kelsey centrifugal jig (kcj) pilot plant...

KELSEY CENTRIFUGAL JIG

(KCJ) PILOT PLANT

FUNCTIONAL SPECIFICATION

MT Project Number: 82040

Revision Date Revision Description BY APPROVED A 04/08/09 Issued for Internal Review TJ AF B 05/03/10 Revised AF AF C 06/04/10 Revised / Updated AF / TJ / SG AF D 10/05/10 Updated with Exxaro Plant Interfaces DE / TJ AF E 17/05/10 Updated with Commissioning Data Tables TJ AF

KCJ Pilot Plant Functional Specification (Namakwa Sands) Rev E

TABLE OF CONTENTS 1 INTRODUCTION ........................................................................................................................................... 4 2 Section A: OVERALL PILOT PLANT OPERATION................................................................................... 5

2.1 Process Description ................................................................................................................................ 5 2.1.1 Overall Process ............................................................................................................................. 5 2.1.2 Process Water................................................................................................................................ 6 2.1.3 Sump Level Control ...................................................................................................................... 6 2.1.4 Exxaro Feed Preparation Plant...................................................................................................... 7 2.1.5 Exxaro Product Handling Facility................................................................................................. 7

2.2 KCJ Pilot Plant Start up and Shutdown Procedures ............................................................................... 8 2.2.1 Plant Start-Up Sequence ............................................................................................................... 8

2.2.1.1 Start Interlocks ......................................................................................................................... 8 2.2.1.2 Plant Start Sequence................................................................................................................. 8

2.2.2 Jig Feed Start-Up Sequence .......................................................................................................... 9 2.2.2.1 Start Interlocks ......................................................................................................................... 9 2.2.2.2 Jig Feed Start Sequence.......................................................................................................... 10

2.2.3 Plant Shutdown Sequence........................................................................................................... 10 2.3 KCJ Pilot Plant Alarms......................................................................................................................... 12

2.3.1 Full Pilot Plant Shutdown Alarms............................................................................................... 12 2.3.2 Feed Off Alarms ......................................................................................................................... 12

2.4 Adjustable Pump Minimum and Maximum Speed Set Points.............................................................. 13 2.4.1 Jig Feed Pump (PU-01)............................................................................................................... 13 2.4.2 Final Tails Pump (PU-02) ........................................................................................................... 13 2.4.3 Jig Tails Pump (PU-03)............................................................................................................... 13

2.5 Interface Signals Between Client Feed and Pilot Plant ........................................................................ 14 2.5.1 Pilot Plant Ready for Feed Signal ............................................................................................... 14 2.5.2 Pilot Plant Faulted Signal............................................................................................................ 14 2.5.3 Exxaro Feed Preparation Plant.................................................................................................... 15 2.5.4 Exxaro Final Tails and Final Concentrate Discharge System ..................................................... 15 2.5.5 Fault Shutdowns.......................................................................................................................... 16 2.5.6 Operator Controls........................................................................................................................ 16

3 Section B: MODEL J1800 KELSEY JIG OPERATION.............................................................................. 17 3.1 Drives ................................................................................................................................................... 17

3.1.1 Jig Spin Motor............................................................................................................................. 17 3.1.2 Jig Pulse Motor ........................................................................................................................... 17 3.1.3 Screen Clean Motor .................................................................................................................... 18 3.1.4 Blast Pump Motor ....................................................................................................................... 19 3.1.5 Lube Pump Motor ....................................................................................................................... 19

3.2 Solenoid Valves.................................................................................................................................... 20 3.2.1 Swing Arm Solenoid Valve ........................................................................................................ 20 3.2.2 Blast Rod Solenoid Valves ......................................................................................................... 20

3.3 Instruments ........................................................................................................................................... 21 3.3.1 Vibration Transmitter.................................................................................................................. 21 3.3.2 Jig Feed Flow Transmitter .......................................................................................................... 21 3.3.3 Hutch Water Flow Transmitter ................................................................................................... 21 3.3.4 Hutch Water Pressure Transmitter .............................................................................................. 21 3.3.5 Lube Oil Tank Level Switch ....................................................................................................... 21 3.3.6 Lube Oil Supply Pressure Switch ............................................................................................... 22 3.3.7 Air Pressure Switch..................................................................................................................... 22 3.3.8 Swing Arm Actuator Reed Switches (ZS32 and ZS33) .............................................................. 22 3.3.9 Blast Rod Actuator Reed Switches (ZS25 and ZS31)................................................................. 22

3.4 Sequences ............................................................................................................................................. 23 3.4.1 Jig Start up Sequence .................................................................................................................. 23

3.4.1.1 Start Signal ............................................................................................................................. 23 3.4.1.2 Stop Signal ............................................................................................................................. 23 3.4.1.3 Start Interlocks ....................................................................................................................... 23 3.4.1.4 Sequence ................................................................................................................................ 24

3.4.2 Jig Shutdown Sequence .............................................................................................................. 24

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3.4.2.1 Start Signal ............................................................................................................................. 24 3.4.2.2 Stop Signal ............................................................................................................................. 24 3.4.2.3 Sequence ................................................................................................................................ 24

3.4.3 Jig Flush Sequence...................................................................................................................... 25 3.4.3.1 Start Signal ............................................................................................................................. 25 3.4.3.2 Stop Signal ............................................................................................................................. 25 3.4.3.3 Start Interlocks ....................................................................................................................... 25 3.4.3.4 Sequence ................................................................................................................................ 25

3.4.4 Jig Screen Clean Sequence ......................................................................................................... 26 3.4.4.1 Start Signal ............................................................................................................................. 26 3.4.4.2 Stop Signal ............................................................................................................................. 26 3.4.4.3 Start Interlocks ....................................................................................................................... 26 3.4.4.4 Sequence ................................................................................................................................ 27

3.4.5 Jig Fast Shutdown Sequence....................................................................................................... 27 3.4.5.1 Start Signal ............................................................................................................................. 28 3.4.5.2 Stop Signal ............................................................................................................................. 28 3.4.5.3 Start Interlocks ....................................................................................................................... 28 3.4.5.4 Sequence ................................................................................................................................ 28

3.5 Alarms .................................................................................................................................................. 29 3.5.1 Fast Trips .................................................................................................................................... 29 3.5.2 Process Shutdown Alarms .......................................................................................................... 29 3.5.3 Jig Motor Fault Alarms ............................................................................................................... 30

3.5.3.1 Jig Spin Motor........................................................................................................................ 30 3.5.3.2 Jig Pulse Motor ...................................................................................................................... 30 3.5.3.3 Lube Pump Motor .................................................................................................................. 30 3.5.3.4 Blast Pump Motor .................................................................................................................. 30 3.5.3.5 Screen Clean Motor................................................................................................................ 30

3.6 Adjustable Control and Alarm Set Points............................................................................................. 31 3.6.1 Sequence Control Set Points ....................................................................................................... 31 3.6.2 Control Set Points ....................................................................................................................... 32 3.6.3 Alarm Set Points ......................................................................................................................... 33 3.6.4 Table of Alarm and Control Commissioning Setpoints .............................................................. 36

3.6.4.1 PAGE: ENGR DATA ENTRY – PUMPS ............................................................................ 36 3.6.4.2 PAGE: ENGRS DATA ENTRY – JIG ................................................................................. 37 3.6.4.3 PAGE: SEQUENCES ........................................................................................................... 38 3.6.4.4 PAGE: SEQUENCES 2 ........................................................................................................ 39 3.6.4.5 PAGE: ALARM SETPOINTS 1........................................................................................... 40 3.6.4.6 PAGE: ALARM SETPOINTS 2........................................................................................... 41 3.6.4.7 PAGE: ALARM SETPOINTS 3........................................................................................... 42 3.6.4.8 PAGE: EXXARO SETPOINTS............................................................................................ 43 3.6.4.9 PAGE: PLANT SEQUENCES ............................................................................................. 44 3.6.4.10 PAGE: JIG CONTROL.................................................................................................... 45 3.6.4.11 PAGE: JIG DRIVES 1 ..................................................................................................... 46 3.6.4.12 PAGE: VFD PUMPS ....................................................................................................... 47 3.6.4.13 PAGE: PUMPS ................................................................................................................ 48

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1 INTRODUCTION This document describes the control and operation of the Kelsey Centrifugal Jig (KCJ) Pilot Plant as configured for Exxaro – Namakwa Sands. As the control and sequences of the KCJ are far more complex relative to the overall plant, this document is divided into two sections as outlined below to make referencing easier: Section A – covers the overall KCJ Pilot Plant function including the screen, pumps, KCJ, etc. Section B – covers in more detail the various KCJ functions that form part of the overall plant. The Control of the KCJ Pilot Plant has two modes of operation:

Automatic Mode o In this mode, there will be pre-defined sequences that the Operator will have to

manually start. o A sequence cannot start until all the other sequences have stopped

Manual Mode

o In this mode, each drive can be operated independently from the HMI A process description, start up and shut down sequences, interlocks and other information are provided in this document.

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2 Section A: OVERALL PILOT PLANT OPERATION 2.1 Process Description Referring to: Flow sheets: Exxaro NSL Pilot Plant 2009 PFD - 40tph (Rev G)

Exxaro NSL Pilot Plant 2009 PFD - 25tph (Rev G) Exxaro NSL Pilot Plant 2009 PFD - 10tph (Rev G)

P+ID Exxaro KCJ Pilot Plant P+ID (Rev D)

2.1.1 Overall Process Feed at 10-40 t/h solids and 20-40 % solids by mass is pumped by the client (after removal of +1 mm material) from their Feed Preparation Plant (not shown on PFD or P&ID) to the Plant Feed Surge Bin (SB-01) located on the bottom of the screening module. A manual sampler at the entry to SB-01 allows for sampling of the incoming feed to the plant. Feed material from BIN-01 is pumped (by PU-06) via a 3-way gravity distributor (DS-01) which in turn feeds each of the lower 3 feed preparation decks of the Derrick Stack Sizer Screen (SC-01). These feed preparation screen decks have 210 μm apertures designed to cut the feed to a top size of 250 μm, with the undersize reporting to the Jig Feed Sump (SU-01) via a discharge chute (CH-01) and the oversize reporting to the Final Tails Sump (SU-02) via a discharge chute (CH-02). Sampling of the undersize stream requires a portable manual sampler which can be placed under the main flow into SU-01. A manual sampler is installed to enable a sample of the oversize stream to be taken. Undersize material is pumped (by PU-01) to a bank of two (2) dewatering cyclones (CY-01&02). Overflow from these cyclones reports to the Motive Water Sump (SU-05) via a manual sampler. The cyclone underflow constitutes the KCJ feed at 30-50% solids by mass and is discharged by gravity into the KCJ, with an in-line flow transmitter measuring the feed rate into the KCJ. A bypass facility allows the KCJ feed (cyclone underflow) to discharge directly to the Jig Tails Sump (SU-03) during start up, screen cleaning and minor trip / alarm clearing procedures. The bypass process is performed by two actuated knife gate valves located on the dewatering cyclone underflow tank (TA-02) that operate in opposite tandem – when one is open the other is shut and vice versa. A manual sampler is installed above the entry to the Jig Tails Sump (SU-03) which enables a sample of KCJ feed to be taken during feed diversion. KCJ concentrate reports to the Jig Concentrate Sump (SU-04) via a manual sampler and is pumped (by PU-04) to the client Product Handling facility (not shown on PFD or P&ID). KCJ tailings containing ragging report to the Jig Tails Sump (SU-03) via a manual sampler. The KCJ tailings are pumped (by PU-03) to the top “ragging recovery” deck of the Derrick Stack Sizer Screen (SC-01). The coarse ragging is scalped out of the KCJ tails with a 500 μm screen deck (designed to cut the tailings and maintain a ragging bottom size of 600 μm) and discharged via chutes back to the Jig Feed Sump (SU-01). The underflow from the ragging recovery deck constitutes final tailings and is discharged to the Final Tails Sump (SU-02). A jet pump (JP-02) located at the bottom of the Final Tails Sump pumps the tailings to the suction of the Final Tails Pump (PU-02), which then pumps the tailings to the client Product Handling facility (not shown on PFD or P&ID). Motive water to drive the jet pump (JP-02) is supplied from the Motive Water Sump (SU-05) via the Motive Water Pump (PU-05) and motive pressure is set via a hand operated diaphragm valve and manual pressure gauge.

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2.1.2 Process Water A Process Water Tank (TA-01) located in the bottom section of the screening module is fed by the client via a pilot operated float valve, which will regulate the inflow of process water assuming the water supply comes from a client water supply manifold with other users. If a dedicated water supply pump is used to feed water to the plant then a level sensor linked to either the water supply pump speed or a proportional control valve may be required to control in place of the float valve to avoid dead heading the pump. In the event of oversupply, the water sump overflows into the Final Tails Sump (SU-02) if overfilled. A low level switch in the tank protects the pumps from running dry. A Process Water Pump (PU-07) supplies process water to:

Derrick Stack Sizer Screen (SC-01) sprayers KCJ screen cleaner and lubrication system Sump make-up lines

KCJ hutch water is supplied by a dedicated Hutch Water Pump (PU-08). Pressure control valves are located in the discharge lines from both PU-07 and PU-08, allowing the system pressure in both these circuits to be adjusted as required. Two sets of 500 µm in-line filters with isolation valves are fitted in parallel in the hutch water delivery line. One filter set at a time is required for operation, allowing the second set to be cleaned without stopping the plant. A flow meter, pressure transducer and pressure gauge are also fitted in the hutch water delivery line to allow the flow rate and pressure to be monitored and interlocked with the operation of the KCJ pulse system via the control system. Two sets of 50 µm in-line filters with isolation valves are fitted in parallel in the process water delivery line prior to the KCJ screen cleaner (blast pump, pre-wash water and scraper head flush) and lubrication system (cooling water). One filter set at a time is required for operation, allowing the second set to be cleaned without stopping the plant.

2.1.3 Sump Level Control The method of sump level control for each pump and sump is described individually below: PU-01 / SU-01 – Jig Feed Sump This pump feeds the dewatering cyclones and requires a constant speed to ensure constant cyclone feed pressure. A VFD (variable frequency drive) is fitted to this pump for initial speed setting only. Sump level control is achieved with a level transmitter and a make up water solenoid valve system driven by a switching controller. PU-02 / SU-02 – Final Tails Sump Sump level control is achieved with a level transmitter and VFD on the pump operating in a PID control loop.

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PU-03 / SU-03 – Jig Tailings Sump Sump level control is achieved with a level transmitter and VFD on the pump operating in a PID control loop. A float valve is also installed and can be used to assist with sump level control if necessary by opening a manual isolation valve. PU-04 / SU-04 – Jig Concentrate Sump This pump is a fixed speed pump. Level control is achieved via a float valve. A pump suction water injection point will also assist with maintaining level. A low level sensor is installed to shut the pump down should the sump run dry. PU-05 / SU-05 – Motive Water Sump This pump is a fixed speed pump. Level control is achieved with a float valve. A low level sensor is installed to shut the pump down should the sump run dry. PU-06 / SB-01 – Screen Feed Bin Sump level control is achieved with a level transmitter and VFD on the pump operating in a PID control loop. PU-07 and PU-08 / TA-01 – Process Water Sump The client feeds water at the correct rate (or just above) into the process water sump via the inlet manifold. The water sump overflows into the Final Tails Sump (SU-02) and the overflow from SU-02 is lower than this level, preventing solids overflowing back into the water sump. A low level sensor is installed to shut the pump down should the sump run dry. In the case of the client supplying water from a manifold with other users, a pilot operated 150NB shut off valve (installed on the inlet flange) will stop flow into the tank should the inflow exceed the outflow. If the client will be using a dedicated water supply pump then a client supplied level sensor and control loop back to the client’s water supply pump or alternatively a client supplied proportional control valve in the client water supply line to the plant will be required.

2.1.4 Exxaro Feed Preparation Plant Concentrate is pumped from the Jig Plant Concentrate sump (SU-04) to an up-current classifier which replaces sea water with fresh water. UCC overflow is directed to the main bunded area floor for removal by a sump pump, while UCC underflow is pumped by a Cons Pump (611) via a dewatering hydrocyclone to final stacking.

2.1.5 Exxaro Product Handling Facility Tails are pumped from the Jig Plant Final Tails sump (SU-02) via a dewatering hydrocyclone to a Tails sump. Cyclone underflow is directed into a Tails sump, while overflow is split between the Tails sump (to control slurry volume/density for pumping) and the main bunded area floor for removal by a sump pump. Three pumps (Tails Pumps 612A, B & C) in series pump the slurry 1.8km from the Tails sump to disposal at the PCP West Plant.

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2.2 KCJ Pilot Plant Start up and Shutdown Procedures

2.2.1 Plant Start-Up Sequence 2.2.1.1 Start Interlocks At start up it is assumed that the water sump (TA-01) is full and all actuated valves and drives are “healthy to start” subject to interlocks. Start-up interlocks:

• All Jig drives are in Automatic Mode and Healthy o Jig Spin Motor o Jig Pulse Motor o Jig Lube Pump o Jig Screen Clean Reciprocating Motor o Jig Blast Pump o Hutch Water Isolation Valve in Auto

• Screen Cleaner Swing Arm retracted, in Auto and Healthy • Screen Cleaner Blast Rod up, in Auto and Healthy • No other sequence running • All E-stops healthy • No Category 1 or 2 Alarms • Derrick Screen Feed Pump (PU-06) in Auto and Healthy • Jig Feed Diverter knife gate valves are in Bypass position • Vibrating Screen (SC-01) in Auto and Healthy • Jig Feed Pump (PU-01) in Auto and Healthy • Jig Tailings Pump (PU-03) in Auto and Healthy • Jig Concentrate Pump (PU-04) in Auto and Healthy • Final Tails Pump (PU-02) in Auto and Healthy • Motive Water Pump (PU-05) in Auto and Healthy • Process Water Pump (PU-07) in Auto and Healthy • Hutch water pump (PU-08) in Auto and Healthy • Compressor power is on and air receiver is fully charged to 600 kPa (this is checked

manually) 2.2.1.2 Plant Start Sequence For the Exxaro plant set-up, before a plant start is initiated:

• Operator starts Exxaro Feed Preparation Plant slurry pump on water • Water enters the Jig Plant Surge Bin (SB-01) and, once the Jig Plant start is initiated,

when this bin level reaches a pre-set (adjustable) level the Derrick Screen Feed Pump (PU-06) will start

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The Plant Start-up Sequence is then as follows:

• Start up alarm sounds for 5 sec. • Jig feed diverter knife gate valves shift to “Bypass” position • Start Jig Lube Motor • Start Vibrating Screen (SC-01) and allow 15 sec of running to settle down • Start Process Water Pump (PU-07) - this will fill all sumps via the make up water float

valves and the spray/wash water valves • Wait 30 seconds to fill sumps • Start Sump Pump (PU-09) [Not applicable – PU-09 replaced by NSL sump pump] • Start Jig Tails Pump (PU-03) • Start Jig Feed Pump (PU-01) • Start Final Tails Pump (PU-02) • As soon as the Jig Plant Final tails Pump (PU-02) starts, the Exxaro Tails Pumps

(612A, B & C) are automatically started in a timed sequence (with adjustable delays) and the Exxaro Cons Pump (611) also starts at the same time as Tails Pump 612A

• Start Motive Water Pump (PU-05) • Start Jig Concentrate Pump (PU-04) • Wait 60 seconds, then Start Kelsey Jig Drives/Valves as per Section B,

o Hutch Water Pump (PU-08) o Open Hutch Water Isolation Valve o Jig Spin Motor o Jig Pulse Motor

2.2.2 Jig Feed Start-Up Sequence 2.2.2.1 Start Interlocks

The start interlocks for this sequence are: • Vibrating Screen (SC-01) running • Jig Feed Pump (PU-01) running • Jig Tails Pump (PU-03) running • Jig Concentrate Pump (PU-04) running • Final Tails Pump (PU-02) running • Motive Water Pump (PU-05) running • Process Water Pump (PU-07) running • Jig lube system running • Hutch water pump (PU-08) running • Hutch water isolation valve open • Hutch water pressure healthy • Hutch water flow healthy • Jig spin motor running • Jig pulse motor running • No other sequence running • Feed Diverter Knife Gate Valves in Automatic Mode • Swing Arm is Healthy, commanded to retract, and in Automatic Mode • Blast Rod is Healthy, commanded to be up and in Automatic Mode

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2.2.2.2 Jig Feed Start Sequence

When the Jig Plant has run up to the point of becoming ready for feed, a “Ready to Receive” signal is sent to the Exxaro PCS (as per Section 2.5) and: • Operator goes to Feed Preparation Plant and starts feed Conveyor • The “Feed On” signal from the Exxaro Feed Preparation Plant indicates that solids are

entering the system and coming to the Jig Plant • The Jig Feed knifegate valves are then cycled between “Bypass” and “To Jig” for a pre-

set (adjustable) duration and a pre-set (adjustable) number of times before staying in the “To Jig” position

• The Jig Process is now operating and will settle to steady state operation with Jig Plant sump levels controlled automatically (as per Section 2.1.3)

• Exxaro Tails and Cons sump levels are not controlled automatically through the Jig Plant PLC and the Operator is responsible for monitoring and controlling these levels

If there is a fault with the Jig which causes the Jig Feed valve to be diverted to “Bypass” then the “Ready to Receive” signal will be lost at the Exxaro Feed Preparation Plant and the solids will be stopped. In this case, once the Jig fault is fixed and the “Ready to Receive” signal is again activated, the Operator must go to the Feed Preparation Plant and restart the solids, so that the sequence above is repeated.

2.2.3 Plant Shutdown Sequence The plant shutdown sequence is initiated from the HMI by pressing the “PLANT STOP” button on the PLANT OVERVIEW page. The Plant Shutdown Procedure is as follows:

• Remove “Ready to Receive” interface signal to main plant o This should in turn stop the feed conveyor at the Exxaro Feed Preparation Plant

and stop solids from entering the plant o The Exxaro Feed Preparation Plant pump will continue on water only until

stopped by the Operator o The Derrick Screen Feed Pump (PU-06) will continue running until it trips out

on low level or until it is stopped (as below) • Shift jig feed diverter knife gate valves to “Bypass” position – wait 5 minutes • Shutdown Jig as per Jig Shutdown Sequence in Section 3.4.2 • Once Jig is shutdown:

o Stop Derrick Screen Feed Pump (PU-06) o Stop Jig Concentrate Pump (PU-04) o Stop Jig Feed Pump (PU-01) o Stop Jig Tails Pump (PU-03) o Stop Motive Water Pump (PU-05) o Stop Final Tails Pump (PU-02) o Stop Process Water Pump (PU-07) o Stop Sump Pump (PU-09) o Stop Vibrating Screen (SC-01)

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• After the Plant Stop is complete, the Operator must manually stop the Exxaro Feed Preparation Plant pump, so water stops being delivered to the Jig Plant

• Stopping the Final Tails Pump (PU-02) initiates a Flush Sequence for the Exxaro Product Discharge system, whereby:

o The Tails Sump Flush Valve opens for a time (adjustable) sufficient to flush out the entire tails pipeline

o Tails and Cons pumps run on while the Tails Sump Flush Valve is open o When the flush time is complete, all pumps stop and the valve closes

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2.3 KCJ Pilot Plant Alarms

2.3.1 Full Pilot Plant Shutdown Alarms The following alarms constitute Process Shutdown alarms:

• Pilot Plant shut down via a Jig Fast Shutdown • Shutdown of the following:

o Derrick Screen Feed Pump (PU-06) o Jig Concentrate Pump (PU-04) o Jig Feed Pump (PU-01) o Jig Tails Pump (PU-03) o Motive Water Pump (PU-05) o Final Tails Pump (PU-02) o Process Water Pump (PU-07) o Sump Pump (PU-09) o Vibrating Screen (SC-01)

• Low level alarm in Process Water Tank (TA-01) for 10sec • Process Water Pump (PU-07) trip alarm • Activation of any of the Plant Emergency Stop Pushbuttons • Loss of the 24VDC Control Power Supply

2.3.2 Feed Off Alarms The following trip alarms cause the de-activation of the “Pilot Plant Ready for Feed” interface signal and cause the Jig Feed Diverter knife gate valves to go to the “Bypass” position:

• Vibrating Screen (SC-01) • Jig Feed Pump (PU-01) • Derrick Screen Feed Pump (PU-06) • Motive Water Pump (PU-05) • Final Tails Pump (PU-02) • Jig Concentrate Pump (PU-04) • Jig Tails Pump (PU-03)

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2.4 Adjustable Pump Minimum and Maximum Speed Set Points The following set points will be tuned during site commissioning:

2.4.1 Jig Feed Pump (PU-01) Set Point is determined by cyclone feed pressure during commissioning and set – VFD not used for level control

2.4.2 Final Tails Pump (PU-02)

Final Tails minimum speed - 90% of steady state speed (settling velocity limit). Final Tails pump maximum speed - 110% of steady state speed.

2.4.3 Jig Tails Pump (PU-03)

Jig Tails minimum speed - 90% of steady state speed (settling velocity limit). Jig Tails pump maximum speed - 110% of steady state speed.

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2.5 Interface Signals Between Client Feed and Pilot Plant

2.5.1 Pilot Plant Ready for Feed Signal The Jig Plant Ready to Receive signal is enabled when all the following conditions are met:

• Hutch Water Pump (PU-08) is Running with Adequate Flow and Pressure • Jig Spin Motor Running at Selected Speed • Jig Pulse Motor Running • Jig Lube Pump Running • Vibrating Screen (SC-01) running • Jig Feed Pump (PU-01) running • Jig Tails Pump (PU-03) running • Jig Cons Pump (PU-04) running • Motive Water Pump (PU-05) running • Final Tails Pump (PU-02) running • Process Water Pump (PU-07) running • Feed bypass knife gate valves in bypass position • No other sequence is Running

Loss of any of these conditions causes the loss of the Pilot Plant Ready for Feed signal.

2.5.2 Pilot Plant Faulted Signal The Pilot Plant Faulted signal is enabled when any of the following conditions are met:

• Jig Category 1 Alarm • Jig Category 2 Alarm • Process Water Tank (TA-01) Low Level Alarm • Vibrating Screen (SC-01) Trip Alarm • Jig Feed Pump (PU-01) Trip Alarm • Derrick Screen Feed Pump (PU-06) Trip Alarm • Jig Tails Pump (PU-03) Trip Alarm • Jig Cons Pump (PU-04) Trip Alarm • Motive Water Pump (PU-05) Trip Alarm • Final Tails Pump (PU-02) Trip Alarm • Process Water Pump (PU-07) Trip Alarm • Hutch Water Pump (PU-08) Trip Alarm

Loss of all of these conditions causes loss of the Pilot Plant Faulted Signal.

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2.5.3 Exxaro Feed Preparation Plant The following control signals between the Exxaro Plant Control System (PCS) and the Jig Plant are connected:

1 “Jig Plant Ready to Receive” DO from Jig Plant to DI in Exxaro PCS Clean contact from Jig Plant, interrogation voltage by Exxaro This signal is active when the Jig Plant has all circulation pumps running,

the jig spin and pulse are up to speed and the jig has run with hutch water to spread the bed for 1 minute (adjustable)

The signal indicates to the Exxaro Feed Preparation Plant that solids feed can be sent to the Jig Plant

2 “Feed On”

DO from Exxaro PCS to DI in Jig Plant Switched 24V signal powered from Exxaro This signal indicates that the Feed Conveyor is running and that solids are

entering the Feed Preparation Plant

2.5.4 Exxaro Final Tails and Final Concentrate Discharge System The following control signals between the Exxaro Plant Control System (PCS) and the Jig Plant are connected:

1 “Run Concentrate Pump 611 and Tails Pump 612A” A 24V powered output to a 24V relay in Exxaro MCC runs both pumps Output is maintained, so that when on the pumps run and when off the

pumps stop

2 “Run Tails Pump 612B” A 24V powered output to a 24V relay in Exxaro MCC runs this pump Output is maintained, so that when on the pump runs and when off the pump

stops

3 “Run Tails Pump 612C” A 24V powered output to a 24V relay in Exxaro MCC runs this pump Output is maintained, so that when on the pump runs and when off the pump

stops

4 “Run Tails Sump Water Valve” A 24V powered output to a 24V relay in Exxaro MCC operates this valve Output is maintained, so that when on the valve is open and when off the

valve is closed

5 “Pumps Running” 4 pump motor MCC contactor auxiliary contacts in series Presents a dry contact to the Jig Plant PLC when all 4 pumps are running

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2.5.5 Fault Shutdowns

• Whenever the Final Tails pump (PU-02) stops, the Plant Stop Sequence will be followed, if possible (typically, if a problem arises in the Jig Plant, then that will apply)

• If a fault occurs in the Exxaro Product Discharge system pumps, then all pumps will be shut down immediately and an alarm will be logged on the Jig Plant Control system

• Failure of the Exxaro Product Discharge system pumps will cause a controlled Jig Plant shutdown and will be immediately passed to the Feed system via the control signals to stop feed

• While the Jig Plant is flushing out and shutting down, tails and concentrate products will continue to pump to the Exxaro sumps which will overflow to the main sump for removal by the Exxaro sump pump

2.5.6 Operator Controls

• A “Pumps Start” pushbutton is shown alongside the Exxaro Product Discharge system

pumps on the PLANT OVERVIEW and PLANT SEQUENCE pages • Pressing this button will start the Exxaro Product Discharge system pumps, if plant

conditions require the pumps to continue to run • If plant conditions do not require the pumps to continue running, then they will go into

a Flush Sequence (as per Section 2.2.3 above) • THIS BUTTON IS FOR ABNORMAL SITUATIONS ONLY, AND SHOULD NOT BE

USED UNDER NORMAL CONDITIONS

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3 Section B: MODEL J1800 KELSEY JIG OPERATION 3.1 Drives

3.1.1 Jig Spin Motor The Jig Spin Motor spins the jig, creating a centrifugal force and pushing the feed and ragging material towards the internal screen. The motor has two speeds of operation in Automatic mode:

• Normal Speed o The Normal speed of the motor is set by the Operator and adjustable from the

touch panel o The minimum speed limit is 30Hz and the maximum is 50Hz o The ramp-up and ramp-down time is set in the VSD to be 90 seconds

• Jog Speed

o The Jog speed is preset in the VSD at 0.4 Hz (~10 rpm) o This speed is used during the Screen Clean Cycle

In Maintenance mode, the Operator has full control of the spin from 0-60 Hz. The motor can be started by:

• An internal control signal • The operator in Maintenance Mode

The motor can be stopped by:

• An internal control signal • The operator in Maintenance Mode • Interlock not healthy • A Motor Fault Alarm

Note: ALL Spin motor braking is via a braking resistor (unless the drive turns off in which case the Jig Bowl will free wheel to a stop).

The interlocks for this motor are:

• Screen Cleaner Arm in retracted position when NOT in Jog Speed Mode • Lube System Healthy (Lube Pump Running & Healthy Oil Level and Pressure) • Vibration Healthy

3.1.2 Jig Pulse Motor

The Jig Pulse Motor controls the off-set cam which drives the arms that pulse the diaphragms around the periphery of the internal jig screen. As the jig spins, the diaphragms at the back of the hutches are pushed in and out, thereby pulsing the water in the hutches backwards and forwards through the screen and ragging bed, elutriating the ragging bed and feed material and allowing the heavier concentrate particles to move through to the hutches.

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The speed of the motor is set by the Operator and adjustable from the touch panel. In Automatic mode, the minimum speed limit is 0Hz and the maximum is 50Hz. The ramp-up and ramp-down time is set in the VSD to be 3 seconds. In Maintenance mode, the speed is preset at 10Hz for Operators. When logged in, Engineers can adjust this setpoint but will be reverted to 10Hz on logout. The motor can be started by:





• Jig Spin Motor Running (unless in maintenance mode) • Lube System Healthy (Lube Pump Running & Healthy Oil Level and Pressure) • Vibration Healthy • Hutch Water Healthy (Sufficient water flow and pressure) (unless in maintenance

mode)

3.1.3 Screen Clean Motor The Screen Clean Motor is mounted on the Screen Cleaning Arm and controls the cam shaft that drives the screen cleaning head. In automatic mode, the head operates up and down the screen while the jig bowl is spun at jog speed The motor can be started by:





• No start unless jig spin motor is running at jog speed

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3.1.4 Blast Pump Motor The Blast Pump controls the blast water used to remove material dislodged from the screens by the cleaning head. The motor can be started by:





• Blast Pump Suction Water Isolation Valve (SV 112) Open • Process Water Pump (PU-07) Running • Blast Pump water supply pressure healthy

3.1.5 Lube Pump Motor

The Lube Pump controls the oil used in the Kelsey Jig. The motor can be started by:





• Nil

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3.2 Solenoid Valves

3.2.1 Swing Arm Solenoid Valve The Swing Arm Valve (SV 201) is a single-acting control valve for the Swing Arm Actuator. When in operation, the Cleaning Swing Arm extends into the Kelsey Jig. In this position the Swing Arm is engaged. When the Jig is in normal operation the Swing Arm is retracted. The valve can be started by:


The valve can be stopped by:

• An internal control signal • The operator in Maintenance Mode • Interlock not healthy

The interlocks for this valve are:

• Jig Spin Motor Running at Jog Speed • Air Pressure Healthy • Jig Spin Motor Not Running(when Swing Arm is in Maintenance)

3.2.2 Blast Rod Solenoid Valves

The Blast Rod Solenoid Valve (SV 202 / SV 203) is a double-acting control valve for the Blast Rod Actuator. When in operation, the Blast Rod directs the blast water up and down the screens. When Solenoid Valve (SV 202) is energized, the Blast Rod extends or travels DOWN. When Solenoid Valve (SV 203) is energized, the Blast Rod retracts or travels UP. The valves can be started by:


The valves can be stopped by:

• An internal control signal • The operator in Maintenance Mode • Interlock not healthy

The interlocks for valve (SV 202 / SV 203) are:

• Swing Arm ENGAGED (ZS32) when Blast Rod is in Manual Mode.

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3.3 Instruments

3.3.1 Vibration Transmitter The Vibration Transmitter provides an analog level of vibration, with alarm and trip of the Kelsey Jig. A Vibration Trip Setpoint is configurable by the Engineer and will trigger a Fast Trip. The Vibration Transmitter is located in Instrument Junction Box near the Jig. The vibration sensor is mounted on the lid. The scaling is: 4-20 mA = 0 – 100% represents 0-2.6mm displacement

3.3.2 Jig Feed Flow Transmitter The Jig Feed Flow Transmitter indicates an analog flow of the slurry feed to the Jig. The minimum and maximum scale for this instrument can be adjusted by the Engineer to ensure that the reading on the PLC panel is close to that on the transmitter. The scaling is: 4-20 mA = 0-75 m3/hr

3.3.3 Hutch Water Flow Transmitter The Hutch Water Flow Transmitter indicates an analog flow of the hutch water. The Low Flow Alarm Setpoint is configurable by the Engineer will trigger a Fast Trip. The minimum and maximum scale for this instrument can be adjusted by the Engineer to ensure that the reading on the PLC panel is close to that on the transmitter. The scaling is: 4-20 mA = 0-75 m3/hr

3.3.4 Hutch Water Pressure Transmitter The Hutch Water Pressure Transmitter indicates an analog Pressure of the hutch water. The Low Pressure Alarm Setpoint is configurable by the Engineer and will trigger a Fast Trip. The minimum and maximum scale for this instrument can be adjusted by the Engineer to ensure that the reading on the PLC panel is close to that on the transmitter. The scaling is: 4-20 mA = 0-1120 kPa

3.3.5 Lube Oil Tank Level Switch The Lube Oil Tank Float Switch indicates a digital, healthy level in the Oil Tank. Loss of the healthy signal will trigger a Low Level Warning. Continual loss of signal for more than the Tank Oil Level Low Time will trigger a Process Shutdown Alarm.

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3.3.6 Lube Oil Supply Pressure Switch

The Lube Oil Supply Pressure Switch indicates a digital, healthy pressure in the Oil Tank. Loss of the healthy signal will trigger a Low Pressure Alarm (Fast Trip) The pressure switch is set at 25psi (rising) and 20psi (falling).

3.3.7 Air Pressure Switch The Air Pressure Switch indicates a digital, healthy pressure in the air supply for the solenoid valves. Loss of the healthy signal will trigger a Low Pressure Alarm (Process Shutdown)

3.3.8 Swing Arm Actuator Reed Switches (ZS32 and ZS33) There are two reed switches on the Swing Arm Actuator to indicate full extension and retraction. Extension of the actuator indicates the Swing Arm is ENGAGED (ZS32) and retraction indicates the Swing Arm is RETRACTED (ZS33).

3.3.9 Blast Rod Actuator Reed Switches (ZS25 and ZS31) There are two reed switches on the Blast Rod Actuator to indicate full extension and retraction. Extension of the actuator indicates the Blast Rod is DOWN (ZS31) and retraction indicates the Blast Rod is UP (ZS25).

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3.4 Sequences There is one Emergency Shutdown sequence and five sequences in Automatic mode:

• Jig Startup • Jig Flush • Jig Screen Clean 1 (initiated when the Jig is Stopped) • Jig Screen Clean 2 (initiated when the Jig is Running) • Jig Shutdown The five sequences in Automatic mode cannot be run concurrently. The Jig Startup, Jig Flush and both Jig Screen Clean sequences need to be manually started by the Operator and can be stopped mid-way. The Jig Shutdown Sequence is initiated if one of the other sequences is stopped mid-way but can also be initiated manually by the Operator.

3.4.1 Jig Start up Sequence

3.4.1.1 Start Signal The Jig Startup Sequence is initiated by the Operator from either Touch Panel or during the Plant Startup sequence. 3.4.1.2 Stop Signal The Jig Startup Sequence can be stopped:

• Manually by the Operator, if a sequence stop has been initiated or if the sequence has completed successfully; or

• By a Fast Trip or Category 2 Alarm 3.4.1.3 Start Interlocks The start interlocks for this sequence are:

• Jig Spin, Pulse and Lube are Stopped, Healthy and in Automatic Mode • Swing Arm Healthy, retracted and in Automatic Mode • Blast Rod Healthy, up and in Automatic Mode • Hutch Water Valve (HV 115) in Automatic Mode • Hutch Water Pump (PU-08) Healthy and in Automatic Mode • No other sequence running • Feed bypassed • Air pressure healthy • E-stops healthy • No Category 1 or 2 Alarms

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3.4.1.4 Sequence 1. Activate Jig System Start output (siren for 5 seconds) 2. Start Lube Pump 3. Wait S11: Lube System Run Up Timer (Adjustable from the Touch Panel) for correct Lube

Pump operation 4. Start Hutch Water Pump (PU-08) and Open Hutch Water Valve (HV 115) 5. Wait S15: Hutch Water Run-Up Time (Adjustable from the Touch Panel) for correct Hutch

Water flow and pressure 6. Start Jig Spin Motor at Auto Speed 7. Wait for Spin Motor at Speed Signal to confirm correct Jig Spin Motor Speed 8. Wait S35: Pulse Motor Start Delay Time (Adjustable from the Touch Panel) 9. Start Jig Pulse Motor at Auto Speed

3.4.2 Jig Shutdown Sequence 3.4.2.1 Start Signal The Jig Shutdown Sequence is initiated if one of the other sequences has stopped mid-way, manually by the Operator from the HMI, by a Process Shutdown Alarm or during the Plant Shutdown Sequence. 3.4.2.2 Stop Signal The Jig Shutdown Sequence can be stopped if the sequence has completed successfully or by a Fast Trip, or by Stop command from the HMI 3.4.2.3 Start Interlocks There are no start interlocks for this sequence. 3.4.2.3 Sequence

1. Activate Jig Shutdown Siren for 5sec(Start-Up Warning Siren) 2. Bypass Feed 3. Wait S36: Feed Bypass Wait Time (Adjustable from the Touch Panel);

If Feed has already been off for this time then continue. 4. Place Jig Pulse Motor to Automatic mode and initiate stop 5. Place Hutch Water Pump (PU-08) to Automatic mode and initiate stop 6. Place Hutch Water Valve (HV 115) to Automatic mode and initiate close 7. Place Jig Spin Motor to Automatic mode and stop 8. Place Blast Rod Solenoid Valve into Automatic mode and retract up 9. Place Swing Arm Solenoid Valve into Automatic mode and retract 10. Place Blast Pump into Automatic mode and stop 11. Place Screen Clean Motor into Automatic mode and stop 12. Place Screen Pre-Wash Water Valve (SV 116) in Automatic mode and close 13. Place Blast Pump Suction and Scraper Head Flush Water Isolation Valve (SV 112) in

Automatic mode and close. 14. Wait for Jig Spin Motor Amps to be below S46: Motor Stopped Current Setpoint

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15. Wait S12: Lube System Stop Time Delay (Adjustable from the Touch Panel) 16. Place Lube Pump into Automatic mode and stop

3.4.3 Jig Flush Sequence 3.4.3.1 Start Signal The Jig Flush Sequence is initiated by the Operator from either Touch Panel. The start signal is not issued unless the Operator confirms that the “Concentrate Spigots have been removed”. The signal is momentary. If there is an unhealthy start interlock, the sequence will not start. 3.4.3.2 Stop Signal The Jig Flush Sequence can be stopped:

• Manually by the Operator, if the sequence has completed successfully; or • By a Fast Trip or Category 2 Alarm

3.4.3.3 Start Interlocks The start interlocks for this sequence are:

• Jig Spin Motor Not Running , Healthy and in Automatic Mode • Jig Pulse Motor Not Running , Healthy and in Automatic Mode • Lube Pump Motor Not Running , Healthy and in Automatic Mode • Swing Arm retracted and in Automatic Mode • Blast Rod up and in Automatic Mode • No other sequence running • Feed bypassed • Air pressure healthy • E-stops healthy • Hutch Water Pump (PU-08) Healthy and in Automatic Mode • Hutch Water Valve (HV 115) in Automatic Mode • Process Water Pump (PU-07) Healthy and in Automatic Mode • No Category 1 or 2 Alarms

3.4.3.4 Sequence 1. Operator confirms that the “Concentrate spigots have been removed” before a start signal is

initiated. 2. Display status “Time remaining” on touch screen 3. Activate Plant Start-Up Warning Siren for 5seconds 4. Start Lube Pump and Process Water Pump (PU-07) 5. Wait S11: Lube System Run-Up Time (Adjustable from the Touch Panel) for correct Lube

Pump operation 6. Start Hutch Water Pump (PU-08) and OPEN Hutch Water Valve (HV-115) 7. Wait S15: Hutch Water Run-Up Time (Adjustable from the Touch Panel) for correct Hutch

Water flow and pressure

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8. Start Jig Spin Motor at Auto Speed 9. Wait for Spin Motor At Speed signal to confirm correct Jig Spin Motor speed 10. Cycle Hutch Water Valve (HV 115) on for S40: Hutch On Time and then off for S41:Hutch

Off Time (Both adjustable from the Touch Panel), for S39: Flush time (Adjustable from the Touch Panel)

11. Wait for S39:Flush Time (Adjustable from the Touch Panel) 12. Stop Hutch Water Pump (PU-08) and Close Hutch Water Valve (HV 115) 13. Leave Spin Motor running for 30sec to empty any water out of the Jig 14. Stop Jig Spin Motor 15. Wait for Jig Spin Motor Amps to be below Motor Stopped Current Setpoint (Adjustable

from the Touch Panel) to confirm stop 16. Wait S12:Lube System Stop Time Delay (Adjustable from the Touch Panel) 17. Stop Lube Pump 18. Prompt Operator of completion of Flush Sequence (Display “Jig Flush Sequence

Complete” on touch screen)

3.4.4 Jig Screen Clean Sequence 3.4.4.1 Start Signal The Jig Screen Clean 1 Sequence is initiated by the Operator from either Touch Panel. This screen clean sequence is to be used for performing a screen clean on the JIG when it is initially stopped and returning the JIG to the stopped state upon completion of the screen clean cycle. The signal is momentary. If there is an unhealthy start interlock, the sequence will not start. 3.4.4.2 Stop Signal The Jig Screen Clean Sequence can be stopped:

• Manually by the Operator, if the sequence has completed successfully; or • By a Fast Trip or Category 2 Alarm

3.4.4.3 Start Interlocks The start interlocks for this sequence are:

• Jig Spin Motor Not Running and in Automatic Mode • Jig Pulse Motor Not Running and in Automatic Mode • Lube Pump Motor Not Running and in Automatic Mode • Swing Arm Healthy, retracted and in Automatic Mode • Blast Rod Healthy, up and in Automatic Mode • No other sequence running • JIG Feed bypassed for at least 60seconds • Air pressure healthy • E-stops healthy • Screen Pre-Wash Water Valve (SV 116) in Automatic Mode • Blast Pump Healthy and in Automatic Mode

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• Blast Pump Suction and Scraper Head Flush Water Isolation Valve (SV112) in Automatic Mode

• No Category 1 or Category 2 Alarms • Process Water Pump PU-07 Running in Auto or Manual. • Blast Pump water supply pressure healthy

3.4.4.4 Sequence

1. Display status “Time remaining” on touch screen 2. Activate Plant Start-Up Warning Siren for 5 seconds 3. Start Lube Pump 4. Wait S11:Lube System Run-Up Time (Adjustable from the Touch Panel) for correct Lube

Pump 5. Start Jig Spin Motor at Jog Speed 6. Wait for Spin Motor At Speed signal to confirm correct Jig Spin Motor Jog Speed 7. Open Screen Pre-Wash Water Valve (SV 116) 8. Wait for S42:Pre Wash Time (Adjustable from the Touch Panel) 9. Open Blast Pump Suction Water and Scraper Head Flush Water Isolation Valve (SV 112) 10. Extend Swing Arm into Jig 11. Start Blast Pump Motor 12. Start Screen Clean Motor 13. On first down extension of the Blast Rod, hold position for S44:Screen Bottom Clean Time

(Adjustable from the Touch Panel) 14. Start Blast Rod Cycle (Activate Blast Rod Solenoid Actuator continuously up and down

between reed limits) 15. Wait for S43: Screen Clean Time (Adjustable from the Touch Panel) 16. Stop Blast Pump Motor 17. Stop Screen Clean Motor 18. Close Screen Pre-Wash Water Valve (SV 116) 19. Stop and retract Blast Rod up 20. Stop and retract Swing Arm 21. Wait 5 seconds 22. Close Blast Pump Suction Water Scraper Head Flush Water Isolation Valve (SV 112). 23. Wait for Jig Spin Motor Amps to be below S46: Motor Stopped Current Setpoint

(Adjustable from the Touch Panel) to confirm stop 24. Wait S12: Lube System Stop Time Delay (Adjustable from the Touch Panel) 25. Stop Lube Pump 26. Prompt Operator of completion of Screen Cleaning (Display “Jig Screen Clean Sequence 1

(Initiated when JIG Stopped) Complete” on touch screen)

3.4.5 Jig Fast Shutdown Sequence The Jig Fast Shutdown Sequence is activated when a Fast Trip becomes active. It will automatically stop any sequence and place every motor into Automatic Mode and stop them.

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3.4.5.1 Start Signal The Jig Fast Shutdown Sequence is initiated if a Fast Trip becomes active. 3.4.5.2 Stop Signal The Jig Fast Shutdown Sequence will stop after it has successfully completed. 3.4.5.3 Start Interlocks There are no start interlocks for this sequence. 3.4.5.4 Sequence 1. Activate Jig System Shutdown output for 5 seconds (Start-Up Warning Siren) 2. Bypass Feed 3. Place Jig Pulse Motor to Automatic mode and initiate stop 4. Place Hutch Water Pump (PU-08) into Automatic mode and initiate stop 5. Place Hutch Water Valve (HV 115) into Automatic mode and Close 6. Place Jig Spin Motor to Automatic mode and stop 7. Place Blast Rod to Automatic and retract up 8. Place Swing Arm to Automatic and retract out 9. Place Blast Pump into Automatic mode and stop 10. Place Screen Clean Motor into Automatic mode and stop 11. Place Screen Pre-Wash Water Valve in Automatic mode and Close 12. Place Blast Pump Suction Water and Scraper Head Flush Water Isolation Valve (SV 112)

into Automatic mode and Close. 13. Wait for Jig Spin Motor Amps to be below S46: Motor Stopped Current Setpoint

(Adjustable from the Touch Panel) to confirm stop 14. De-activate Jig System Running output 15. Wait S12: Lube System Stop Time Delay (Adjustable from the Touch Panel) 16. Place Lube Pump into Automatic mode and stop

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3.5 Alarms All alarms are latched and will need to be Acknowledged and reset from the Touch Panel. There are two categories of alarms:

• Fast Trip Alarm • Process Shutdown Alarm

Each motor has a Motor Fault Alarm which consists of:

• Isolator Not Healthy Alarm • Faulted Alarm (type of fault signal dependant on motor) • Failed to Start Alarm.

The Jig System Healthy Output will be activated if there is no Fast Trip or Process Shutdown Alarms present.

3.5.1 Fast Trips Fast Trips will initiate a Fast Shutdown Sequence. The Fast Trips are:

• Jig Pulse Motor Fault Alarm • Jig Spin Motor Fault Alarm • Lube Pump Motor Fault Alarm • Low Oil Tank Pressure Alarm – Triggered if after S11: Lube System Run-Up Time,

(Adjustable from the Touch Panel) the pressure is not healthy after the Lube Pump is run

• Hutch Water Low Pressure Alarm – Triggered if after S15:Hutch Water Run-Up Time, the pressure is below the S18:Hutch Water Low Pressure Setpoint (Both adjustable on the Touch Panel)

• Hutch Water Low Flow Alarm – Triggered if after S15: Water Run-Up Time, the pressure is below the S16:Hutch Water Low Flow Setpoint (Both adjustable on the Touch Panel)

• Vibration Hi Hi Trip Alarm – Triggered if after 10 seconds, if the vibration is above the S20: Vibration Hi Hi Setpoint (Adjustable from the Touch Panel)

• Emergency Stop Not Healthy Alarm • Swing Arm Failed To Position Alarm – Triggered if after S9: Swing Arm Fail to

Retract/S10: Failed to Engage Setpoint, the Swing Arm has not reached the reed switch (Adjustable from the Touch Panel)

• 24VDC Control Supply Failed Alarm • Hutch Water Pump (PU-08) Fault • Process Water Pump (PU-07) Fault • Process Water Tank (TA-01) Low Level Alarm • Exxaro Pumps Fail alarm – caused by the failure of any of the 4 Exxaro downstream

product pumps

3.5.2 Process Shutdown Alarms The Process Shutdown alarms make up the rest of the alarms and will initiate a Shutdown Sequence. These alarms are:

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• Tank Oil Level Low Alarm – Triggered if after S14:Tank Oil Low Level Time

(Adjustable from the Touch Panel), the level is not healthy • Screen Clean Motor Fault Alarm • Blast Pump Motor Fault Alarm • Blast Rod Failed To Position Alarm – Triggered if after S7:Blast Rod Fail to Position

Up/S8: Blast Rod Fail to Position Down Setpoint, the Blast Rod has not reached the reed switch (Adjustable from the Touch Panel)

• Solenoid Valve Air Pressure Not Healthy Alarm

3.5.3 Jig Motor Fault Alarms Each Motor has a Motor Fault Alarm that will stop the motor from running. This is regardless of whether the motor is being driven by a sequence in automatic mode or by an operator in maintenance mode. 3.5.3.1 Jig Spin Motor Motor Fault Alarm consists of:

• VSD Not Healthy Alarm – PLC Input from VSD • Failed to Start Alarm – S1:Fail to Start Setpoint (Adjustable from the Touch Panel) • Failed to Stop Alarm – S2:Fail to Stop Setpoint (Adjustable from the Touch Panel)

3.5.3.2 Jig Pulse Motor Motor Fault Alarm consists of:

• VSD Not Healthy Alarm – PLC Input from VSD • Failed to Start Alarm – S3:Fail to Start Setpoint (Adjustable from the Touch Panel)

3.5.3.3 Lube Pump Motor Motor Fault Alarm consists of:

• Overload Alarm – PLC Input from motor overload contact • Failed to Start Alarm – S6:Fail to Start Setpoint (Adjustable from the Touch Panel)

3.5.3.4 Blast Pump Motor Motor Fault Alarm consists of:

• Overload Alarm – PLC Input from motor overload contact • Failed to Start Alarm – S5:Fail to Start Setpoint (Adjustable from the Touch Panel)

3.5.3.5 Screen Clean Motor Motor Fault Alarm consists of:

• Overload Alarm – PLC Input from motor overload contact • Failed to Start Alarm S4:Fail to Start Setpoint (Adjustable from the Touch Panel)

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3.6 Adjustable Control and Alarm Set Points

3.6.1 Sequence Control Set Points S35: Pulse Motor Start Delay Time Time delay after the Jig Spin Motor is running before starting the Jig Pulse Motor. Min 60 seconds. Operator adjustable. S37: Pre-feed Bypass ON/OFF Cycle Time The time Feed Bypass is on/off in the pre-feed start sequence. Min 0 seconds. Operator adjustable. S38: Pre-feed Bypass ON/OFF Number of Cycles The number of Feed Bypass on/off cycles in the pre-feed start sequence. Min 0 seconds. Operator adjustable. S36: Feed Bypass Wait Time Time delay after the feed has been bypassed before stopping the pulse motor in the shutdown sequence. Min 0 seconds. Operator adjustable. S39: Flush Time Flush sequence time duration. Min 60 seconds. Operator adjustable. S40: Hutch On Time Time the Hutch Water is on in the flush sequence. Min 0 seconds. Operator adjustable. S41: Hutch Off Time Time the Hutch Water is off in the flush sequence. Min 0 seconds. Operator adjustable. S42: Pre Wash Time Time delay after the Jig Spin Motor is running before starting the screen clean sequence. Min 0 seconds. Operator adjustable. S44: Screen Bottom Clean Time Time the Blast Rod is in the extended down position on the first cycle to allow the bottom of the screen to be properly cleaned. Min 0 seconds. Operator adjustable.

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S43: Screen Clean Time Screen Clean sequence time duration. Min 60 seconds. Operator adjustable.

3.6.2 Control Set Points S45: Jig Spin Motor Auto Speed Setpoint Min 30 Hz. Operator adjustable. S46: Jig Spin Motor Manual Speed Setpoint Min 0 Hz. Operator adjustable. S47: Jig Spin Motor At Speed Debounce Setpoint Time delay after the At Speed signal is off before rechecking the signal state. Min 0 seconds. Engineer adjustable. S48: Motor Stopped Current Setpoint The motor is considered to be stopped if the current is less than this setpoint. Min 0 amps. Engineer adjustable. S49: Jig Pulse Motor Auto Speed Setpoint Min 0 Hz. Operator adjustable. S50: Jig Pulse Motor Manual Speed Setpoint Min 0 Hz. Default 10 Hz. Engineer adjustable. Changes back to default when an Operator logs in. S51: Vibrating Screen (SC-01) Motor Manual Speed Setpoint Min 0 %. Operator Adjustable. S52: Vibrating Screen (SC-01) Motor Auto Speed Setpoint Min 70 %. Operator Adjustable. S72: Ragging Recovery Screen Feed Pump (PU-03) Minimum Speed Control Setpoint Min 0 %. Operator Adjustable

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S73: Ragging Recovery Screen Feed Pump (PU-03) Maximum Speed Control Setpoint Min 0 %. Operator Adjustable S74: Final Cons Pump (PU-04) Minimum Speed Control Setpoint Min 0 %. Operator Adjustable S75: Final Cons Pump (PU-04) Maximum Speed Control Setpoint Min 0 %. Operator Adjustable S76: Jig Plant Feed Pump (PU-06) Minimum Speed Control Setpoint Min 0 %. Operator Adjustable S77: Jig Plant Feed Pump (PU-06) Maximum Speed Control Setpoint Min 0 %. Operator Adjustable S78: Final Tails (PU-02) Minimum Speed Control Setpoint Min 0 %. Operator Adjustable S79: Final Tails (PU-02) Maximum Speed Control Setpoint Min 0 %. Operator Adjustable

3.6.3 Alarm Set Points S11: Lube System Run-Up Time

Time delay to ensure Lube Pump is running correctly. Also used in the Oil Tank Low Pressure Alarm. Min 30 seconds. Engineer adjustable. S12: Lube System Stop Delay Time Time delay after the Jig Spin Motor has stopped before stopping Lube Pump. Min 0 seconds. Engineer adjustable

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S14: Tank Oil Level Low Time Time delay after the Low Level signal becomes active before initiating an alarm. Min 0 seconds. Engineer adjustable. S15: Hutch Water Run-Up Time Time delay to ensure Hutch Water is running correctly. Also used in the Hutch Water Low Flow Alarm and Hutch Water Low Pressure Alarm. Min 0 seconds. Operator adjustable. S16: Hutch Water Low Flow Setpoint Min 0 m3/hr. Engineer adjustable S18: Hutch Water Low Pressure Setpoint Min 0 kPa. Engineer adjustable S20: Vibration Hi Hi Trip Setpoint Min 0 %. Engineer adjustable. S1: Jig Spin Motor Fail to Start Time Setpoint Min 0 seconds. Engineer Adjustable. S2: Jig Spin Motor Fail to Stop Time Setpoint Min 0 seconds. Engineer Adjustable. S3: Jig Pulse Motor Fail to Start Time Setpoint Min 0 seconds. Engineer Adjustable. S4: Screen Clean Motor Fail to Start Time Setpoint Min 0 seconds. Engineer Adjustable. S5: Blast Pump Motor Fail to Start Time Setpoint Min 0 seconds. Engineer Adjustable. S6: Lube Pump Motor Fail to Start Time Setpoint Min 0 seconds. Engineer Adjustable. S7: Blast Rod Fail to Position Up Time Setpoint Min 0 seconds. Engineer Adjustable.

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S8: Blast Rod Fail to Position Down Time Setpoint Min 0 seconds. Engineer Adjustable. S9: Swing Arm Fail to Retract Time Setpoint Min 0 seconds. Engineer Adjustable. S10: Swing Arm Fail to Engage Time Setpoint Min 0 seconds. Engineer Adjustable.

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3.6.4 Table of Alarm and Control Commissioning Setpoints

3.6.4.1 PAGE: ENGR DATA ENTRY – PUMPS Parameter Commissioning

Setpoint PID Execution Time Base 25 Final Tails LIC106 Kc Proportional Gain 65 Final Tails LIC106 Ti Integral Time 260 Final Tails PU02 Minimum Speed (Hz) 20 Jig Tails LIC120 Kc Proportional Gain 40 Jig Tails LIC120 Ti Integral Time 100 Jig Tails PU03 Minimum Speed (Hz) 10 Jig Feed LIC104 Kc Proportional Gain 40 Jig Feed LIC104 Ti Integral Time 80 Jig Feed PU01 Minimum Speed (Hz) 10 Jig Feed PU01 Maximum Speed (Hz) 60 PU01 LIC104 SELECT PID Water Addition Screen Feed LIC132 Kc Gain 85 Screen Feed LIC132 Ti Integral Time 260 Screen Feed PU06 Minimum Speed (Hz) 15 Jig Feed PU01 Low Level Trip (%) 0 Final Tails PU02 Low Level Trip (%) 5 Jig Tails PU03 Low Level Trip (%) 5 Screen Feed PU06 Low Level Trip (%) 2 Alarm Hooter Silence Alarm Available

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3.6.4.2 PAGE: ENGRS DATA ENTRY – JIG Parameter Commissioning

Setpoint JIG SPIN MOTOR Pulley Ratio 5.72 At Speed Signal Debounce Setpoint (secs) 20 Motor Stopped Current Setpoint (Amps) 1.0 JIG PULSE MOTOR Pulley Ratio 0.89

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3.6.4.3 PAGE: SEQUENCES Parameter Commissioning

Setpoint START Feed Start Delay Time (secs) 60 Pulse Motor Start Delay Time (secs) 60 Pre-feed Bypass ON/OFF Cycle Time (secs) 5 Number of Cycles 3 SHUTDOWN Feed Bypass Wait Time (secs) 60 Spindry Wait Time (secs) 30 Feed Auto Stop ENABLE/DISABLE DISABLE

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3.6.4.4 PAGE: SEQUENCES 2 Parameter Commissioning

Setpoint FLUSH Flush Time (secs) 180 Hutch On Time (secs) 10 Hutch Off Time (secs) 10 SCREEN CLEAN Pre Wash Time (secs) 10 Screen Clean Time (secs) 150 Screen Bottom Clean Time 10

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3.6.4.5 PAGE: ALARM SETPOINTS 1 Parameter Commissioning

Setpoint Jig Spin Motor Fail To Start Setpoint (secs) 10 Jig Spin Motor Fail To Stop Setpoint (secs) 150 Jig Pulse Motor Fail To Start Setpoint (secs) 10 Screen Clean Motor Fail To Start Setpoint (secs) 10 Blast Pump Fail To Start Setpoint (secs) 10 Lube Pump Fail To Start Setpoint (secs) 10 Blast Rod Fail To Position Up Setpoint (secs) 10 Blast Rod Fail To Position Down Setpoint (secs) 10 Swing Arm Fail To Position In Setpoint (secs) 10 Swing Arm Fail To Position Out Setpoint (secs) 10

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Setpoint Lube System Start Delay Time Setpoint (secs) 60 Lube System Stop Time Setpoint (secs) 30 Lube Spin Drive Fault Stop Time Setpoint (secs) 600 Lube Low Level Time Setpoint (secs) 120 Lube Return Oil High Temperature Setpoint (degC) 80 Lube Return Oil High Temp Time Setpoint (secs) 3 Hutch Water Start Delay Time Setpoint (secs) 10 Hutch Water Low Flow Setpoint (m3/hr) 24 Hutch Water Low Flow Time Setpoint (secs) 3 Hutch Water Low Pressure Setpoint (kPa) 250 Hutch Water Low Pressure Time Setpoint (secs) 3

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Setpoint Blast Water Start Delay Time Setpoint (secs) 10 Vibration High TRIP Setpoint (%) 18 Vibration High Trip Time Setpoint (%) 20 Vibration Warning Alarm Setpoint (%) 10 Spin Motor Ramp Time from VSD (secs) 120 Belt Slip Dead-Band (Hz) 7.0 Belt Slip Alarm Time Setpoint (secs) 600 PU01 Jig Feed Sump Low Level Trip Setpoint (%) 0 PU02 Final Tails Sump Low Level Trip Setpoint (%) 5 PU03 Jig Tails Sump Low Level Trip Setpoint (%) 5 PU06 External Feed Delay Time Setpoint (secs) 6

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3.6.4.8 PAGE: EXXARO SETPOINTS Parameter Commissioning

Setpoint Feed Input Transit Time Setpoint (secs) 6 Pump 612A & 611 Start Delay Setpoint (secs) 10 Tails Pump 612B Start Delay Setpoint (secs) 20 Tails Pump 612C Start Delay Setpoint (secs) 30 Tails Flush Time Setpt. From PU02 Stop (secs) 180 PU06 Bin Start Level (%) 0

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3.6.4.9 PAGE: PLANT SEQUENCES Parameter Commissioning

Setpoint Hooter Time (secs) 5 Screen Start Delay Time (secs) 0 Process Water PU07 Start Delay Time (secs) 3 Jig Tails PU03 Start Delay Time (secs) 3 Jig Feed PU01 Start Delay Time (secs) 3 Final Tails PU02 Start Delay Time (secs) 3 Motive Water PU05 Start Delay Time (secs) 3 Jig Cons PU04 Start Delay Time (secs) 30

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3.6.4.10 PAGE: JIG CONTROL Parameter Commissioning

Setpoint JIG SPIN MOTOR Auto Speed Setpoint (rpm) 175 At Speed Signal Debounce Setpoint (secs) 20 Motor Stopped Current Setpoint (Amps) 1.0 JIG PULSE MOTOR Auto Speed Setpoint (rpm) 1525

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3.6.4.11 PAGE: JIG DRIVES 1 Parameter Commissioning

Setpoint JIG SPIN MOTOR Manual Speed Setpoint (rpm) 175 JIG PULSE MOTOR Manual Speed Setpoint (rpm) 10

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3.6.4.12 PAGE: VFD PUMPS Parameter Commissioning

Setpoint PU01 JIG FEED PUMP High Level Setpoint (%) 80 Low Level Setpoint (%) 70 PU02 FINAL TAILS PUMP Level Setpoint (%) 70 PU03 JIG TAILS PUMP Level Setpoint (%) 70 PU06 SCREEN FEED PUMP Level Setpoint (%) 70

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3.6.4.13 PAGE: PUMPS Parameter Commissioning

Setpoint SC01 RAGGING SCRN Speed Setpoint (Hz) 40

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