DELKOR (SOUTH AMERICA) LTDA.

Av. Galvarino Gallardo # 1690, Providencia, Santiago – Chile

Fono: + 56 2 650 47 00 Fax : + 56 2 650 47 01

DELKOR SOUTH AMERICA LTDA.

PASCUA LAMA PROJECT
PROJECT Nº P5SL
P.O Nº P5SL-47-0001-01

CONTROL PHILOSOPHY

DOC. #: D288THK006-6202
E212 CODE: 27, 29

Ø 62m NEUTRALIZATION THICKENERS # 2

MODEL Nº: 62HR/3000HRL6/40W
TAG Nº 3200-5TH-002

RG RG CERTIFIED FOR CONSTRUCTION 07.06.2010 0

DG RG ISSUED FOR APPROVAL 30.03.2010 A
PREPARED CHECKED REASON FOR REVISION DATE REV.

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TABLE OF CONTENTS

1 PURPOSE OF SYSTEM......................................................................................................5

2 PROCESS CONDITIONS ..................................................................................................5

3 REFERENCE DOCUMENTS..............................................................................................6

3.1 Process Flow Diagram:.............................................................................................................................................. 6

3.2 Electrical Drawings:.................................................................................................................................................... 6

4 SYSTEM EQUIPMENT DESCRIPTION ...........................................................................6

4.1 Equipment Supply ....................................................................................................................................................... 6

4.2 Electric Motor and Hydraulic Pump for Hydraulic Drive ................................................................................. 7

4.3 Hydraulic Drive Motor and Gearbox: ................................................................................................................... 7

4.4 Electric Motor and Hydraulic Pump for Hydraulic Rake Lifting Cylinders. .................................................. 7

4.5 Manual Hydraulic Pump for Hydraulic Rake Lifting Cylinders......................................................................... 7

4.6 Hydraulic Lifting Cylinder: ........................................................................................................................................ 7

4.7 Local Control Panel ................................................................................................................................................... 7

4.8 Push Buttons and Selectors...................................................................................................................................... 8

4.9 Indicators ...................................................................................................................................................................... 9

4.10 Lamps ........................................................................................................................................................................ 9

4.11 Sound Alarm ............................................................................................................................................................ 9

5 INSTRUMENTS ................................................................................................................10

5.1 Rake Position Upper Limit Switch (3200-ZSH-40636) : ................................................................................. 10

5.2 Rake Position Lower Limit Switch (3200-ZSL-40636) : .................................................................................. 10

5.3 Rake Position Sensor (3200-ZIT-40637) : .......................................................................................................... 10

5.4 Bed Level Interface Detector (3200-LIT-40630) : ............................................................................................ 10

5.5 Torque Pressure Transducer (3200-OIT-40632) :........................................................................................... 10

5.6 Bed Pressure Detector (3200-PIT-40635) : ....................................................................................................... 10

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5.7 Over Torque Pressure Switch (3200-PSHH-40601) : ..................................................................................... 10

5.8 Oil Tank Level Transmitter (3200-LIT-40608) : ............................................................................................... 10

5.9 Oil Tank Temperature Transmitter (3200-TIT-40604) : ................................................................................ 11

5.10 Oil tank Level Gauge (3200-LI-40608) :.......................................................................................................... 11

5.11 Rake Raise Solenoid (3200-XV-40636A) :...................................................................................................... 11

5.12 Rake Lower Solenoid (3200-XV-40536B) :.................................................................................................... 11

5.13 Pressure Gauge Rake Drive (3200-PI-40602) : ............................................................................................. 11

5.14 Temperature Gauge Rake Drive (3200-TI-40602):...................................................................................... 11

5.15 Pressure Gauge Rake Lift (3200-PI-40607) :.................................................................................................. 11

5.16 Temperature Gauge Rake Lift (3200-TI-40607) :......................................................................................... 11

6 VALVES..............................................................................................................................12

6.1 Pressure Relief Valve: PRV 001 (3200-PSV-40606A); PRV 002 (3200-PSV-40603); PRV 003 (3200-
PSV-40606B)........................................................................................................................................................................... 12

6.2 Directional Valve (DCV 001):................................................................................................................................ 12

6.3 Directional Valve (DCV 002):................................................................................................................................ 12

6.4 Flow Control Valve (FCV 001): ............................................................................................................................ 12

7 AUTOLUBRICATION SYSTEM .....................................................................................12

7.1 Filter Regulator With Manometer (TAG 3200-PCV-40610)......................................................................... 13

7.2 Solenoid Valve Reservoir Line (TAG 3200-XV-40609) .................................................................................. 13

7.3 Linear Filter 300 Microns ...................................................................................................................................... 13

7.4 Regulator With Pressure Gauge (TAG 3200-PCV-40621) ............................................................................ 13

7.5 Solenoid Valve Spray Line (TAG 3200-XV-40610) ......................................................................................... 13

8 OPERATING SYSTEMS...................................................................................................13

8.1 REMOTE/AUTOMATIC MODE........................................................................................................................... 13

8.2 LOCAL/MANUAL MODE ..................................................................................................................................... 13

9 REMOTE CONTROL LOGIC ..........................................................................................14

9.1 Lifting System (Manual and Automatic)............................................................................................................... 14

9.2 Bed Level Interface Detector / Sensor................................................................................................................ 15

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9.3 Bed Pressure Detector ........................................................................................................................................... 15

9.4 Rake Level Sensor & Indicator .............................................................................................................................. 15

9.5 Operation Ranges & Alarms .................................................................................................................................. 16

10 START-UP AND SHUTDOWN SEQUENCES...........................................................16

10.1 Start up sequence. ....................................................................................................................................................... 16

10.2 Shutdown Sequence .................................................................................................................................................... 17

11 EMERGENCIES ...............................................................................................................18

11.1 Emergency Scenarios ........................................................................................................................................... 18

11.2 Safety Devices ....................................................................................................................................................... 18

11.3 Power Shutdown Instructions........................................................................................................................... 18

11.4 Operator Discretion ........................................................................................................................................... 19

12 I/O LIST SUMMARY .......................................................................................................19

12.1 Signals to Local Control Panel LCP. ................................................................................................................ 19

12.2 M.C.C. Signals........................................................................................................................................................ 21

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1 PURPOSE OF SYSTEM

The overall function of the thickener is to increase the density of slurry stream. This is achieved by feeding
the slurry stream into the thickener and by allowing the solids to settle. Supernatant then overflows into a
collection launder for further processing or disposal whilst the settled solids are raked to the centre cone
of the thickener and are removed as thickened slurry suitable for further processing.

The High Rate thickener operates as follows:

The feed to the thickener enters through the feed pipe into the feedwell. The feed is either flocculated
from flocculant addition in the mixing tank prior to the thickener or flocculant is added directly into the
feedwell.

The solids in the feed slurry settle towards the floor of the thickener creating high density slurry. The
entering feed creates a motion in the sludge bed that improves the solids contact of the particles which
further promotes settlement. Sludge bed rakes then move the thickened solids towards the centre of
thickener and into the underflow bottom cone for discharge through the underflow nozzles and onto the
discharge pumps.

The liquor in the feed slurry travels upwards through the previously formed flocculated sludge bed which
effectively filters out the ultra fines or unflocculated particles. This filtered liquor is then discharged as
supernatant via the thickener overflow resulting in common overflow clarities in the range of 100-200ppm.

Under normal operating conditions, there is a sharp interface between the sludge bed and clarified liquid
above the sludge bed. For best operational results, it is important that the level of the sludge bed be
maintained at an appropriate elevation above the feed inlet. A bed level interface detector is used to detect
the interface between the sludge bed and the liquid. The signal from the sensing device is used to regulate
the rate of flocculant addition so that the sludge bed level is maintained at a normal operating level.

A bed pressure detector is installed in the underflow bottom cone to monitor the pressure of the
concentrated slurry in the underflow bottom cone. This measurement can be used to regulate underflow
removal.

2 PROCESS CONDITIONS
The equipment to be provided by Delkor to Barrick Gold / Fluor Techint, Pascua Lama Project is a 62m
diameter thickener, fed from Refractory circuit and the overflows from Non Refractory circuit.

Model: 62 HR / 3000HRL6 / 40W

Type: Hi Rate
Capacity: 1038.3 TPH

The continuously actuated thickener is fed with slurry at 17.3% solids, -30º up to 30ªC temperature and
average pH 10.5. The slurry is fed into the Mix Tank.

The flocculant is added at a rate of 26,5 g per tonne of solids. This will be provided by one (1) dosing point
into the Drop Box and six (6) dosing points directly into the Feedwell.

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A hydraulic drive rotates the rakes at 0.06 rpm which guides the underflow slurry towards the centre of
the discharge cone which is situated in the discharge cone. In the event of high torque of the hydraulic
drive, independently operated hydraulic cylinders will raise the rakes. The equipment was designed for 3000
KNm maximum operation torque (MOT).

The underflow is discharged at 62% solids by pumps (customer supply), while the liquid generated from the
overflow will be discharged by gravity at 100 ppm of solids.

The following control philosophy is based on the control logic of rakes lifting depending on the percentage
of the drive torque (directly proportional to the pressure generated by the hydraulic unit), on the
flocculant consumption depending of the interface level , and on the UF pump speed depending of the UF
density. All will be controlled from the client control system.

3 REFERENCE DOCUMENTS
3.1 Process Flow Diagram:

- Process flow diagram drawing Nº T288CC62201

3.2 Electrical Drawings:

- Electrical Drawings: T288SF62201 @ 207

4 SYSTEM EQUIPMENT DESCRIPTION

4.1 Equipment Supply

Item Delkor reference Client’s reference

1 off 62m High Rate Thickener T288CB62201 3200-5TH-002

Comprising of the following equipment :

1 off drive system T288HGB150001 TBC
1 off Hydraulic Power Pack T288HL150001 TBC
1 off Local Control Panel T288SF62202 TBC

Refer to instruments data sheets (Doc. Nº D288THK009) or motors data sheets (Doc. Nº D288THK008)
for additional information.

Plant Details:

− Location: The site and area of interest is situated in the Cordillera de Los Andes, in a border
area between Chile and Argentina, the temperature range between -30ºC to 30ºC
− Elevation Wet Process Plant : 3999 - 4048 masl
− LV Distribution and Power:

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Service Voltage Phase Wire Frequency

Control Voltage 120 V ac single phase 2 Wires 50 Hz

Auxiliaries (lighting, 230 V, for 220 V nominal 2 Wires
single phase 50 Hz
heaters, etc.) voltages
Motor 400 V, solid grounded for 4 Wires
3 phases 50 Hz
Voltages 380 V nameplate motor

4.2 Electric Motor and Hydraulic Pump for Hydraulic Drive

Within the Power Pack, an electric motor drives a hydraulic pump which delivers the hydraulic pressure for
the hydraulic drive motors. A control valve is connected to the hydraulic line which enables the manual
reduction or increase of the pressure of the hydraulics and allows control of the rakes rotational speed.

Note: The suction valve between the drive hydraulic pump and the oil reservoir tank must be open prior to
thickener operation. This valve is delivered with a padlock and in the open position.

The electric motor is connected directly to the client Motor Control Centre M.C.C.

4.3 Hydraulic Drive Motor and Gearbox:

Each hydraulic drive motor is connected directly to a drive gearbox (with 3 stages of reduction) each which
drives a pinion onto a ring gear.

4.4 Electric Motor and Hydraulic Pump for Hydraulic Rake Lifting Cylinders.
Within the Power Pack, an electric motor drives a hydraulic pump which delivers the hydraulic pressure
for the rake lifting cylinders to raise the rakes.

The rake lifting electric motor and hydraulic pump must always remain running while the thickener is in
operation. If the electric motor fails then an audible alarm in the local control panel & DCS/PCS sounds.

The electric motor is connected directly to the M.C.C..

4.5 Manual Hydraulic Pump for Hydraulic Rake Lifting Cylinders.

Within the Power Pack, there is too an manual hydraulic pump which delivers the hydraulic pressure for
the rake lifting cylinders to raise the rakes, in case of emergency.

4.6 Hydraulic Lifting Cylinder:

Hydraulic lifting cylinders are used to lift the drive frame, raising the rakes. The position of the lifting
cylinder is controlled by the value of the pressure transducer connected to the hydraulic line for the
hydraulic drive motors.

4.7 Local Control Panel

Delkor will supply a Nema 4X Local Control Panel installed on the inlet bridge near the drive to allow for
manual control of the thickener. This Control Panel will be enabled with Foundation Fieldbus
communication protocol.
For safety reasons two operators are required for start up of the thickener, one operator must be at the
thickener local control panel and one operator must be at the clients control system. The Operator at the
thickener local control panel must check that the thickener control and hydraulic settings are satisfactory
prior and during start-up.

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In addition to the digital indicators for the site devices, signals and buttons selectors allow system operation
(For further detail, see Control Panel drawing T288SF62202@09).

4.8 Push Buttons and Selectors

The following selectors and buttons are provided:

Emergency Stop (3200-HSS-40616) : This button is directly connected to the DCS and stops the
electric motors for the hydraulic drive system and the hydraulic lifting system, and there are other available
to connect to the M.C.C. (Motor Control Centre) if the client requires.

Rake Raise Jog Button (Green) (3200-HS-40636A) : The hydraulic lifting motor will raise the rakes
by activation of the local control panel rake raise Jog button when the local/remote mode is set to local.

Rake Lower Jog Button (Green) (3200-HS-40636B): The hydraulic lifting motor will lower the rakes
by activation of the local control panel rake lower Jog button when the local/remote mode is set to local.

Rake Drive Motor Jog (Black) (3200-HS-40617): The hydraulic drive motor will rotate when rake
drive jog push button is pressed with local/remote selector set to local.

Rake Lift Motor Start Button (Green) (3200-HS-40615A) : The Local Control Panel rake lift motor
start button can be used to start the rake lift hydraulic motor with local/remote selector set to local..

Rake Lift Motor Stop Button (Red) (3200-HS-40615B) : The Local Control Panel rake lift motor
stop button can be used to stop the rake lift hydraulic motor with local/remote selector set to local.

Alarm Cancel Push Button (Black) (3200-HS-40614) : When the audible alarm is activated it will
be necessary to push the alarm cancel button to silence alarm. This ensures that the operator has to
return to the control panel and inspect the equipment.

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Very High Torque Reset Button (Red) (3200-HS-40632) : When the very high torque level is
reached it will be necessary to push the reset button to re-start the operation. This ensures that the
operator has to return to the control panel and inspect the equipment before the unit can be re-started.

Hand switch Main Switch (Red) (3200-HS-40613) : Selector in position On will enable the Control
Panel and in position Off will de-enable the Control Panel.

4.9 Indicators

Display Indicator 752 (3200-OI-40632 & 3200-ZI-40637):

• Torque Indicator: Displays the torque of the drive motors as a measure of percentage.
• Rake Position: Displays the height of the rakes as a measure of percentage.
• The information is displayed alternately each 2 [sec]

4.10 Lamps

Emergency Stop Light Indication (Red) (3200-XL-40616) : The Emergency Stop lamp is illuminated
when the Emergency Stop Button is pressed.

Rake up Travel Indication (Blue) (3200-XL-40611A) : The travel up lamp is illuminated when the
signal is sent to the rake raise solenoid, activated by DCS.

Rake down Travel Indication (Blue) (3200-XL-40611B) : The travel down lamp is illuminated when
the signal is sent to the rake lower solenoid, activated by DCS.

Rake Raised Indication (White) (3200-XL-40636A) : The rake raised lamp is illuminated when the
rake position upper limit switch is activated.

Rake Lowered Indication (White) (3200-XL-40636B) : The rake lowered lamp is illuminated when
the rake position lower limit switch is activated.

Rake Drive Motor Running Indication (Green) (3200-XL-40618): The Drive Motor lamp is
illuminated when the drive motor is running.

High Torque Indication (Red) (3200-XL-40632A) : There is an alarm light on the Panel which
illuminates in a High Torque alarm condition.

High High Torque Indication (Red) (3200-XL-40632B) : There is an alarm light on the Panel which
illuminates in a High High Torque alarm condition.

4.11 Sound Alarm

Horn Siren Alarm (3200-XA-40631) : The alarm sounds in the event of an alarm condition.

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5 INSTRUMENTS
See Instrument List L288THK004 for further information on all instruments listed in this section. All set
point values and timers such as :
- Timer for Rake down travel in mode Remote/Automatic : 10 [sec]
- Timer for wait some time after of occur the rake down travel in mode Remote/Automatic : 10
[min]

for instruments in the client control system are provisional and subject to change during commissioning,
therefore timers / settings must be adjustable in the clients control system. Instruments supplied by others
listed in this section are Delkor recommendations for good operation and control.

5.1 Rake Position Upper Limit Switch (3200-ZSH-40636) :

An proximity detector is mounted onto the drive frame to act as a limit switch and indicate when the
maximum rake lift level is reached. The signal is normally open under normal operating conditions.

5.2 Rake Position Lower Limit Switch (3200-ZSL-40636) :

An proximity detector is mounted onto the drive frame to act as a limit switch and indicate when the
minimum rake lift level is reached. The signal is normally closed under normal operating conditions.

5.3 Rake Position Sensor (3200-ZIT-40637) :

An ultrasonic level transmitter is mounted onto the drive frame to measure the height of the rakes. The
rake lift sensor transmits the signal via Foundation Fieldbus to the display indicator. This instrument
delivery two alarms :
.- Alarm High – High when the maximum rake lift level is exceeded and Stop the lifting.
.- Alarm Low – Low when the minimum rake lift level is exceeded and Stop the lowering.

5.4 Bed Level Interface Detector (3200-LIT-40630) :

The bed level interface detector is a ultrasonic level sensor and follows the mud bed level interface. The
bed level interface detector transmits a 4 – 20 mA signal to the Control Panel.

5.5 Torque Pressure Transducer (3200-OIT-40632) :

A pressure transducer is connected in the hydraulic line for the supply to the hydraulic drive motors and
measures the hydraulic pressure which is proportional to the rake drive torque. The torque pressure
transducer transmits the signal via Foudation Fieldbus to the display indicator.

5.6 Bed Pressure Detector (3200-PIT-40635) :

The bed pressure detector measures the pressure of the slurry in the underflow cone. The bed pressure
detector transmits the signal via Foundation Fieldbus to the PCS.

5.7 Over Torque Pressure Switch (3200-PSHH-40601) :

An over torque pressure switch is connected to the hydraulic line for the hydraulic drive motors. When a
pressure corresponding to 105% of the maximum operating torque is experienced the electric motors for
the hydraulic pumps for both the hydraulic drive motors and the lifting cylinders are stopped. The pressure
switch is connected to the DCS and when is activated, the audible alarm which is located in the control
panel will sound.

5.8 Oil Tank Level Transmitter (3200-LIT-40608) :

The Oil Tank capacitive level sensor measures the height of oil inside the tank. The oil level transmitter

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transmits via Foundation Fieldbus to client control system. This instrument delivery two alarms :
- Alarm Low : Minimum oil level inside the tank allowing the operation of the electric motors for the
hydraulic pumps for both the hydraulic drive motors and the lifting cylinders.
- Alarm Low – Low : The electric motors for the hydraulic pumps for both the hydraulic drive
motors and the lifting cylinders are stopped.

5.9 Oil Tank Temperature Transmitter (3200-TIT-40604) :

The Oil Tank temperature RTD measures the Temperature of oil inside the tank. The oil temperature
transmitter transmit via Foundation Fieldbus to client control system. This instrument delivery two alarms :
- Alarm High : Maximum Temperature of oil inside the tank allowing the operation of the electric
motors for the hydraulic pumps for both the hydraulic drive motors and the lifting cylinders.
- Alarm High – High : The electric motors for the hydraulic pumps for both the hydraulic drive
motors and the lifting cylinders are stopped.

5.10 Oil tank Level Gauge (3200-LI-40608) :

This tank level gauge is mounted direct on hydraulic unit tank.

5.11 Rake Raise Solenoid (3200-XV-40636A) :

When a signal is sent from the clients control system to the solenoid XV-40636A it opens a port on the
directional valve (DCV 001) and allows hydraulic pressure to the rake lifting cylinder which lifts the rakes.

5.12 Rake Lower Solenoid (3200-XV-40536B) :

When a signal is sent from the clients control system to the solenoid XV-40636B it opens a port on the
directional valve (DCV 001) and allows hydraulic pressure to the rake lifting cylinder which lowers the
rakes.

5.13 Pressure Gauge Rake Drive (3200-PI-40602) :

This pressure gauge is mounted on the hydraulic line between the rake drive and the pump and drive
motor.
− Instrument Pressure range: 0 – 22 MPa as minimum.

5.14 Temperature Gauge Rake Drive (3200-TI-40602):

This temperature gauge is mounted on the hydraulic line between the rake drive and the pump and drive
motor.
− Instrument Temperature range: 0 – 200 °C

5.15 Pressure Gauge Rake Lift (3200-PI-40607) :

This pressure gauge is mounted on the hydraulic line between the rake lift cylinder and the solenoid valve.
− Instrument Pressure range: 0 – 26 MPa as minimum.

5.16 Temperature Gauge Rake Lift (3200-TI-40607) :

This Temperature gauge is mounted on the hydraulic line between the rake lift cylinder and the solenoid
valve.
− Instrument Temperature range: 0 – 200 °C
Note : If an instrument fails must be changed. The instruments with Foundation Fieldbus capacity in case
of disconnect send an alarm. To change an instrument refer to the Operation and Maintenance Manual.

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6 VALVES
6.1 Pressure Relief Valve: PRV 001 (3200-PSV-40606A); PRV 002 (3200-PSV-40603); PRV
003 (3200-PSV-40606B)

There are three pressure relief valves within the hydraulic power pack as follows:
PRV 001 is connected on the rake lifting hydraulic circuit and is set to 22 Mpa (TBC)
PRV 002 is connected on the drive motor hydraulic circuit and is set to 18 Mpa (TBC)
PRV 003 is connected on the rake lifting hydraulic circuit and is set to 25 Mpa (TBC)

6.2 Directional Valve (DCV 001):

The directional valve (DCV 001) controls the lifting of the rakes. Solenoids XV-40636A and XV-40636B
control the valve position, enabling the rakes to be lifted or lowered as required.

6.3 Directional Valve (DCV 002):

The directional valve (DCV 002) can be used to control the direction of the rotation of the rakes. This is a
manual valve and operates as follows:
When the manual lever is in the upper position, the rakes operate in a clockwise direction which is the
normal operating condition for the thickener.
When the manual lever is in the central position, the drive system is in neutral and the rakes will not
rotate.
When the manual lever is in the lower position, the rakes operate in an anti-clockwise direction and are for
maintenance purposes only.

6.4 Flow Control Valve (FCV 001):

The flow control valve can be used to control the flow of the hydraulics for the drive motors and thus
control the speed of the rakes rotation. This is set up on commissioning.

7 AUTOLUBRICATION SYSTEM

When Drive is running the auto lubrication system is active.

− Lubrication cycle duration is 14 minutes.

− Each 2 minutes the spray valve will be active throwing grease into the ring gear. Next two
minutes this valve will be closed, and then it will be open again.
− Time space between cycles of lubrication is 100 hours.

See Instrument List L288THK004 for further information on all instruments listed in this section. All set
point values and timers such as :

- Timer for to indicate frequency of Auto lubrication Cycle: 100 [hrs]

- Timer for to indicate duration of Auto lubrication Cycle: 14 [min]
- Timer for to indicate frequency of opening of solenoids valves 3200-XV-40609 and 3200-XV-40610
in Auto lubrication system : 4 [min]
- Timer for to indicate duration of opening of solenoids valves 3200-XV-40609 and 3200-XV-40610
in Auto lubrication system : 2 [min]

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7.1 Filter Regulator With Manometer (TAG 3200-PCV-40610)

It allows to filter and regulate the air pressure at the entrance of the system, with a connection to the
process for the client of ¼ BSP, this filter regulator allows to operate to a maximum pressure of 10 bar

7.2 Solenoid Valve Reservoir Line (TAG 3200-XV-40609)

This solenoid valve, after being energized from the operator panel or the client's DCS, fulfills the function
of opening the way to the air that will enter to the pump of grease which will push the fluid toward the
Linear filter and later to the SMX valves. Finished the time of lubrication, the solenoid valve 4A must to
denergize and stop the pump, the solenoid valve must be denergized by a greater time (30 to 60 seconds)
in order to make a cleaning of the line and to avoid that lubricant enters. After that, the system must enter
into cycle of pause.

7.3 Linear Filter 300 Microns

This instrument filters the grease sludges that comes from the deposit entering this way to the SMX valves
that distribute the lubricant to the raceway of the ring gear as well as the tooth at the pinion and the ring
gear.

7.4 Regulator With Pressure Gauge (TAG 3200-PCV-40621)

This pressure regulator allows to optimize the air pressure to produce a proper mixture in the spray
valve (V20) that lubricates the tooth of the ring gear as well as the tooth of the pinion.

7.5 Solenoid Valve Spray Line (TAG 3200-XV-40610)

This valve solenoid, after being energized from the operator panel or the client's DSC, fulfills the function
of allowing the air to enter through the pressure regulator (HPI22) and than later to enter to the spray
valve (V20).

8 OPERATING SYSTEMS
The units can be operated in local/manual or remote/automatic mode as selected by the local/remote
selector by PCS (TAG No. TBC).

8.1 REMOTE/AUTOMATIC MODE

The Remote/Automatic mode is the normal operation of the thickener. During remote/automatic mode, a
control loop programmed within the clients control system raises or lowers the rakes according to the
torque of the drive mechanism.

The Rake Drive Jog, Rake Inch Up and Rake Inch Down push buttons on the Local Control Panel do not
function when the thickener is in the Remote(Automatic mode.

When the thickener is stopped in the Remote/Automatic mode, the rakes should raise until the upper limit
switch is reached.

8.2 LOCAL/MANUAL MODE

The operator has the ability to manually lift, lower the rakes from the Local Control Panel when the
local/remote selector is in the Local/Manual mode. This action might be required for situations such as
testing, unit maintenance, slurry build up or any other emergency situations but is not the normal
operational mode for the thickener.

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The thickener should only be operated in Local/Manual mode by authorised and trained personnel.

NOTE: EXTREME CAUTION MUST BE TAKEN WHEN OPERATING IN THE

LOCAL/MANUAL MODE AS THE CONTROL LOGIC FOR THE RAKE DRIVE
PROTECTION IS ONLY FUNCTIONAL WHEN OPERATING IN THE
REMOTE/AUTOMATIC MODE.

9 REMOTE CONTROL LOGIC

9.1 Lifting System (Manual and Automatic)

The drive includes a pressure transducer (3200-OIT-40632) giving a signal proportional to the torque
developed by the drive unit. The signal via Foundation Fieldbus is sent to the display indicator (3200-OI-
40632) which transmits via Fundation Fieldbus to the client control system. This is used as the input for the
rake torque-lifting control loop.

With the selector in remote or automatic mode, the control logic will operate within the client control
system as is described as follow:

•
If the torque value reaches a value of SP1, the alarm sounds
•
If the torque value reaches a value of SP2, the rakes raise until the torque reaches a value lower than
SP1 or until reaching the upper limit switch.
•
If the torque reaches a value lower than SP1, the rake lifting stops for 10 minutes. The rakes then lower
for 10 seconds and then stop for a further 10 minutes. This cycle continues until the rake low limit
switch is reached. If at anytime the torque reaches the value of SP2, the rakes begin to rise, and the
whole cycle starts again.
•
If the torque value reaches a value of SP3, the rakes will stop rotating and will lift until the upper limit
switch is reached at which point the hydraulic lifting motor will stop.
•
3200-PSHH-40601 is an over pressure safety switch which activates when 105% of the maximum
operating torque is reached. If this condition is reached, the rakes will stop rotating and will lift until the
upper limit switch is reached at which point the hydraulic lifting motor will stop.

The following table shows control logic summary:

SET- kNm % FUNCTION ALARMS

POINT TORQUE
SP1 1500 50% If the torque reaches a value lower Audible alarm in the
than SP1, the rake lifting stops for 10 local control panel &
DCS / PCS sounds.
minutes. The rakes then lower for 10
seconds and then stop for a further
10 minutes. This cycle continues until
the rake low limit switch is reached.
SP2 1950 65% Rakes rise until: Audible alarm in the
•The pressure transducer reaches a local control panel &
value less than SP1 DCS / PCS sounds.
•The rakes reach the rake upper limit
switch.

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SET- kNm % FUNCTION ALARMS

POINT TORQUE
SP3 3000 100% The electric motor for the hydraulic - Audible alarm on the
pump for the drive motors is stopped local control panel &
immediately. DCS / PCS sounds.
The rakes lift until the rake upper - High Torque trip
activated
limit switch is reached.

PS1 3150 105% The electric motor for the hydraulic - Audible alarm in the
pump for the drive motors is
local control panel
stopped.
The rakes lift until the rake upper sounds.
limit switch is reached.
The electric motor for the hydraulic
pump for the lifting cylinder is
stopped.

DELKOR recommends that the rakes are not left, and or operated in a raised position for extended
periods of time to reduce the probability of solid build up which could ultimately result in a requirement to
drain the thickener. A high torque alarm is raised to advise the operator that the torque is higher than
normal and action should be taken, the rakes are raised in order to protect the rakes while the operator
investigates the high torque, i.e. if the rakes are continuously operating in a raised position or continuously
cycling up and down then the thickener is operating outside its process design envelope. It is incumbent on
the operators to inspect the plant and to ascertain why this is happening.

Note: Plant operation at these conditions is not conducive to machine reliability and or long term
availability. Plant operation should be reviewed and adjusted accordingly. If in doubt please contact Delkor
for assistance.

9.2 Bed Level Interface Detector / Sensor

The bed level interface detector transmits a 4 – 20 mA signal to the mud bed level indicator which then
transmits to the control panel and from here via Foundation Fieldbus to the client control system.
The mud bed level is used to control the flocculant dosage. If the bed level rises, the flocculant dosage is
increased to increase the particle settling rate and lower the bed. If the bed level low, the flocculant dosage
is decreased to decrease the particle settling rate and lift the bed.

9.3 Bed Pressure Detector

The bed pressure detector measures the pressure in the underflow cone which can be used as a measure
of the solids contents in the underflow.
The bed pressure transducer transmits via Foundation Fieldbus to the client control system.
The bed pressure may be used to control the underflow discharge pump but is not recommended. The
control loop recommended is using a densimeter. If the underflow density rises, the discharge pump speed
is increased to increase the underflow and lower the density. If the underflow density low, the discharge
pump speed is decreased to decrease the underflow and increase the density.

9.4 Rake Level Sensor & Indicator

The signal of the rake position sensor via Foundation Fieldbus is sent to the display indicator (3200-ZI-
40637) which transmits via Fundation Fielbus to the client control system. This instrument delivery two
alarms :

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.- Alarm High – High when the maximum rake lift level is exceeded and Stop the lifting.
.- Alarm Low – Low when the minimum rake lift level is exceeded and Stop the lowering.

9.5 Operation Ranges & Alarms

10 START-UP AND SHUTDOWN SEQUENCES

10.1 Start up sequence.

IMPORTANT NOTE: BEFORE DOING THE START-UP PROCEDURE, IT IS VERY IMPORTANT

THAT THE TORQUE SETTING AND ADJUSTMENT ARE CORRECTLY SET UP. IF THIS IS NOT DONE
PROPERLY IT CAN CAUSE SERIOUS DAMAGE TO THE EQUIPMENT.

NOTE: FOR SAFETY REASONS, TWO OPERATORS ARE REQUIRED FOR STARTING OF THE
THICKENER, ONE OPERATOR AT THICKENER AND ONE OPERATOR AT THE CLIENTS CONTROL
SYSTEM. BOTH OPERATORS MUST BE IN CONSTANT COMMUNICATION. THE OPERATOR AT
THE THICKENER MUST CONFIRM THAT THE CONTROL AND HYDRAULIC SETTINGS ARE
CORRECT DURING START UP.

It is assumed that the dry running and water tests for the tank have been completed as part of the
installation procedure. Under no circumstances should the drive be stopped with the thickener full of
slurry.

1. Check that the operation of all valves is satisfactory.

2. Check the rakes are fully lowered, that the tank is empty of large debris and that the underflow cone is
clear. Pay particular attention to the discharge cone.
3. Check the rake drive rotation (i.e. that the manual lever on directional valve (DCV 002) is in the upper
position).
4. Switch the control panel into Local Mode and fill the thickener with water.
5. Carry out a check on all valves and ensure that all pumps are operating correctly.
6. Start the rake drive ensuring that the rakes are in the lower position.
7. Forming the compact zone under the scrapers. The formation of this zone can take up to 2 days. The
feed rate is intermittent. The flow and frequency to feed is selected by Delkor Specialist during the
start up. Flocc dose is not permitted. Rake lift is not recommended. This stage can take up to 2 days.

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8. Begin the slurry feed and flocculant dosage (if is required) as per the design rate. The formation of the
sludge bed can take up to 2 days during which recirculation should be maintained. The rake lift drive
should not need to raise the rakes during this stage.
9. Check the underflow solids content and cut the recycle when the proper density by client is reached
(45% solids), in accordance with the torque values. After that, the underflow discharge must be open
(in relation to operation status) to accumulate solids until reach the design density (62% solids). This
may take up to 2 days.
10. Once the thickener has reached stable operation in accordance with the design data, the unit should be
switched to the Remote Mode.
11. Constant supervision is recommended during the start up period.
12. The operation should continue to be closely monitored for at least 24 hours.

NOTE: Before starting-up the thickener it is necessary to carry out a complete pre-start-up check as
detailed in the Operation and Maintenance Manual.

10.2 Shutdown Sequence

1. Stop the flocculant feeding (if there is).

2. Stop the slurry feeding.
3. Continue to discharging the underflow to the downstream equipment whilst it is within the design
specification for the solids content.
4. On reaching the minimum solids allowable, continue to recycle the underflow.
5. The thickener rake drive should not be stopped unless the tank is empty of solids.
Warning: Coordinate the thickener shut down with other plant operations.

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11 EMERGENCIES

11.1 Emergency Scenarios

11.1.1 If action is required because the overflow clarity exceeds 100ppm, either the discharge flow should
be increased and/or the thickener feed flow should be cut or reduced.

11.1.2 If action is required because the underflow has a very high density (greater than 62% solids of
course, preliminary between 64 – 65 %) and/or torque is quickly increasing (greater than 25 %),
either the discharge flow should be increased and/or the thickener feed flow should be cut or
reduced.

11.1.3 In the event of a control error, stop the thickener feed and check the operation of all components
including feed and discharge valves, level sensor, flocculant dosing, pipe obstructions, etc.
Occasionally it is possible that the feed could contain abnormally large particles which could cause
blockages and upset the system.

11.1.4 Feed material variations could affect the operation of the unit. In order to minimise these affects, it
is recommended that the operator is attentive to any changes and takes the necessary precautions.

11.1.5 Is recommendable that the Drive motor thickener will be connected to the plant emergency power
system. This means, than to a failure of communication between the IED and the DCS, this
equipment must continue operating.

11.2 Safety Devices

11.2.1 High Torque Pressure Trip Switch (3200- PSHH-40601):

This instrument is directly connected to PCS with the function of stopping the rake system when the
torque is equal to 105% MOT (3150 KNm).

When the high torque trip is activated the main rake drive motors are shut down.

11.3 Power Shutdown Instructions

In case no backup power is provided

11.3.1 Close knife valves located in the thickener cone.

11.3.2 Open the water process valve in the line towards the cone.

11.3.3 Discharge underflow lines, before and after underflow pumps, and if is possible wash with water.

11.3.4 When the backup power is available, open the knife valves located in the thickener cone and close
the water process valve.

11.3.5 Start the underflow pump.

11.3.6 Check the rakes are operating.

11.3.7 Start the unit according to Start up Sequence.

Note: If there is back up power available, the system must be restarted quickly otherwise the full power
shutdown procedure may still be necessary.

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11.4 Operator Discretion

When faults occur that do not warrant an emergency stop or process shutdown, an alarm is raised and the
fault is indicated in the client control system. The operator can decide the necessary course of action.

The process situation and the action required are as follows:

Process Situation Actions to be taken

Overflow has high solids content
The discharge flow should be increased, and/or decrease/cut the
(determined visually or through
feed flow
frequent monitoring)
The underflow has very high density
(preliminary on 64 – 65 % solids) The discharge flow should be increased, and/or decrease/cut the
and/or torque is rapidly increasing feed flow.
(preliminary on 25%)
The feed flow to the thickener must be cut and the correct
operation of all components must be verified. Check feed and
The control system is failing to discharge valves, sensor level, system preparation and flocculant
control the process dosing, and for pipe obstructions. An exceedingly heavy feed of
large particle size can destabilise the unit operation and produce
feeding embankments and discharge lines.
In order to avoid sharp changes in the operation, it is
A feed material type change could
recommended that the operator is attentive to these changes to
affect the unit operation variables.
take the necessary actions in advance.

Note: The electric motors which are driving the hydraulic pumps should be connected to the plant
emergency power system.
The hydraulic pressure switch (3200-PSHH-40601) must be directly connected to the DCS and its function
will be to stop the thickener when the torque is equal to 105% MOT (3150 kNm).

12 I/O LIST SUMMARY

12.1 Signals to Local Control Panel LCP.

The table below lists the required inputs and outputs from the local control panel.
All connecting wiring by others.

All signals listed are relative to Delkor supplied equipment only.

NO = Normally Open Contact.

NC = Normally Closed Contact.

FIELD MEASUREMENT
REF. CONVERSION TAG REFERENCE
ANALOGUE INPUT
Rake Position Sensor F.F. 3200-ZIT-40637
Torque Pressure Transducer F.F. 3200-OIT-40632
Bed Level Interface Detector 4 – 20 mA 3200-LIT-40630
Bed Pressure Detector F.F. 3200-PIT-40635
Hydraulic Oil Tank Level F.F. 3200-LIT-40608
Hydraulic Oil Tank temperature F.F. 3200-TIT-40604

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FIELD SWITCHES
REF. FAIL STATE TAG REFERENCE
DIGITAL INPUT
Rake High Limit Switch NO 3200-ZSH-40636
Rake Low Limit Switch NO 3200-ZSL-40636
Over Torque Pressure Switch NC 3200-PSHH-40601

REF. ANALOGUE INPUTS CONVERSION TAG REFERENCE

Rake Position Sensor F.F. 3200-ZIT-40637
Torque Pressure Transducer F.F. 3200-OIT-40632
Interface sludge Level sensor 4 – 20 mA 3200-LIT-40630
Mud Bed Pressure Detector F.F. 3200-PIT-40635
Hydraulic Oil Tank Level F.F. 3200-LIT-40608
Hydraulic Oil Tank temperature F.F. 3200-TIT-40604

REF. DIGITAL INPUTS FAIL STATE TAG REFERENCE

Main Switch NO 3200-HS-40613
Rake Lift Inch Up NO 3200-HS-40636A
Rake Lift Inch Down NO 3200-HS-40636B
Rake Drive Jog NO 3200-HS-40617
Alarm Cancel NO 3200-HS-40614
Over Torque Pressure Switch
NC 3200-PSHH-40601
High Pressure Trip 105%
Rake High Limit Switch NO 3200-ZSH-40636
Rake Low Limit Switch NO 3200-ZSL-40636
Emergency Stop NC 3200-HSS-40616

REF. DIGITAL OUTPUTS FAIL STATE TAG REFERENCE

Rake Lift Solenoid NO 3200-XV-40636A
Rake Lower Solenoid NO 3200-XV-40636B
Audible Alarm (Horn and beacon) NO 3200-XA-40631
Rake Up Indication NO 3200-XL-40636A
Rake Down Indication NO 3200-XL-40636B
Rake drive rotation running NO 3200-XL-40618
Emergency stop activated NO 3200-XL-40616

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12.2 M.C.C. Signals

The recommended signal from and to the client control system are as follows:

REF M.C.C. TO CLIENT CONTROL SYSTEM REFERENCE

Rake Drive Motor Running TBC
Rake Drive motor Stopped TBC
Rake lift Pump Motor Running TBC
Rake Lift Pump Motor Stopped TBC
REF M.C.C. FROM CLIENT CONTROL SYSTEM REFERENCE
Start Rake Motor Drive TBC
Stop Rake Motor Drive TBC
Start Rake Motor Lift TBC
Stop Rake Motor Lift TBC

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