC or a separate MCC
supplied by the client. All interconnecting cables from the drives and field devices to the mill
control panel and any local isolators or remote stop/start station are by others.

The following description is a written guide for the programming parameters for the PLC, but
not intended to cover the full programming requirements.

2.0 MILL CONTROL PANEL

The Mill Control Panel comprises of the following main components :

 Emergency Stop push button

 Surge protection
 Control & power circuit breaker
 PLC
 Mill mimic panel with indicating LED’s
 Temperature indicators
 Selector switches for Local/Remote and Standby/Duty selections.

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 Push buttons for the following
 Mill main drive Start/Stop
 Motor cooling fans Start/Stop
 Barring drive Start/Stop
 Gearbox lube oil pump Start/Stop
 Gearbox Lube cooling fan Start/Stop
 Bearing extra lube
 Girth gear extra lube
 Alarm accept
 Alarm reset
 Lamp test

The mill motor philosophy is one of sequence interlocks, with minimum automation. A
Local/Remote selector switch is provided on the Panel to allow the drives to be started in
sequence remotely from the Central Control Panel via a communication link or locally at the
panel in a manual sequence. T he Ball Mill PLC will carry out all sequence interlocking.

The following indication is provided on the Mill Control Panel:

1 - Gear Box sump oil temperature

4 - Gear Box bearing temperatures
2 - Pinion bearing temperatures
4 - Trunnion bearing temperature

A mimic panel is provided to show a graphic representations of the mill and ancillary
equipment.

The mimic panel indicating LED’s displays the status of the drives and alarms as listed below.

Mill Motor

Ready (Green) This LED is illuminated when the mill is ready to start. ie. H.V.
Starter healthy, LRS healthy, Mill lubrication systems running.
Running (Red) This Led will illuminate after a start warning siren is complete and
when the high voltage circuit breaker is closed.

Barring Drive

Ready (Green) Illuminates when barring drive selected and control circuit interlock
healthy.
Running (Red) Illuminates when drive running.

The status of the following drives are also indicated by LED’s.

Mill Motor Cooling Fans

Gear Box Lubrication Pump
Gear Box Cooling Fan
Bearing Lubrication Pumps
Lubrication Cooling Fans

Ready (green) Illuminates when control circuit healthy

Running (Red) Illuminates when running.

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 The above drives require voltage free contacts from their relevant starters

N/O Drive Ready (closed when ready)

N/O Drive running (closed when running)
N/O Drive TOL (closed when O/L)

Alarms

An amber LED is provided for all mill field device faults.

Indicators

The mimic indicators are controlled by the PLC mounted in the Mill Control Panel. A lamp test
button is provided to detect a faulty lamp.

The drive ready lamp serves a dual purpose.

 When illuminated in a steady state the drive is healthy and ready to start.
 When flashing at a fast rate a fault is present but unacknowledged (siren on).
 When flashing at a slow rate the fault has been acknowledged by the operator but still
exists.
 Lamp off indicates the drive is isolated ie., loss of all inputs.

The amber lamps are associated with field faults, ie., high temperature and the status is:

LED OFF – no fault

LED flashing at fast rate – Unacknowledged fault ( siren on)
LED ON – acknowledged fault but fault still present (siren off)

NOTE: When an alarm such as High temperature and High High temperature are used the
steady state will change to flashing and the siren sound again when the second set point
is reached (ie. High – High High).

An audible alarm is mounted on the side of the control panel and will sound continuously
(15 seconds) before the start of the mill.

For fault conditions the alarm siren will sound until acknowledgment by the operator.

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3.0 MILL MOTOR

The mill motor system consists of the following main items of equipment:

 Mill motor 1 off 3650 kW, 4160 v 6 pole

 Internal air conditioning fan 2 off 15 kW, 380 v, 4 pole
 External chamber cooling fan 2 off 7.5 kW, 380 v, 4 pole
 Slipring chamber cooling fan 1 off 5.5 kW, 380 v, 4 pole
 Anti condensation heater 1 off 1000W, 200 v, 1 phase

The mill motor is fitted with the following PT100  RTD Temperature Sensors

 Motor red winding (U) TE 001 A/B

 Motor white winding (V) TE 001 C/D
 Motor blue winding (W) TE 001 E/F
 Motor drive end bearing TE 002 A/B
 Motor non drive end bearing TE 002 C/D
 Ambient air temperature TE 003

The mill motor is also fitted with the following pressure switches to prove the integrity of the
cooling fans:

 Internal air pressure switch PSL 004 A/B

 External air pressure switch PSL 005 A/B
 Slip ring chamber pressure switch PSL 006

4.0 SYSTEM DESCRIPTION

The mill motor consists of a 3650 kW, 4160 v, 6 pole, 50 Hz wound rotor motor. The motor is
started by means of a secondary liquid resistance starter. The primary starter complete with
motor protection device for monitoring the status is part of the clients mill switchboard.

The motor windings are fitted with RTD Temperature Sensors, two per phase. The sensors
are connected to the motor protection device. Should the winding temperature reach the
alarm setting an alarm is raised. If the winding temperature continues to rise to the trip setting
the motor is shutdown.

The mill motor has RTD sensors installed in the drive end and non drive end bearings. Each
sensor is connected to the motor protection relay. If the bearing temperature reached the
alarm set point an alarm is sounded. Should the temperature continue to increase to the trip
setting the motor is immediately shut down. The mill motor is equipped with an air to air heat
exchanger. There are two electrically driven internal air circulating fans along with two
electrically driven external air circulatory fans. A fifth fan is used to cool the slipring chamber of
the mill motor.

An ambient air temperature sensor is fitted to measure the air inlet temperature.

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Each of the air chambers is fitted with an air pressure switch which monitors the operation of
each individual fan. Should any of the pressure switches fail an alarm is sounded.

The mill motor stater panel includes a Fortress Captive Key interlock system consisting of two
keys B1 & B2. Key B1 can only be inserted in one three places.

1. The mill motor starter panel.

2. The barring drive engagement lever.
3. The jacking cradle hydraulic panel.

Key B1 can only be removed from the mill motor primary starter panel when the high voltage
circuit breaker is tripped, racked out and earthed. Key B1 is inserted into the barring drive
engagement lever which enables movement of the barring drive lever. When the drive is fully
engaged Key B2 is released from the lock. B2 is then placed in the lock of the mill panel
enabling the barring motor to be energised in a continuous mode.

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CONTROL PHILOSOPHY

The mill motor start sequence may be initiated from more than one station either manually
following a defined sequence or automatically utilising the control system to perform a
sequence start.

Prior to starting the mill motor, the Fortress Interlock Key B1 must be inserted in the clients
motor starter panel allowing the primary starter circuit breaker to be racked into position.

In either automatic or manual mode the auxiliary drives, cooling fans and lubrication systems
must be started and feed back received that all prerequisites are satisfied before the start
circuit can be initiated. A 15 second warning siren will sound prior to closure of the primary
circuit breaker.

The mill shutdown is initiated by the operation from either a local or remote push buttons or
any of the Emergency Stops. Activation of any of these buttons will bring the mill to an
immediate stop. The gear box lubrication oil pump is to continue to run for 5 minutes after mill
shutdown while the motor cooling fans are to continue for 15 minutes following mill motor
shutdown.

The mill motor protection relay trip criteria and protection parameters are to be set to comply
with mill motor manufacturer’s operation manual.

Should the mill motor winding temperature reach the alarm setting of the protection relay an
alarm is raised. Should the temperature continue to rise to the trip point the motor is tripped.
If the bearing temperature reaches the alarm set point an alarm is raised and should the
temperature continue to rise to the trip set point the motor is tripped.

The Mill protection Trip Circuit must be a fail – safe system. If shunt trips are used for the trip
circuit, it must be monitored. The circuit breaker panel interposing relay must be normally
energised to ensure any circuit failure will trip the Mill. When tripping batteries are used the
tripping mechanism must be a fail - safe system. Manual circuit breaker closing facilities must
be disabled.

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PREREQUISITES

Before the mill motor may be started the following prerequisites must be fulfilled.

 The Mill Motor Emergency Stop Push Buttons not depressed

 The Mill Motor Protection Device reset with no faults
 Mill motor Cooling Fans running and air pressure detected
 Fortress Key in position in Mill Motor Starter Panel and H.V. Starter ready
 Liquid Resistance Starter ready and no faults
 Gearbox Lube Oil Temperature not high
 Gearbox High Speed Bearing temperature not high
 Gearbox Low Speed Bearing temperature not high
 Gearbox Lube Filter Differential Pressure not high
 Gearbox Lube Oil Pressure not low
 Pinion Bearing Temperature not high
 Trunnion Bearing Temperature not high
 Pinion Bearing Lube Oil Pressure not low
 Pinion Bearing Lube Oil Filter Differential Pressure not high
 Pinion Bearing Lube Oil Temperature not high
 Pinion Bearing Lube Oil Level not low
 Trunnion Bearing Greasing System air pressure OK
 Trunnion Bearing Grease Drum not low
 Trunnion Bearing Metering Valves feedback
 Girth Gear Grease System Air Pressure healthy
 Girth Gear Grease Air Spray Pressure healthy
 Girth Gear Grease Drum not low
 Girth Gear Grease Metering Valves feedback

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MILL MOTOR TRIP

The following conditions will trip the Mill Motor.

 Any Emergency Stop Button

 Motor Protection Relay fault
 Motor Winding Temperature High High TE 001(A to F)
 Motor Bearing Temperature High High TE 002(A to D)
 Motor Cooling Fans fault PAL 004 (A to B)
PAL 005 (A to B)
PAL 006
 Liquid Resistance Starter fault (during startup) X1 012B
 Liquid Resistance Starter shorting contactor open during running X1 012A
 Gearbox Lube Oil Temperature High High TAH 027
 Gearbox High Speed Bearing Temperature High High TAH 028 (A to B)
 Gearbox Low Speed Bearing Temperature High High TAH 029 (A to B)
 Gearbox Lube Oil Pressure Low Low PALL 026 B
 Gearbox Lube Oil Filter blocked (1 hour delay) PDAH 021
 Pinion Bearing Temperature High High TAH 059 (A to B)
 Trunnion Bearing Temperature High High TAH 078 (A to B)
TAH 079 (A to B)
 Pinion Bearing Lube Oil Pressure Low Low PAL 051
 Pinion Bearing Lube Oil Filter blocked (1 hour delay) PADH 055 (A to B)
 Pinion Bearing Lube Oil Temperature High High TAH 057
 Pinion Bearing Lube Oil Level Low Low LALL 058
 Trunnion Bearing Grease Pressure fault (1 hour delay) Refer Section
 Trunnion Bearing Grease Metering Switches failure (1 hour delay) Refer Section
 Trunnion Bearing Grease Drum Low (1 hour delay) ZAL 073
 Trunnion Bearing Grease System Air Pressure low Client Supply
 Girth Gear Grease Pressure fault (delayed 20 minutes) Refer Section
 Girth Gear Grease Drum Low (delayed 20 minutes) ZAL 095
 Girth Gear Grease Metering Switches failure (delayed 20 minutes) Refer Section
 Girth Gear Grease System Air Pressure Low Client Supply

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5.0 LIQUID RESISTANCE STARTER

The Mill Motor Secondary Liquid Resistance Starter consists of the following main items of equipment.

 Liquid Resistance Starter Electrode Drive 0.37 kW 4 pole

 Liquid Resistance Starter Agitator Motor 0.37 kW 4 pole

The Mill Motor Secondary Resistance Starter System consists of the following control and alarm
signals.

 Rotor short circuited XSC 012A

 Starter Fault indicator XIA 012B
 Motor Trip signal XMA 012C
 Ready to Start XSI 012D
 Electrolyte Level Low LSL 012E
 Electrolyte Over Temperature TSH 012F
 Starter Start Switch XSC 012G
 Inverter Fault Reset Switch XSC 012H

System Description

The Mill Motor Secondary Resistance Starter is used to start the mill while limiting the motor starting
current. The Secondary Resistance is a liquid electrolyte type with moveable electrodes. The
electrodes are gradually lowered into the liquid, using a geared drive, during the starting phase. When
the mill motor is up to speed and the electrodes fully lowered a contactor shorts the rotor leads, thus
bypassing the liquid resistance bath to provide a fixed speed operation.

Refer to the motor Suppliers Manual for further information.

Control Philosophy

The Liquid Resistance Starter begins to function as soon as the mill motor primary circuit breaker is
closed. This is initiated by a set of auxiliary contacts closing on the primary circuit breaker. Before the
mill can be started a secondary resistance Ready to Start signal must be received at the mill control
panel. The Ready signal indicates that the moveable electrodes are in the fully raised position and that
the rest of the system is in a healthy state. As soon as the mill motor is energised the secondary
resistance starter electrodes begin to lower until they reach the fully lowered position at which stage the
shorting contactor is energised.

If the electrode level drops below the set level an alarm is raised and the mill motor start is disabled if it
has not started.

The following Liquid Resistance Starter conditions prevent the mill from starting.

 Secondary Resistance Starter Temperature High TSH 012F

 Secondary Resistance Starter Electrolyte Level low LSL 012E
 Secondary Resistance Starter fault. XIA 012B
 Secondary Resistance Starter Motor trip. XMA 012C
 Secondary Resistance Starter Isolator opened. Client Supply

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Interlocks

The following conditions trip the Secondary Resistance Starter, and in turn, the mill motor during
starting only.

 Secondary Resistance Starter Electrolyte Temperature High TSH 012F

 Secondary Resistance Starter Electrolyte Level low LSL 012E
 Secondary Resistance Starter fault XIA 012B
 Secondary Resistance Starter excess starting time XMA 012C
 Secondary Resistance Starter Isolator opened Client Supply

Note: 1. Depressing any mill Stop button during startup will trip the mill and reset the Liquid
Resistance Starter to enable another attempt.

2. If the Electrolyte Low Level or High Temperature occurs after the shorting contactor is
closed only alarms are raised.

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6.0 GEAR BOX LUBRICATION SYSTEM

The Gear Box Lubrication System consists of the following main items of equipment.

 Gearbox Lube Pump 7.5 kW 4 pole

 Gearbox Lube Cooling Fan 1.5 kW 6 pole
 Gearbox Lube Oil Dual Filters
 Air to Oil Heat Exchanger
 Gearbox Lube Oil Temperature Control Valve

The Gearbox Lubrication system consists of the following control instrumentation

 Gearbox Lube Oil Filter Pressure Differential Switch PDS 021

 Gearbox Lube Oil Filter Pressure Differential Gauge PI 021
 Gearbox Lube Oil Temperature Switch TSN 023 (A to B)
 Gearbox Lube Oil Temperature Indicator TI 024
 Gearbox Lube Oil Pressure Indicator PI 025
 Gearbox Lube Oil Pressure Switch PSL 026 (A to B)

System Description

The Gearbox Lubrication System consists of a gear pump fitted with a pressure limiting valve and direct
coupled to a 7.5 kW 4 pole motor which circulates the oil to the gearbox. The Gearbox Lubrication
System must be started by the operator from a local control panel or remotely as part of an auto start
sequence, before the Ball Mill Motor or the barring drive can be started, and it must always be in
operation whenever the Ball Mill is rotating. The Gearbox Lubrication System is manually shutdown by
the operator when no longer required or automatically 5 minutes after the mill motor has stopped.

The Gearbox Lubrication Oil System is fitted with a duplex oil filter incorporating a differential pressure
indicator and a differential pressure switch which is set to alarm when the operating filter is blocked.
The Gearbox oil is air cooled through an oil/air heat exchanger fitted with an electrically driven fan
controlled by temperature switches in the oil that start and stop the fan as required. The oil/air heat
exchanger is bypassed at low temperatures by a temperature control valve. The temperature control
valve delivers only the required amount of oil for the cooler to maintain the desired oil temperature.

Should the lube oil pressure fall below the desired operating level, the Lube Oil Low Switch will raise an
alarm and the Lube Oil Low Low Switch will trip the mill motor if the pressure falls below the motor trip
set point.

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Control Philosophy

Before the mill can be started, the Gearbox Lubrication System must be running for 5 minutes.

The temperature sensor TE027 in the gearbox sump is used to control the operation of the gearbox
lube oil heater. If the oil temperature falls below the minimum oil operating temperature the heater is
energised; the heater is de-energised when the oil rises above the operating set point.

The temperature control valve bypasses the oil/air heat exchanger at low temperatures allowing rapid
heating to the required operating temperature. On reaching the desired temperature the oil line to the
cooler is opened and the bypass line is closed to the same degree. The supply to the cooler increases
constantly in response to the increase in oil temperature until reaching a completely open cooling line
at which stage the bypass line is fully closed. The oil temperature control valve regulates the
temperature of the oil within the fixed temperature range and delivers only the required amount of oil to
the cooler to reach the desired oil temperature.

The Oil/Air heat exchanger fan is switched on when the oil temperature reaches the “fan on”
temperature and switched off when the “fan off” temperature is reached. If the oil temperature exceeds
the alarm set point an alarm is raised and if the temperature continues to rise to the High High set point
the mill motor is tripped.

A blocked filter alarm PDSH021 will raise an alarm but will not shut down the motor unless the blockage
is not cleared within one hour.

When running a Lube Oil Low Pressure Switch PSL026A will signal an alarm, should the Lube oil
Pressure continue to fall an Oil Low Low Pressure Switch PSL026B will shut the mill motor down.

The following conditions will stop the Gearbox Lube Pump from starting.

 The Drive MCC not ready

 The motor field isolator is not closed

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7.0 GEAR BOX

The gearbox oil is circulated by the gearbox lubrication system. The gearbox is filled with the following:

 Gearbox heater
 Bearing RTD’s
 Sump oil RTD

System Description

The gearbox heater is controlled between the operating set points by the inbuilt temperature sensors.

The gearbox is used to reduce the mill motor speed to the required drive speed of the mill and is also
coupled to the barring drive motor gear box for barring the mill to enable liner changes and for
maintenance. The barring drive is engaged to the low speed coupling by the clutch operating
mechanism.

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8.0 BARRING DRIVE SYSTEM

The Mill Barring System consists of the following:

 Barring Drive Motor

 Barring Drive Coupling

The Mill Barring System consists of the following control instrumentation:

 Barring Key Interlock

System Description

The Mill Barring System is used to slowly rotate the mill to a desired position for maintenance. Barring
is performed utilising the mill gearbox. The barring drive can only be coupled to the gearbox shaft if the
B1 Fortress Key is removed from the mill motor high voltage starter when isolated and then inserted
into the barring coupling receptacle. With this key properly inserted, the baring mechanism can be
operated to engage the drive. The barring drive can be jogged only, by using the mill control panel
Start/Stop buttons, when in the disengaged position to allow the coupling to be lined up for smooth
engagement. Once the coupling has been fully engaged, the B2 Key can be removed from the
coupling receptacle and inserted into the Mill Control Panel Rotary Switch to allow continuous operation
of the Barring Drive.

Control Philosophy

To energise the barring drive, the mill must be selected for barring mode at the Mill Control Panel. To
select the barring position on the Rotary Switch the Fortress Key must be removed from the Mill Motor
Isolator(Key B1) and inserted in the barring drive receptacle. The coupling is then engaged to release
the B2 Key which is then inserted at the Mill Control Panel to operate the Rotary Switch. This enables
the barring drive to be run in the continuous mode.

Refer the Bradken Mineral Processing Barring Drive Procedures mounted at the drive.

The Barring Drive can only be run if the following conditions are met:

 Mill motor not running

 Local mode selected
 Fortress Key removed from main drive isolator B1
 Fortress Key inserted in barring drive lever mechanism B1
 Fortress Key inserted in Mill Control Panel B2
 Mill Lubrication System running

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Interlocks

The following conditions will trip the Barring Drive:

 Gearbox Bearing Temperatures High High TAH 028 (A to B)

TAH 029 (A to B)
 Gearbox Lube Pump not running Client Supply
 Trunnion Bearing Temperatures High High TAH 078 (A to B)
TAH 079 (A to B)
 Pinion Bearing Temperatures High High TAH 059 (A to B)
 Pinion Bearing Lube Oil Pressure Low PAL 051
 Gearbox Lube Oil Pressure Low PALL 026B
 Gearbox Lube Oil temperature High High TAH 027

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9.0 PINION BEARING LUBRICATION SYSTEM

The Pinion Bearing Lubrication System consists of the following main items of equipment.

 Pinion Bearing Duty Lube Pump 1.1 kW 4 pole

 Pinion Bearing Standby Lube Pump 1.1 kW 4 pole
 Pinion Bearing Dual Filters
 Pinion Bearing Air/Oil Heat Exchanger

The Pinion Bearing Lubrication System consists of the following control instrumentation.

 Pinion Bearing Lube Oil Tank Level LowLSL 05B

 Pinion Bearing Lube Oil Tank Level Low Low LSLL 05B
 Pinion Bearing Lube Oil Temperature Low TSL 057
 Pinion Bearing Lube Oil Temperature High TSH 057
 Pinion Bearing Lube Oil Temperature High High TSHH 057
 Pinion Bearing Duty Filter Pressure Differential Switch PDSH 055A
 Pinion Bearing Standby Filter Pressure Differential Switch PDSH 055B
 Pinion Bearing Lube Oil Pressure Switch PSL 051
 Pinion Bearing Lube Oil Temperature Indicator TI 053A
 Pinion Bearing Lube Oil Pressure Indicator PI 052
 Pinion Bearing Lube Oil Flow Control Valves FCV 050 (A to B),
FCV 054

System Description

The Pinion Bearing Lubrication System is filled with two electrically driven gear pumps. One pump is a
duty pump while the other is standby. The duty pump is selected via a selector switch on the Mill
Control Panel. The Pinion Bearing Lubrication System must be started 5 minutes prior to the starting
the main mill motor and shutdown either manually or automatically 5 minutes after the mill motor has
stopped.

Dual oil filters are fitted with visual differential pressure indicators and differential pressure switches to
alert of a blocked filter.

The pinion bearing is air cooled through an Air/Oil heat exchanger which has a cooling fan attached. A
heater is provided in the oil tank to ensure that the oil temperature does not fall below the operating
temperature.

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Control Philosophy

Before the mill can be started the Pinion Bearing Lubrication System must be running.

If the Pinion Bearing oil reservoir temperature falls below the temperature set point the tank heater is
energised. The heater is de-energised when the temperature rises above the set point. If the oil
temperature reaches the “Fan On” set point the cooling fan is energised and remains energised till the
oil temperature drops below the “Fan Off” temperature.

Should the oil temperature continue to rise to the High High set point the motor is tripped.

A blocked filter alarm PDAH 055A/B will raise an alarm but not stop the lubrication pump unless the
blocked filter is not cleared within one hour.

When running a Lube Oil Low pressure signal PAL 051 will raise an alarm and trip the motor.

The following conditions will prevent the Pinion Lube Oil Pump from starting.

 Drive Mill not ready

 Field Isolator not closed
 Drive not selected (duty standby)

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10.0 TRUNNION BEARING GREASE LUBRICATION SYSTEM

The Trunnion Bearing Grease Lubrication System consists of the following main items of equipment:

 High Pressure Pneumatically driven Grease Pump

 180 Kg Grease Tank
 Dual Line Automatic Grease Inverter
 Dual Line Grease Metering Valves

Trunnion Grease Lubrication System consists of the following control instrumentation:

 Pneumatic Pump Pressure Indicating and Control Valve

 Pneumatic Pump Air Solenoid Valve
 Bearing Grease Line A Solenoid Valve
 Bearing Grease Line B Solenoid Valve
 Bearing Grease Drum Level Switch
 Grease Line Pressure Switch
 Line “A” Grease Pressure Indicator
 Line “B” Grease Pressure Indicator
 Feed End Trunnion Metering Valve Switches
 Feed End Trunnion Bearing Temperature Sensor
 Discharge End Trunnion Metering Valve Switches
 Discharge End Trunnion Bearing Temperature Sensor

System Description

The bearings are provided with a Lubrication System and Temperature Monitoring Sensors. The
lubrication system uses a pneumatic pump to deliver grease to the trunnion bearings and seals. The
system is controlled by the Mill PLC and is interlocked to the Mill Motor Running.

The PT 100 RTD temperature sensors transmit temperature signals back to the PLC for alarm and trip
control and to the Mill Control Panel for display if required.

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Control Philosophy

The Bearing Lubrication System is enabled via the PLC on startup of the Mill. The Lubrication System
then starts to dose grease to the bearings once the Mill is running. The lubrication cycle will the
activate every 20 minutes.

At the initiation of a cycle, solenoid valves YV 074 and YV 075A are energised which starts the pump
and pumps grease via the inverter solenoid into Line “A”. Once the pressure switch PSL 072 is
energised indicating the minimum pressure required in Line “A” solenoids YV 074, and YV 075A are
de-energised and an internal timer in the PLC (T1) starts timing.

When the PLC timer (T1) has timed out (pressure switch PSL 072 should have re-opened) Solenoid
Valves YV0 74 and YV 075B are energised changing over the inverting solenoid to its opposite state
and feeding grease to Line “B”.

When the required minimum pressure in Line “B” is reached, pressure switch PSL 072 again closes
initiates the PLC timer (T1) and de-energising solenoids YV074 and YV075B. (The Pressure Switch
PSL072 must open before (T1) times out).

The PLC Timer (T1) once timed out initiates the cycle internal timer. This timer once timed out restarts
the grease cycle at Line “A”.

When Line “A” and Line “B” are pressured alternatively, the metering valves on each bearing discharge
metered volumes of grease to the bearings and seals.

The Limit Switches within each metering valve are monitored by the PLC to ensure that grease is being
discharged at each outlet.

During a pumping cycle, if the PLC detects that any metering valve has failed to operate an alarm is
raised and a 60 minutes shutdown timer started. This timer can only re beset by a successful lube
cycle ie all metering valve limit switches operate correctly. If a successful cycle is not registered within
60 minutes the timer times out and the Mill motor will be tripped.

Also, during a pumping cycle the grease pressure switch PSL 72 is monitored to ensure that minimum
pressure is reached for each line during the cycle. If either line fails to reach minimum pressure, an
alarm is raised and a 60 minute shutdown timer initiated. This timer can only be reset by a successful
Lube Cycle ie minimum pressure reached on both lines, and if this does not occur within 60 minutes,
the timer times out and the Mill Motor will be tripped.

If a low level in the Bearing Grease Drum is detected, an alarm is raised and the shutdown timer
initiated. If the drum is not replaced within 60 minutes and the alarm reset, the Mill Motor will be
tripped.

A “Test” lube button is provided to manually initiate a lube cycle when required. This button should be
used to test the system when an alarm occurs and can assist in fault finding. A manual cycle can be
initiated at any time, with the Mill running or stopped.

Temperature Sensors installed in the Trunnion Bearings will generate an alarm if the bearing
temperature rises above the alarm set point in the PLC. If the temperature continues to rise beyond
the High High set point the Mill will be tripped.

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Interlocks

The following interlocks will trip the Mill Motor

 Trunnion Bearing temperature High High

 Grease Cycle Switch (delayed fault – 1 hour)
 Grease Pressure Fault (delayed fault – 1 hour)
 Grease Drum Low Level (delayed fault – 1 hour)

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11.0 MILL GIRTH GEAR GREASE SPRAY SYSTEM

The Mill Girth Gear Spray System consists of the following main items of equipment:

 High Pressure Pneumatically driven grease pump

 180 Kg Grease tank
 Dual Line Automatic Grease inverter
 Dual Line Grease Metering Valve

The Mill Gear Spray System consists of the following control instrumentation:

 Pneumatic Pump Pressure Indicating and Control Valve

 Pneumatic Pump Air Solenoid Valve
 Bearing Grease Line “A” Solenoid Valve
 Bearing Grease Line “B” Solenoid Valve
 Grease Line Pressure Switch
 Line “A” Pressure Indicator
 Line “B” Pressure Indicator
 Grease Drum Level Switch
 Girth Gear Monitoring Valve Switches
 Spray Air Pressure Indicating and Control Valve
 Spray Air Solenoid Valve

System Description

The system uses a pneumatic pump to deliver grease to the Girth Gear. Control of the Gear Spray
System is via the Mill Control Panel PLC system and is interlocked to the motor running.

Control Philosophy

The Girth Gear Spray System is enabled via the PLC on start of the Mill. The Gear Spray system starts
to dose grease to the pinion gear once the Mill is started. A dose of grease will be injected every 10
minutes.

At the initiation of the cycle solenoid valves YV096 and YV097A are energised starting the pump and
pumping grease into Line “A”. At the same time solenoid valve YV098 is energised to deliver spray air
to the nozzles. Once the pressure switch PSL093 registers the minimum pressure required for Line
“A”, solenoid valves YV096 and YV097 are de-energised and an internal air spray timer is initiated.
When the Air Spray Timer times out the Air Spray Solenoid Valve YV098 de-energises and initiates a
second timer. When this timer times out solenoid valves YV096, YV097B and the air spray solenoid
YV098 are energised switching the inverter valve across to Line “B” resulting in the grease flow into
Line “B”. When the required minimum pressure in Line “B” is reached pressure switch PSL072 closes
initiating the air spray timer and de- energising solenoids YV096 and YV097B. When the Air Spray
Timer times out solenoid YV098 is de-energised and a 20 minutes cycle timer is initiated. This cycle
once timed out restarts the grease cycle at Line “A”.

When Line “A” and Line “B” are pressurised alternately, the metering valves on Line discharges
metered volumes of grease to the spray nozzles. The limit switches within the metering valves are
monitored by the PLC to ensure that grease is being discharged at each outlet.

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During a spray cycle, if the PLC detects that any metering valve has failed to operate an alarm is raised
and a 60 minute shutdown timer initiates.. This timer can only be reset by a successful spray cycle ie.,
All metering valve Limit Switches operate correctly. If a successful cycle is not registered within 60
minutes the timer times out and the Mill Motor will be tripped.

Also during a pumping cycle the grease pressure switch PSL 072 is monitored to ensure that minimum
pressure is reached for each line during the cycle. If either line fails to reach minimum pressure, an
alarm is raised and a 60 minute shutdown timer is initiated. This times, and if this does not occur within
60 minutes, the timer times out and the Mill Motor will be tripped.

If a low level in the bearing grease drum is detected, an alarm is raised and the shutdown timer started.
If the drum is not replaced within 60 minutes and the alarm reset the Mill Motor will be shutdown.

A “Test” button is provided to manually initiate a spray cycle when required. This button should be
used to test the system when an alarm occurs and can assist with fault finding. A manual cycle can be
initiated at any time with the mill running or stationary.

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12.0 ALARMS

The following function raise an alarm.

Mill Motor

Mill Motor Air Pressure Switch External Air A – Low PAL 004A
Mill Motor Air Pressure Switch External Air B – Low PAL004B
Mill Motor Air Pressure Switch Internal Air A – Low PAL005A
Mill Motor Air Pressure Switch Internal Air B – Low PAL005B
Mill Motor Air Pressure Switch Internal Air B – Low PAL006

Liquid Resistance Starter

Liquid Resistance Starter Fault XIA012B

Liquid Resistance Starter Motor Trip XMA012C
Liquid Resistance Starter Electrolyte Level – Low LSL012E
Liquid Resistance Starter Electrolyte Temperature – High TSH012F

Gear Box Lube System

Filter Differential Pressure Alarm – High PDAH021

Lube Oil Pressure Alarm – Low PAL026A
Lube Oil Pressure Alarm – High TAH027
Lube Oil Temperature – High High TAHH027
Gear Box High Speed Bearing Temperature – High TAH028A
Gear Box High Speed Bearing temperature – High High TAHH028A
Gear Box High Sped Bearing temperature – High TAH028B
Gear Box High Speed Bearing temperature – High High TAHH028B
Gear Box Low Speed Bearing Temperature – High TAH029A
Gear Box Low Speed Bearing temperature – High High TAHH029A
Gear Box Low Speed Bearing temperature – High TAH029B
Gear Box Low Speed Bearing temperature – High High TAHH029B

Pinion Bearing Lube System

Bearing Lube Oil Pressure Alarm – Low PAL051

Duty Filter Differential Pressure Alarm – High PDAH055A
Standby Filter Differential Pressure Alarm – High PHAH055B
Bearing Lube Oil Temperature Alarm – Low TAL057
Bearing Lube Oil Temperature Alarm – High TAH057
Bearing Lube Oil Temperature Alarm – High High TAHH057
Bearing Lube Oil Reservoir Lever Alarm – Low LAL058
Bearing Lube Oil Reservoir Lever Alarm – Low Low LALL058
Drive End Pinion Bearing Temperature Alarm – High TAH059A
Drive End Pinion Bearing Temperature Alarm – High High TAHH059A
Feed End Pinion Bearing Temperature Alarm – High TAH059B
Feed End Pinion Bearing Temperature Alarm – High High TAHH059B

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Trunnion Bearing Lube System

Trunnion Bearing Grease Pressure Alarm

Trunnion Bearing Grease Tank Level Low ZAL073
Feed End Trunnion Bearing Grease Metering Switch Alarm ZA076A
Feed End Trunnion Bearing Grease Metering Switch Alarm ZA076B
Feed End Trunnion Bearing Grease Metering Switch Alarm ZA076C
Drive End Trunnion Bearing Grease Metering Switch Alarm ZA077A
Drive End Trunnion Bearing Grease Metering Switch Alarm ZA077B
Feed End Trunnion Bearing Temperature Alarm High TAH078A
Feed End Trunnion Bearing Temperature Alarm – High High TAHH078A
Feed End Trunnion Bearing temperature Alarm – High TAH078B
Feed End Trunnion Bearing temperature Alarm – High High TAHH078B
Drive End Trunnion Bearing Temperature Alarm – High TAH079A
Drive End Trunnion Bearing Temperature Alarm – High High TAHH079A
Drive End Trunnion Bearing Temperature Alarm – High TAH079B
Drive End Trunnion Bearing temperature Alarm – High High TAHH079B

Girth Gear Lubrication System

Girth Gear Grease Pressure Alarm

Girth Gear Grease Tank Level Low ZAL095
Girth Gear Grease Metering Switch Alarm ZA099A
Girth Gear Grease Metering Switch Alarm ZA099B
Girth Gear Grease Metering Switch Alarm ZZ099C1
Girth Gear Infrared Temperature Alarm –High TAH100A
Girth Gear Infrared Temperature Alarm – High High TAHH100A
Girth Gear Infrared Temperature Alarm – High TAH100B
Girth Gear Infrared Temperature Alarm – High High TAHH100B
Girth Gear Infrared Temperature Alarm – High TAH100C
Girth Gear Infrared Temperature Alarm – High High TAHH100C

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13.0 SET POINTS

Mill Motor

Description Tag Number Setting

Winding Temperature High Alarm xxTSH001 A to F 125-155C
Winding temperature High High Trip xxTSHH001 A to F 175C
DE Bearing Temperature High Alarm xxTSH002 A to B 100-115C
NDE Bearing Temperature High High Alarm xxTSHH002 C to D 130C
Mill Motor Air Inlet Temperature xxTSH003 C
Mill Motor External Air Pressure Switch Low Alarm xxPAL004 A to B Bar
Mill Motor Internal Air Pressure Switch Low Alarm xxPAL005 A to D Bar
Mill Motor Slipring Chamber Pressure Chamber Switch Low Alarm xxPAL006 Bar

Liquid Resistance Starter

Description Tag Number Setting

Electrolyte Temperature High xxTSH012F 85C
Excess Start Time xxXMA012C Seconds

Gear Box and Lube System

Description Tag Number Setting

Oil Filter Differential Pressure High xxPDAH021 >2 Bar
Lube Oil temperature Cooling Fan Off xxTCS023A 40C
Lube Oil temperature Cooling Fan On xxTSC023B 50C
Lube Oil temperature Immersion Heater On xxTSLL027 40C
Lube Oil temperature Immersion Heater Off xxTSL027 45C
Lube Oil temperature High Alarm xxTAH027 60C
Lube Oil temperature High Trip xxTAH027 65C
High Speed Bearing Temperature Alarm xxTAH028 A to B 85C
High Speed Bearing Temperature Trip xxTAHH028 A to B 90C
Low Speed Bearing Temperature Alarm xxTAH029 A to B 65C
Low Speed Bearing Temperature Trip xxTAH029 A to B 70C

Pinion Bearing and Lube System

Description Tag Number Setting

Pinion Bearing Lube Oil Pressure Low Alarm xxPAL051 Bar
Pinion Bearing Lube Oil Flow Control Valve xxFCV054 7.5 l/min
Pinion Bearing Filter Differential Pressure High xxPDSG055 A to B Bar
Pinion Bearing Lube Oil Pressure relief Valve xxPCV056 8 Bar
Pinion Bearing Lube Oil Temperature Low xxTAL057 40C
(Heater ON – Fan OFF)
Pinion Bearing Lube Oil temperature xxTAH057 55C
(Fan ON – Heater OFF)

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Pinion Bearing Lube Oil temperature High High xxTAHH057 70C
Bearing Lube Oil reservoir Low Alarm xxLAL058 L
Bearing Lube Oil reservoir Low Low Alarm xxLALL058 L
Pinion Bearing Temperature High Alarm xxTAH059 A to B 75C
Pinion Bearing Temperature High High Alarm xxTAHH059 A to B 80C

Trunnion Bearing and Lube System

Description Tag Number Setting

Bearing Lube System Air Supply Client 566L/
s@550kpa
Bearing Lube Air Pressure Control Valve xxPCV070 550kpa
Bearing Grease Pressure Alarm Low xxPAL072 113790kpa
Feed End Bearing Temperature Alarm High xxTAH078A 55C
Feed End Bearing Temperature Alarm High High xxTAH078A 60C
Discharge End Bearing Temperature Alarm High xxTAH078B 55C
Discharge End Bearing Temperature Alarm High High xxTAHH078B 60C

Girth Gear Spray System

Description Tag Number Setting

Gear Spray Lube System Air Supply Client 5666/5@550
kpa
Gear Spray Pump Air Pressure Control Valve xxPCV090 410-550kpa
Gear Spray Blast Air Pressure Control Valve xxPVCV091 410-550kpa
Gear Spray Blast Air Supply Low xxPAL094 270kpa
Gear Spray Grease Pressure Alarm Low xxPAL093 13790kpa

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 TIERRA AMERILLA BALL MILL

CONTROL PHILOSOPHY

TABLE OF CONTENTS

CONTROL PHILOSOPHY........................................................................................................................ 1

1.0 GENERAL...................................................................................................................................... 1

2.0 MILL CONTROL PANEL................................................................................................................ 1

3.0 MILL MOTOR................................................................................................................................. 4

4.0 SYSTEM DESCRIPTION............................................................................................................... 4

5.0 LIQUID RESISTANCE STARTER..................................................................................................9

6.0 GEAR BOX LUBRICATION SYSTEM..........................................................................................11

7.0 GEAR BOX................................................................................................................................... 13

8.0 BARRING DRIVE SYSTEM.........................................................................................................14

9.0 PINION BEARING LUBRICATION SYSTEM...............................................................................16

10.0 TRUNNION BEARING GREASE LUBRICATION SYSTEM.........................................................18

11.0 MILL GIRTH GEAR GREASE SPRAY SYSTEM.........................................................................21

12.0 ALARMS....................................................................................................................................... 23

13.0 SET POINTS................................................................................................................................ 25