EFE Gyratory Crusher

(1)

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(ELECTRICAL)

CUSTOMER:

SOCIEDAD MINERA

CERRO VERDE S.A.A.

PLANT LOCATION :

_A

_{AREQUIPA, PERU}

_{REQUIPA, PERU}

PURC

PURCHASE ORDER No.:

HASE ORDER No.:

A

A1WF-59-0

1WF-59-001-PO

01-PO

FFEM CONTRACT No.:

04-31645-720

EQUI

EQUIPMEN

PMENT No

T No.:

.:

C-3110-CR-001

CO

COVE

VER PAGE

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VOLUME 3

LUME 3

Manual

Manual Volume Volume 3 Manual 3 Manual Section Section PrefacePrefaceai ai _{Contract No.}_{Contract No.}

_04-31645-720

Prep

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FFE MINE

FFE MINERAL

RALS USA., INC.

S USA., INC.

DISTRIBUTION and REVISION RECORD SHEET

FOR

15 1525 X

25 X 28

2870 (

70 (60

60““ x113“

x113“ ))

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CUSTOMER:

MER:

SOCIE

SOCIEDAD

DAD MINER

MINERA

A

CERRO VERDE S.A.A

..

Manual

Manual Volume Volume

REMARKS

REMARKS REV.REV.

No.

No. BYBY TRANSMITTALTRANSMITTAL_DATE_DATE 3

3 MANUAL MANUAL - - CERTIFIED CERTIFIED 0 0 S.R. S.R. HARRIS HARRIS 12/22/200512/22/2005 3

3 ELECTRONIELECTRONIC C MANUAL MANUAL - - CERTIFIECERTIFIED D 0 0 S.R. S.R. HARRIS HARRIS 12/22/200512/22/2005

Manual

Manual Distribution: Distribution: Customer Customer : : 6 6 Hard Hard & & 3 3 Electronic Electronic copiescopies FFEM

FFEM CHQ CHQ Engineering Engineering : : 1 1 Hard Hard & & 3 3 Electronic Electronic copycopy FFEM

FFEM Chile Chile Office Office : : 3 3 Hard Hard & & 3 3 Electronic Electronic copycopy

DISTRIBUTION AND REVISION RECORD

Manual

(4)

DISCLAIMER

This manual

This manual is a service

is a service of

of FFE Minerals U.S.A. Inc.

FFE Minerals U.S.A. Inc. In spite of

In spite of our

our

best efforts certain of the information in this manual may become out

of date

of date over time. FFE

over time. FFE Minerals U.S.A. Inc.

Minerals U.S.A. Inc. accepts no

accepts no liability for the

liability for the

accuracy or completeness or use of, nor any liability to update, the

information contained on this manual. These materials are provided

"AS IS" WITHOUT WARRANTY OF ANY KIND, EITHER

EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO,

THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS

FOR A PARTICULAR PURPOSE, OR NON-INFRINGEMENT. YOU

ASSUM

ASSUME

E COMP

COMPLETE

LETE RESPO

RESPONSIBI

NSIBILITY

LITY AND

AND RISK

RISK FOR

FOR USE

USE OF

OF

THESE

THESE MATERIALS.

MATERIALS. Some

Some jurisdictions d

jurisdictions do

o not

not allow

allow the

the exclusion

exclusion

of implied warranties, so the above exclusion may not apply to you.

FFE MINERALS U.S.A. INC. ITS AGENTS, REPRESENTATIVES

AND

AND EMPL

EMPLOYEES

OYEES ARE

ARE NEITH

NEITHER

ER RESPO

RESPONSIBL

NSIBLE

E NOR

NOR LIAB

LIABLE

LE

FOR ANY DIRECT, INDIRECT, INCIDENTAL, CONSEQUENTIAL,

SPECIAL, EXEMPLARY, PUNITIVE, OR OTHER DAMAGES

ARISIN

ARISING

G OUT OF

OUT OF OR RELATING IN ANY

OR RELATING IN ANY WAY TO

WAY TO THIS MANUAL

THIS MANUAL

AND/OR

AND/OR CONTENT

CONTENT OR

OR TRANS

TRANSLATIO

LATION

N OR

OR INFOR

INFORMATIO

MATION

N

CONTAINED WITHIN THE MANUAL. YOUR SOLE REMEDY FOR

DISSATISFACTION WITH THE MANUAL IS TO STOP USING THE

MANUAL.

All content within this manual, including, but not limited to

All content within this manual, including, but not limited to text, logos

text, logos

and images

and images are the

are the property of

property of FFE Minerals U.S.A. Inc.

FFE Minerals U.S.A. Inc. No portion

No portion

of the materials on these pages may be reprinted or republished in

any form without the express written permission of FFE Minerals

U.S.A. Inc.

BY USING THIS MANUAL YOU AGREE THAT YOU HAVE READ,

UNDERSTAND AND AGREE TO THE TERMS OF USE.

(5)

SAFETY STATEMENT

Manual Volume all Manual Section prefac _Contract _ALL

BASIC RULES REGARDING SAFETY IN AND AROUND A

MINERAL PROCESSING PLANT ARE OUTLINED IN THIS

MANUAL IN SECTION 1.2,

SAFE JOB PROCEDURES

_.

OPERATOR SAFETY—AND THE SAFETY OF OTHERS—DEPENDS

UPON REASONABLE CARE AND JUDGEMENT IN THE OPERATION

OF MINERAL PROCESSING EQUIPMENT.

A CAREFUL OPERATOR IS GOOD INSURANCE AGAINST AN

ACCIDENT.

MOST ACCIDENTS, NO MATTER WHERE THEY OCCUR, ARE

CAUSED BY FAILURE TO OBSERVE AND FOLLOW SIMPLE

FUNDAMENTAL RULES OR PRECAUTIONS. FOR THIS REASON,

MOST ACCIDENTS CAN BE PREVENTED BY RECOGNIZING

HAZARDS AND TAKING STEPS TO AVOID THEM BEFORE AN

ACCIDENT OCCURS.

REGARDLESS OF THE CARE USED IN THE DESIGN AND

CONSTRUCTION OF THIS TYPE OF EQUIPMENT, THERE

ARE CONDITIONS THAT CANNOT BE COMPLETELY

SAFEGUARDED AGAINST WITHOUT INTERFERING WITH

REASONABLE

ACCESSIBILITY

AND

EFFICIENT

OPERATION.

WARNINGS ARE INCLUDED IN THIS

INSTRUCTION

MANUAL

TO

HIGHLIGHT

THESE

CONDITIONS.

(6)

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

MANUAL DE INSTAL ACION, OPERACION Y MANTENIMIENTO

A Spanish translation of this Installation, Maintenance and

Operation manual has been provided. The Spanish translation was

prepared by an outside service. FFE Minerals USA, Inc. cannot

guarantee or warrant the accuracy of the translation, and therefore

the English version of this manual shall be the official manual for all

purposes.

In the event of any inconsistency or conflict between the English and

Spanish version, or in the event that the Spanish version omits or

fails to accurately state in Spanish what is stated in English, the

English version shall prevail.

*******************************************************

Se ha hecho llegar una versión en Español para el Manual de

Instalatción, Mantención y Operación. Esta versión fue realizada

por servicios externos a nuestra compañia. Aunque fue FFE

Minerals USA, Inc. No se hace responsable ni garantiza su exacto

traducción, este manual se considerará como el documanto oficial

para cualquier propósito.

En la eventualidad de existir alguna disconformidad o mala

interpretación de la traducción Inglés al Español, o que su versión

omita o no corresponda con lo indicado en Inglés, prevalecerá e

término en Inglés

(7)

AB OUT THIS MANUAL

THIS MANUAL CONSISTS OF 3 VOLUMES.

EACH VOLUME CONTAINS THIS DESCRIPTION AND A TABLE OF

CONTENTS FOR THE VOLUME.

THE CONTENTS OF THE VOLUMES ARE:

VOLUME 1: MECHANICAL - INSTALL ATION, OPERATION,

AND MAINTENA NCE INSTRUCTIONS AND FFEM

MECHANICAL DRA WINGS.

VOLUME 2: VENDOR DRAWINGS AND INSTRUCTIONS.

VOLUME 3: ELECTRICAL

ABOUT THIS MANUAL

Manual Volume all Manual Section preface _Contract

No.

04-31645-720

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VOLUME 3

SECTION

_TITLE

Drawing No.

(or p age No.)

Rev

ai

_{Cover Page}

_5.401478

₀

aii

_{Distribution and Revision Record}

_5.401479

₀

aiii

_Disclaimer

_7.500267

₁

aiv

Safety Statement

7.500268

1

av

_{Translation Warning}

_7.500433

₀

avi

_{About This Manual}

_5.401468

₀

INDEX

5.401480

0

1 CONTROL & INSTRUMENTS DIAGRAMS

1 Legend Sheet 1

8.500980-1

0

2 Legend Sheet 2

8.500980-2

0

3 Legend Sheet 3

8.500980-3

0

4 Crusher Overview

8.500980-4

3

5 Crusher Hydraulic Oil System

8.500980-5

3

6 Crusher Spider Bushing Lubrication System

8.500980-6

3

7 Crusher Lube Oil System Lube Skid

8.500980-7

3

2 ELECTRICAL LOAD L IST

8.500983

2

3 FIELD INSTRUMENT LIST

8.500981

2

4 I/O LIST

8.500982

2

5 FUNCTIONAL SPECIFICATION

8.500985

1

6 CRUSHER DRIVE MOTOR

(9)

6 CRUSHER DRIVE MOTOR – CON’T

2 Nameplate

6.506948

2

3 Main Terminal Box

6.506949

1

4 Space Heater Terminal Box

6.506950

2

5 Stator RTD Terminal Box

6.506951

1

6 Shaft Outline

6.506952

1

7 Starting Characteristic Curve

6.506991

0

8 Thermal Curve

6.506992

0

9 Motor Specifications

6.506997

0

10 Installation & Maintenance Manual – English

EME000077-D

11 Installation & Maintenance Manual – Spanish

EME300051-a

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Revision JYY JYY MDS Original JYY JYY MDS Scale: Sign. Sign. Sign

NONE Drawn Chkd. Appr.

I/O SIGNAL LIST CRUSHER

CERRO VERDE PROJECT PERU, S. AMERICA

The information transmitted by this document is proprietary and confidential property of FFE MINERALS and may not be duplicated disclosed or utilized without written consent from FFE MINERALS.

30 JULY 05 Date

PERU, S. AMERICA CONTRACT NO. 04-31645-720

FFE MINERALS USA INC.

FFE MINERALS USA INC. No.: 8.500982 2

A MEMBER OF THE F.L. SMIDTH-FULLER ENGINEERING GROUP 3235 SCHOENERSVILLE ROAD P.O. BOX 810 BETHLEHEM, PA 18016-0810 TEL. 610-264-6900 FAX. 610-264-6996 30 JULY 05

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V TAG NUMBER HEET NO. DEVICE AI AO DI DO EQUIPMENT OR SYSTEM SUBSYSTEM MEASURED VARIABLE STATE STATUS UNITS MIN. MAX. COMMENTS 31 ZSO-6717 7 OPEN LIMIT SWITCH 1 CRUSHER LUBRICATION LUBE OIL FILTER DRAIN VALVE OPEN

NOTE 1 MOTOR CONTROL IO NOT INCLUDED NOTE 2 IO FOR LOCAL PB STATION

BY OTHERS NOT INCLUDED

(24)

Gyratory Crusher

Prepared for:

CERRO VERDE PROJECT

Gyratory Crusher

PERU, S. AMERICA

FFE Minerals Contract No. 04-31645-720

Prepared by:

FFE Minerals USA Inc.

3235 Schoenersville Road

Bethlehem, PA 18017-2103

USA

Tel. (610) 264-6900

Rev. Date Designed Checked Approved Description

01 16SEP05 JYY JYY MDS REVISED PER CUSTOMER COMMENTS 00 30JULY05 JYY JYY MDS

(25)

1 About This Document ... 4

Equipment... 4

Normal Startup Sequence... 4

Normal Operation... 4

Normal Shutdown Sequence... 5

Abnormal and Emergency Shutdowns ... 5

HMI Control Summary... 5

Alarms... 5

Interlocks... 6

2 Overview ... 8

A. Function Groups ... 8

B. System Startup Sequence ... 8

C. System Shutdown Sequence... 8

D. Equipment/Device Descriptions... 9

E. Equipment/Device Parameter Descriptions ... 13

F. Reference Documents ... 15

3 Crusher Lubrication Group ...16

A. Equipment... 16

B. Normal Startup Sequence... 19

C. Normal Operation ... 20

D. Normal Shutdown Sequence ... 20

E. Abnormal and Emergency Shutdowns... 20

F. HMI Control Summary ... 21

G. Alarms... 22

H. Interlocks ... 23

4 Crusher Hydraulic Adjustment Group... 26

A. Equipment... 26

B. Normal Startup Sequence... 29

C. Normal Operation ... 29

D. Normal Shutdown Sequence ... 30

E. Abnormal and Emergency Shutdowns... 30

F. HMI Control Summary ... 30

G. Alarms... 31

H. Interlocks ... 32

5 Crusher Spider Bushing Lubrication Group... 33

A. Equipment... 33

B. Normal Startup Sequence... 34

C. Normal Operation ... 35

(26)

D. Normal Shutdown Sequence ... 35

E. Abnormal and Emergency Shutdowns... 35

F. HMI Control Summary ... 36

G. Alarms... 36

H. Interlocks ... 36

6 Crusher Dust Seal Air Group ...37

A. Equipment... 37

B. Normal Startup Sequence... 37

C. Normal Operation ... 37

D. Normal Shutdown Sequence ... 38

E. Abnormal and Emergency Shutdowns... 38

F. HMI Control Summary ... 38

G. Alarms... 39

H. Interlocks ... 39

7 Crusher Main Drive Motor ... 40

A. Equipment... 40

B. Normal Startup Sequence... 42

C. Normal Operation ... 43

D. Normal Shutdown Sequence ... 43

E. Abnormal and Emergency Shutdowns... 43

F. HMI Control Summary ... 44

G. Alarms... 45

H. Interlocks ... 46

(27)

The purpose of this functional specification is to describe the system control

phi-losophy in a user-friendly, yet practical approach. It is intended to provide

guid-ance to the control system programmers and to plant operators. With this in

mind, this document provides the following major headings for each function

group:

Equipment

This section lists and describes the equipment included in each function group,

including a description of the auxiliary devices associated with the equipment.

Equipment and devices will be identified by their descriptive name, which can be

used to cross-reference the corresponding tag numbers, listed in the

Equip-ment/Device Descriptions section (Section D of Chapter 2), for use with other

FFE Minerals documents.

Normal Startup Sequence

This section describes the function group’s startup sequence. If the group has

an automatic start sequence, time delays between equipment will also be listed

(if required). Any group preconditions required prior to startup are also listed

herein. However, interlocks required for individual or predefined groups of

equipment are listed in the Interlocks section (Section H of the same chapter).

Normal Operation

This section describes the function group’s normal operation, including operator

functions (if any). There are three modes of operation, as described below:

Operation Auto: “Operation Auto” mode is when the different function

groups are controlled by the Control system. Process set points are

moni-tored by the control system and are used to automatically control

equip-ment. All Safety, Start and Process interlocks (Section H of the same

chapter) must be met in order to operate.

Operation Manual: “Operation Manual” mode is when the different

func-tion groups are controlled by the operator. All Safety interlocks (Secfunc-tion H

of the same chapter) must be met in order to operate.

(28)

Maintenance: “Maintenance” mode is when the individual equipment

within each function group can be controlled separately by the operator (or

maintenance personnel). All Safety interlocks (Section H of the same

chapter) must be met in order to operate.

Normal Shutdown Sequence

This section describes the function group’s shutdown sequence. If the group has

an automatic shutdown sequence, time delays to allow for equipment cleanout or

deceleration will also be listed (if required).

Abnormal and Emergency Shutdowns

This section describes abnormal shutdown conditions caused by isolated

proc-ess or equipment abnormalities or activation of individual equipment safety

de-vices. It also describes emergency shutdowns due to automatic activation of

personnel safety systems or field emergency stop push buttons.

HMI Control Summary

This section describes how the HMI shall be programmed for the associated

function group. Requirements include any special pop-up windows or HMI

but-tons and a list of all process values, which are displayed on the HMI graphics

screen(s) and the controller faceplates.

Alarms

This section describes alarm messages and alarm conditions/parameters for all

equipment or devices within the function group.

Some alarms are “debounced” using timers of various durations to help prevent

nuisance chatter or spikes. Non-debounced alarms are generated without a time

delay from the control system, to immediately begin the Abnormal and

Emer-gency Shutdown process (Section E of the same chapter).

(29)

Interlocks

The Interlocks section describes all interlocks for the individual equipment or

function groups of equipment within the associated software function group.

In-terlock is defined herein as an input/output signal or a PLC/DCS internal logic

condition, which automatically prevents the operation of an individual or function

group of equipment from the control system Human Machine Interface (HMI).

That is, only PLC/DCS

software

interlocks are listed in the interlock table.

Hard-wired interlocks (not through the PLC/DCS) are NOT listed in the interlock table.

Interlocks are defined in the condition or state which

permits

operation, so loss of

this signal or logic condition inhibits operation. When the condition of an interlock

or interlocks is such that operation of a related piece of equipment or an

equip-ment group is permitted, the interlock is defined as being “satisfied.” Interlocks

consist of three types and are described in detail below:

Safety interlocks: Safety interlocks are those interlocks which prevent

damage to that associated piece of equipment. As a result, safety

inter-locks apply when operating in “REMOTE AUTO”, “REMOTE HAND”

and

“MAINTENANCE” modes.

Example

Safety interlock for a fan or pump would be “no high-high bearing

temperature.”

Safety interlock for a belt conveyor would be “no zero speed.”

Safety interlocks for every motor will also include the “MCC/motor

ready” signal and receipt of a run confirmation from the motor

con-tactor after a run command is sent. These interlocks apply to all

motors and are not listed in the interlock table for this reason.

Start interlocks: Start interlocks are those interlocks which prevent an

in-dividual or function group of equipment from being started in “Operation

Auto” mode only (not “Operation Manual” or “Maintenance” mode). Once

the individual or function group of equipment is running, the start interlock

will no longer inhibit operation.

Example

A start interlock for a fixed speed fan with automatic damper would

be that the “damper be closed” (limit switch or position transmitter)

prior to starting.

(30)

Process interlocks: Process interlocks are those interlocks which prevent

an individual or function group of equipment from starting or running in

“Operation Auto” mode only (not in “Operation Manual” or “Maintenance”

mode). The term ‘process’ is commonly used because these interlocks

are often dependent on another individual or function group of equipment

within the process.

Example

A process interlock for a belt conveyor would be that the

“down-stream conveyor is running.”

The following table summarizes the modes of operation for the three types of

in-terlocks defined above:

INTERLOCK MODES OF OPERATION

Interlock Type Mode Selector

Switch

Operator Control Station Component Mode Selection

Safety Start Process MAINTENANCE ---

X

_---

---MANUAL

X

_--- ---OPERATION

(31)

This functional specification is for the Electrical Control of a Gyratory Crusher

and its auxiliary components for the Cerro Verde Project.

A. Function Groups

The following function groups combine to deliver a complete Gyratory

Crusher control and operating system. Details for FFEM-supplied function

groups are described in each group’s relevant chapter:

3. Crusher Lubrication Group

4. Crusher Hydraulic Adjustment Group

5. Crusher Spider Bushing Lubrication Group

6. Crusher Dust Seal Air Group

7. Crusher Main Drive Motor

B. System Startup Sequence

When starting the Crusher from a total shutdown, refer to the Contract

In-struction Manual for the Gyratory Crusher. For details of individual subgroups,

refer to the appropriate chapters of this document.

C. System Shutdown Sequence

When a system shutdown is required, refer to the Contract Instruction Manual

for the Gyratory Crusher. For details of individual subgroups, refer to the

ap-propriate chapters of this document.

(32)

D. Equipment/Device Descriptions

Note: All instrument tags are prefixed by “31“.

Equipment/Device Tag Equipment/Device Description

M-1.0 CRUSHER MAIN DRIVE MOTOR

H-10.0 CRUSHER MAIN DRIVE MOTOR HEATER

M-7.0 CRUSHER SEAL AIR BLOWER

FISL-0143 CRUSHER INNER ECCENTRIC BUSHING LUBE OIL SUPPLY LINE FLOW SWITCH

FISL-0141 CRUSHER OUTER ECCENTRIC BUSHING LUBE OIL SUPPLY LINE FLOW SWITCH

FISL-0142 CRUSHER COUNTERSHAFT BEARING LUBE OIL SUPPLY LINE FLOW SWITCH

TE-0111A CRUSHER MAIN DRIVE MOTOR INBOARD BEARING TEMPERA-TURE ELEMENT

TE-0111B CRUSHER MAIN DRIVE MOTOR OUTBOARD BEARING TEMPERA-TURE ELEMENT

TE-0112A CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0112B CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0112C CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0112D CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0112E CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0112F CRUSHER MAIN DRIVE MOTOR STATOR WINDING TEMPERATURE ELEMENT

TE-0140A CRUSHER COUNTERSHAFT INBOARD BEARING TEMPERATURE ELEMENT

TE-0140B CRUSHER COUNTERSHAFT OUTBOARD BEARING TEMPERATURE ELEMENT

ZE-0118 CRUSHER MANTLE POSITION SENSING ELEMENT

ZY-0118 CRUSHER MANTLE POSITION CONVERTER

ZIT-0118 CRUSHER MANTLE POSITION-INDICATING TRANSMITTER

M-3.0 CRUSHER LUBE OIL MAIN SUPPLY PUMP

(33)

H-12.0 CRUSHER LUBE OIL RESERVOIR HEATER 2

LSL-6721 CRUSHER LUBE OIL RESERVOIR LOW LEVEL SWITCH

LSLL-6721 CRUSHER LUBE OIL RESERVOIR LOW-LOW LEVEL SWITCH

TE-6722 CRUSHER LUBE OIL RETURN LINE TEMPERATURE ELEMENT

TE-6723 CRUSHER LUBE OIL RESERVOIR TEMPERATURE ELEMENT

TI-6706 CRUSHER LUBE OIL RESERVOIR TEMPERATURE GAUGE

HV-6717 CRUSHER LUBE OIL FILTER DRAIN VALVE

LG-6704 CRUSHER LUBE OIL RESERVOIR LEVEL GAUGE

PI-6703 CRUSHER LUBE OIL PUMPS DISCHARGE OIL PRESSURE GAUGE

PSV-6701 CRUSHER LUBRICATION MAIN OIL PUMP DISCHARGE OIL PRES-SURE RELIEF VALVE

PSV-6702 CRUSHER LUBRICATION STANDBY OIL PUMP DISCH. OIL PRES-SURE RELIEF VALVE

ZSO-6717 CRUSHER LUBE OIL FILTER DRAIN VALVE OPEN POSITION LIMIT SWITCH

ZSC-6717 CRUSHER LUBE OIL FILTER DRAIN VALVE CLOSED POSITION LIMIT SWITCH

PDSH-6719 CRUSHER LUBE OIL SUPPLY FILTER DIFFERENTIAL PRESSURE SWITCH

TI-6707 CRUSHER LUBRICATION RETURN LINE OIL TEMPERATURE GAUGE

M-5.0 CRUSHER LUBE OIL COOLER #1 FAN

M-6.0 CRUSHER LUBE OIL COOLER #2 FAN

HV-6716 CRUSHER LUBE OIL COOLER DRAIN VALVE

ZSC-6716 CRUSHER LUBE OIL COOLER DRAIN VALVE CLOSED POSITION LIMIT SWITCH

ZS0-6716 CRUSHER LUBE OIL COOLER DRAIN VALVE OPEN POSITION LIMIT SWITCH

PI-6709 CRUSHER LUBE OIL FILTER OUTLET OIL PRESSURE GAUGE

(34)

TE-6718 CRUSHER LUBE OIL COOLER OUTLET TEMPERATURE ELEMENT

TI-6708 CRUSHER LUBE OIL FILTER OUTLET OIL TEMPERATURE GAUGE

TI-6711 CRUSHER LUBE OIL COOLER OUTLET OIL TEMPERATURE GAUGE

PSV-6713 CRUSHER LUBE OIL COOLER PRESSURE RELIEF VALVE

M-2.0 CRUSHER HYDRAULIC OIL MAIN SUPPLY PUMP

M-9.0 CRUSHER HYDRAULIC OIL STANDBY SUPPLY PUMP

XV-6507 CRUSHER MANTLE RAISE/LOWER HYDRAULIC OIL CONTROL VALVE

LG-6501 CRUSHER HYDRAULIC OIL RESERVOIR LEVEL GAUGE

LSL-6511 CRUSHER HYDRAULIC OIL RESERVOIR LOW LEVEL SWITCH

LSLL-6511 CRUSHER HYDRAULIC OIL RESERVOIR LOW-LOW LEVEL SWITCH

PDSH-6506 CRUSHER HYDRAULIC OIL FILTER DIFFERENTIAL PRESSURE SWITCH

PI-0102 CRUSHER HYDRAULIC ACCUMULATOR OIL PRESSURE GAUGE

PI-6504 CRUSHER HYDRAULIC PUMP DISCHARGE PRESSURE GAUGE

PSV-0103 CRUSHER HYDRAULIC OIL PRESSURE RELIEF VALVE

PSV-6503 CRUSHER HYDRAULIC PUMP DISCHARGE OIL PRESSURE RELIEF VALVE

CP1 CRUSHER SPIDER BUSHING GREASE LUBRICATION CONTROLLER

M-8.0 CRUSHER SPIDER BUSHING GREASE PUMP

FQS-6603 CRUSHER SPIDER BUSHING GREASE SUPPLY LINE FLOW CYCLE SWITCH

HS-6507A CRUSHER HYDRUALIC MANTLE RAISE PUSH BUTTON

HS-6507B CRUSHER HYDRUALIC MANTLE LOWER PUSH BUTTON

HS-6505A CRUSHER HYDRUALIC MAIN OIL PUMP START PUSH BUTTON

HS-6505B CRUSHER HYDRUALIC MAIN OIL PUMP STOP PUSH BUTTON

(35)

HS-6705A CRUSHER LUBRICATION MAIN OIL PUMP START PUSH BUTTON

HS-6705B CRUSHER LUBRICATION MAIN OIL PUMP STOP PUSH BUTTON

HS-6710A CRUSHER LUBRICATION STANBY OIL PUMP START PUSH BUTTON

HS-6710B CRUSHER LUBRICATION STANDBY OIL PUMP STOP PUSH BUTTON

YL-6505 CRUSHER HYDRUALIC MAIN OIL PUMP RUNNING INDICATION LIGHT

YL-6705 CRUSHER LUBRICATION MAIN OIL PUMP RUNNING INDICATION LIGHT

YL-6710 CRUSHER LUBRICATION MAIN OIL PUMP RUNNING INDICATION LIGHT

(36)

E. Equipment/Device Parameter Descriptions

In the sections that follow, specific control system signals and set points are

printed in bold italics. The definitions and/or values of these signals and set

points are defined in the table below.

Signal / Set point Description Type Value Lube Oil Reservoir Low

Level Low alarm/interlock reservoir level. Constant 2/3 FULL Lube Oil

Reservoir Low-Low Level

Low-low alarm/interlock oil reservoir level

(* must be above tank discharge line). Constant 1/3 FULL Lube Oil

Reservoir Low Temperature

Low oil reservoir temperature alarm set

point. Constant Lube Oil

Reservoir Heater On

Low oil reservoir temperature heater

con-trol set point. Constant <90 DEGF Lube Oil

Reservoir Heater Off

High oil reservoir temperature heater

con-trol set point. Constant >100 DEGF Lube Oil

Reservoir High Temperature

High oil reservoir temperature alarm set

point. Constant Lube Oil Cooler Main

Fan Off

Low Lube Oil Cooler Outlet Temperature Moving Average Main Cooler Fan “OFF” control set point.

Constant <90 DEGF

Lube Oil Main Cooler Fan On

High Lube Oil Cooler Outlet Temperature Moving Average Main Cooler Fan “ON” control set point.

Constant >105 DEGF

Lube Oil Cooler Standby Fan Off

Low Lube Oil Cooler Outlet Temperature Moving Average Standby Cooler Fan “OFF” control set point.

Constant <105 DEGF

Lube Oil Cooler Standby Fan On

High Lube Oil Cooler Outlet Temperature Moving Average Standby Cooler Fan “ON” control set point.

Constant >115 DEGF Lube Oil Cooler Outlet

Temperature Moving Average

The average Lube Oil Cooler Outlet Tem-perature continuously calculated over a selected time interval.

Variable Calculated Lube Oil Cooler Outlet

Temperature Moving Average Interval

The adjustable time interval over which the Lube Oil Cooler Outlet Temperature Moving Average is calculated.

Adjustable 2-5 minutes Lube Oil High Return

Line Temperature

High alarm oil reservoir return line

tem-perature. Constant Lube Oil High-High Re-

turn Line Temperature

High-high alarm/interlock oil reservoir

re-turn line temperature. Constant Lube Oil Filter High

Differential Pressure

Pressure at or above this value is alarmed

indicating filter is dirty or clogged. Constant Inner Eccentric

Bushing Lube Oil Low Flow

Low alarm/interlock for lube oil flow to

Inner Eccentric Bushing. Constant 34 GPM Outer Eccentric

(37)

Signal / Set point Description Type Value Countershaft Bearings

Lube Oil Low Flow

Low alarm/interlock for lube oil flow to

Countershaft Bearings. Constant 2 GPM Countershaft Inboard

Bearing High Tempera- ture

High alarm/interlock bearing temperature. Constant Countershaft Inboard

Bearing High-High Temperature

High-high alarm/interlock bearing

tem-perature. Constant Countershaft Outboard

Bearing High Tempera- ture

High alarm/interlock bearing temperature. Constant Countershaft Outboard

Bearing High-High Temperature

tem-perature. Constant Hydraulic Oil Reservoir

Low Level Low alarm/interlock reservoir level. Constant 2/3 FULL Hydraulic Oil Reservoir

Low-Low Level

Low-low alarm/interlock reservoir level

(* must be above tank discharge line). Constant 1/3 FULL Crusher Mantle

Position Position (elevation) of the crusher mantle. Analog Varies Hydraulic Oil Filter High

Differential Pressure Set Point

Pressure at or above this value is alarmed

indicating filter is dirty or clogged. Constant Crusher Mantle Low

Position Low alarm/interlock mantle position. Constant

50mm above minimum point

of travel Crusher Mantle High

Position High alarm/interlock mantle position. Constant

25mm below maximum point

of travel Crusher Main Drive Mo-

tor Minimum Run Time

Minimum duration Crusher Main Drive Motor must run prior to adjusting mantle position.

Constant

Provided by Motor

Manufac-turer Crusher Main Drive Mo-

tor Minimum Stop Time

Minimum duration from when the Crusher Main Drive Motor is stopped to when it may be restarted.

Constant

Provided by Motor

Manufac-turer Crusher Main Drive Mo-

tor Winding High Tem- perature

High alarm/interlock winding temperature. Constant 135 DEGC Crusher Main Drive Mo-

tor Winding High-High Temperature

High-high alarm/interlock winding

tem-perature. Constant 145 DEGC Crusher Main Drive Mo-

tor Inboard Bearing High Temperature

High alarm/interlock bearing temperature. Constant 90 DEGC Crusher Main Drive Mo-

tor Inboard Bearing High-High Temperature

tem-perature. Constant 100 DEGC Crusher Main Drive Mo-

tor Outboard Bearing High Temperature

High alarm/interlock bearing temperature. Constant 90 DEGC Crusher Main Drive Mo-

tor Outboard Bearing High-High Temperature

(38)

F. Reference Documents

FFE Doc./Dwg. Number Document/Drawing Description

8.500980, SHT. 1 CONTROL AND INSTRUMENTATION DIAGRAM, LEGEND SHEET 1

8.500980, SHT. 4 CONTROL AND INSTRUMENTATION DIAGRAM, CRUSHER OVERVIEW

8.500980, SHT. 5 CONTROL AND INSTRUMENTATION DIAGRAM, CRUSHER HYDRAULIC OIL SYSTEM

8.500980, SHT. 6 CONTROL AND INSTRUMENTATION DIAGRAM, CRUSHER SPIDER BUSHING LUBE SYSTEM 8.500980, SHT. 7 CONTROL AND INSTRUMENTATION DIAGRAM,

CRUSHER LUBE OIL SYSTEM 8.500981 FIELD INSTRUMENT LIST

8.500982 INPUT/OUTPUT SIGNAL LIST 8.500983 ELECTRICAL LOAD LIST

(39)

The Crusher Lubrication Group provides pressurized lubricating oil to the

Crusher components, such as the countershaft bearings and the inner

eccen-tric and outer ecceneccen-tric bushings. Refer to FFE Minerals Control and

Instru-mentation Diagrams 8.500980 Sheets 4 and 7 for details.

A. Equipment

This group consists of the following equipment, which is monitored and

con-trolled by the Control system:

A1. Crusher Lubrication System Reservoir

A2. Crusher Lubrication Supply Circuit

A3. Crusher Countershaft Bearing Temperature Elements

A1. Crusher Lubrication System Reservoir

The Crusher Lubrication System and Crusher Hydraulic System share one

common reservoir with an internal sealed partition. The Crusher

Lubrica-tion System Reservoir has the following devices associated with it:

1. Level Switches

There are two (2) oil level switches 31-LSL-6721 and

31-LSLL-6721located in the lubrication system reservoir. The level switches share

a common housing. The level switch contacts for Lube Oil Reservoir

Low Level

and Lube Oil Reservoir Low-Low Level are wired to the

Control system for alarming and interlocking.

2. Temperature Elements

Three (3) temperature elements are provided as part of the Crusher

Lu-brication System; one (1) element 31-TE-6723 is located in the lube oil

reservoir, one (1) element 31-TE-6718 is located in the Crusher lube oil

system cooler outlet line, and one (1) 31-TE-6722 is located in the

Crusher lube oil system return line.

The temperature element 31-TE-6723 located in the lube oil reservoir is

wired to the control system. For indicating temperature and controlling the

cycling of the reservoir heaters in response to the Lube Oil Reservoir

Heater On

and Lube Oil Reservoir Heater Off set points.

(40)

The element located in the cooler outlet line is wired to the Control system

and its signal is used to generate the Lube Oil Cooler Outlet Tempera-

ture Moving Average 31-TY-6718 . The Lube Oil Cooler Outlet Tem-

perature 31-TE-6718 Moving Average

is compared to the Lube Oil

Cooler Main Fan Off 31-TCLL-6718, Lube Oil Cooler Main Fan On

TCH-6118, Lube Oil Cooler Standby Fan Off 31-TCL-6718 and the Lube

Oil Cooler Standby Fan On

31-TCHH-6718 set points to cycle the cooler

fans on and off to control the temperature of the lube oil supply to the

Crusher. The moving average is continuously calculated over an operator

selected time period called the Lube Oil Cooler Outlet Temperature

Moving Average Interval

to “smooth out” transient temperature swings

that might cause rapid on-off cycling of the Lube Oil Cooler fans. The best

setting of this interval is determined empirically in the field during actual

operation of the crusher.

The element located in the Crusher lube oil system return line 31-TE-6721

is wired to the Control system. Its signal is compared to the Lube Oil High

Return Line Temperature

and Lube Oil High-High Return Line Tem-

perature

set points for alarming and interlocking.

3. Heaters

Four (4) oil immersion heaters are located in the reservoir. The ON-OFF

cycling of the reservoir heaters is done through the control system in

re-sponse to the signal from the temperature element 31-TE-6723described

above.

A2. Crusher Lubrication Supply Circuit

The Lubrication Supply Circuit has the following devices associated with it:

1. Lube Oil Pumps

There are two (2) Lube Oil pumps. In normal operation only one of the

pumps is running and the other is standby. Each pump has inlet and

out-let isolation valves for maintenance.

2. Lube Oil Pump Pressure Relief Valve

Each Lube Oil Pump is protected by a pressure relief valve 31-PSV-6701,

31-PSV-6702in its discharge piping. The relief valve outlets are piped

back to the Lube Oil Reservoir.

(41)

3. Oil Filter with Differential Pressure Switch

There is one (1) oil filter with a differential pressure switch 31-PDSH-6719.

If the filter is dirty, as indicated by an input to the control system from its

differential pressure switch, when the pressure exceeds the Lube Oil Fil-

ter High Differential Pressure

set point, an alarm is generated. The dirty

filter should be manually taken out of service and cleaned or replaced.

4. Flow-Switches

Three (3) flow switches monitor the oil flow rate to the countershaft

bear-ings and the inner eccentric and outer eccentric bushbear-ings. Each flow

switch is wired to the Control system for alarming and interlocking when

the lube oil flow is below the Inner Eccentric Bushing Lube Oil Low

Flow 31-FISL-0143 , Outer Eccentric Bushing Lube Oil Low Flow 31-

FISL-0141,

or the Countershaft Bearings Lube Oil Low Flow 31-FISL-

0142 set points as applicable.

5. Lube Oil Cooler (Oil Cooling Fans)

The Lube Oil Cooler consists of two (2) heat exchangers (radiators), each

with its own cooling fan for controlling the temperature of the lube oil

sup-ply to the Crusher.

6. Lube Oil Supply Pressure Relief Valve

One (1) pressure relief valve 31-PSV-6713 is provided to bypass lube oil

flow around the Lube Oil Cooler assembly in the event of a blockage or

inadvertent closure of individual cooler isolation valves.

7. Automatic Oil Drain Valves

Two (2) normally closed motorized valves 31-HV-6716 & 31-HV-6717 are

provided to automatically drain oil from the coolers and filters to the

reser-voir, when the Lubrication System is not in operation. These valves are

wired to the Control system for automatic lube oil draining.

8. Other Local Instruments

Other local instruments, such as pressure gauges, temperature gauges,

level indicators etc. are identified on the Control and Instrumentation

Dia-grams and in the Field Instrument List.

(42)

1. Temperature Elements

Two (2) temperature elements monitor the countershaft (inboard and

out-board) bearings’ temperature. The signal from the countershaft inboard

bearing is compared to the Countershaft Inboard Bearing High Tem-

perature

31-TAH-0111A and Countershaft Inboard Bearing High-High

Temperature 31-TAHH-0111A set points for alarming and interlocking.

The signal from the countershaft outboard bearing is compared to the

Countershaft Outboard Bearing High Temperature

31-TAH-0111B

and Countershaft Outboard Bearing High-High Temperature

31-TAHH-0111B set points for alarming and interlocking.

B. Normal Startup Sequence

Prior to starting the Crusher Lubrication Group, the operator should first

per-form the following actions:

1. Verify that the Crusher Lube System Oil Reservoir is not at the Lube Oil

Reservoir Low Level 31-LAL-6721.

2. Verify that the Crusher Lubrication System Reservoir heaters are in

“AUTO.” (31-XS-6725) A/M STATION

3. Verify that the desired lube oil supply pump’s inlet and outlet isolation

valves are fully open.

After the operator has performed the actions listed above, the normal order of

starting the Crusher Lubrication Group is as follows:

1. Place cooler drain valve in “AUTO” mode A/M STATION XS-6717,

31-XS-6716, so that they may open (pump off) and close (pump on)

auto-matically as determined by the status of the lube oil supply pumps.

2. The reservoir heaters start automatically as determined by the Crusher

lube oil reservoir temperature element 31-TE-6723.

3. Place the cooling fans in “AUTO” 31-XS-6715 and 31-XS-6716 run mode,

so that they may start automatically as determined by the Crusher supply

line lube oil temperature element 31-TE-6718.

4. Start the desired lube oil supply pump. The pump cannot start unless the

reservoir temperature is above the Lube Oil Reservoir Low Tempera-

ture

31-TCL-6723 set point. Once started, this temperature may drop

(43)

C. Normal Operation

Once the Crusher Lubrication Group is started, normal operation simply

con-sists of ensuring that lubricating oil is steadily supplied to the receiving points.

Also, normal operation ensures that the required function group interlocks

(listed in Section H of this chapter) are satisfied.

The reservoir heaters will automatically operate as required, maintaining the

oil temperature in the reservoir between the Lube Oil Reservoir Heater On

set point 31-TCL-6723 and Lube Oil Reservoir Heater Off set point

31-TCH-6723. An ON-OFF controller in the Control system will control the operation

of the reservoir heaters.

The Lube Oil Cooler Fans will automatically cycle on and off as required to

maintain the lube oil supply temperature at or below the Lube Oil Supply

Standby Cooler Fan On

set point 31-TCHH-6718.

D. Normal Shutdown Sequence

The normal order for short-term shutdown of the Crusher Lubrication Group is

as follows:

1. After the Crusher has come to a complete stop, stop the operating lube oil

supply pump. If desired (i.e., to lower the lube oil temperature), the lube

oil pump can be allowed to run continuously even after the Crusher has

stopped.

2. If the cooling fans are running, allow them to first lower the return line oil

temperature to the coolers OFF temperature setting 31-TCL-6718. These

motors may then be taken out of “AUTO" mode by the operator.

3. The cooler drain valves may then be taken out of “AUTO” mode by the

operator.

E. Abnormal and Emergency Shutdowns

1. Abnormal Shutdown, Lube Oil Supply Pump Trips

If the Crusher Lubrication Group is operating and the running lube oil

sup-ply pump trips, the Control system will provide an alarm 31-XA-6705

(MAIN), 31-XA-6710 (STANDBY) to the operator. The remainder of the

Crusher Lubrication Group (Crusher lubrication oil cooling system) will

continue to operate unless shutdown by the operator or other required

in-terlocks (see Section H of this chapter).

(44)

2. Abnormal Shutdown, Cooling Oil Fan Trips

If the Crusher Lubrication Group is operating and either of the lube oil

cooling fans trip, the Control system will provide an alarm 31-XA-6715

(MAIN) 31-XA-6720 (STANDBY) to the operator. The remainder of the

Crusher Lubrication Group (Crusher lubrication oil supply system) will

con-tinue to operate unless shutdown by the operator or other required

inter-locks (see Section H of this chapter).

3. Emergency Shutdowns

If the emergency stop push button(s) (by others) is depressed while the

Crusher Lubrication Group is running all function group motors will

imme-diately and simultaneously stopped. Furthermore, all motors associated

with the Crusher Lubrication Group are prohibited from restarting until the

emergency stop push button(s) is reset.

F. HMI Control Summary

The following signals are displayed on the Owner’s operator control stations:

1. Lube Oil Reservoir Low Level. (31-LAL-6721)

2. Lube Oil Reservoir Temperature. (31-T1-6723)

3. Status of each Lube Oil Supply Pump Motor (ready, running, stopped

or tripped). (31-XL-6705) (31-XL-6710)

4. Lube Oil Filter High Differential Pressure. (31-PDAH-6719)

5. Status of each Lube Oil Cooler Cooling Fan Motor (ready, running,

stopped or tripped). (31-XL-6715) (31-XL-6720)

6. Lube Oil Cooler Outlet Temperature Moving Average. (31-TI-6718)

7. Crusher Countershaft Bearings Oil Low Flow. (31-FAL-0142)

8. Crusher Inner Eccentric Bushing Oil Low Flow. (31-FAL-0143)

9. Crusher Outer Eccentric Bushing Lube Oil Low Flow (31-FAL-0141)

10. Crusher Return Line Lube Oil Temperature. (31-TI-6722)

11. Crusher Inboard Countershaft Bearing Temperature. (31-TI-0140A)

12. Crusher Outboard Countershaft Bearing Temperature. (31-TI-0140B)

13. Status of the Lube Oil Cooler Drain Valve (open or closed).

(45)

G. Alarms

Debounced Alarms

Alarm Tag Alarm Text LAL-6721 LUBE OIL RESERVOIR LOW LEVEL

LALL-6721 LUBE OIL RESERVOIR LOW-LOW LEVEL TAL-6723 LUBE OIL RESERVOIR LOW TEMPERATURE TAH-6723 LUBE OIL RESERVOIR HIGH TEMPERATURE PDAH-6719 CRUSHER LUBE OIL FILTER DIRTY

FAL-0142 CRUSHER INNER ECCENTRIC BUSHING LUBE OIL LOW FLOW FAL-0141 CRUSHER OUTER ECCENTRIC BUSHING LUBE OIL LOW FLOW FAL-0143 CRUSHER COUNTERSHAFT BEARINGS LUBE OIL LOW FLOW TAH-6722 LUBE OIL HIGH RETURN LINE TEMPERATURE

TAHH-6722 LUBE OIL HIGH-HIGH RETURN LINE TEMPERATURE

TAH-0140A CRUSHER COUNTERSHAFT INBOARD BEARING HIGH TE MPERATURE TAH-0140B CRUSHER COUNTERSHAFT OUTBOARD BEARING HIGH TEMPERATURE TAHH-0140A CRUSHER COUNTERSHAFT INBOARD BEARING HIGH-HIGH TEMPERATURE TAHH-0140B CRUSHER COUNTERSHAFT OUTBOARD BEARING HIGH-HIGH TEMPERATURE

Non-debounced Alarms

Alarm Tag Alarm Text 31-XA-6705 CRUSHER MAIN LUBE SUPPLY PUMP TRIP

(If trips on run command)

31-XA-6710 CRUSHER STANDBY LUBE SUPPLY PUMP TRIP (If trips on run command)

31-XA-6715 _{CRUSHER LUBE OIL COOLER COOLING FAN A TRIP} (If trips on run command)

31-XA-6720 CRUSHER LUBE OIL COOLER COOLING FAN B TRIP (If trips on run command)

(46)

H. Interlocks

Interlock Type Equipment or

Control System Permissive

Signals _Safety _Start _Process

LUBE OIL RESERVOIR TEMPERATURE NOT HIGH (below the Lube Oil Reservoir

High Temperature )

X

LUBE OIL

RESERVOIR HEATERS

LUBE RESERVOIR OIL LEVEL NOT LOW-LOW (below the Lube Oil Reservoir Low-

Low Level )

X

LUBE OIL RESERVOIR LEVEL NOT LOW-LOW (below the Lube Oil Reservoir Low-

Low Level )

X

LUBE RESERVOIR OIL TEMPERATURE NOT LOW (below the Lube Oil Reservoir

Low Temperature

X

MAIN LUBE OIL SUPPLY PUMP

STANDBY LUBE OIL SUPPLY PUMP NOT

RUNNING

X

LUBE OIL RESERVOIR LEVEL NOT LOW-LOW (below the Lube Oil Reservoir Low-

Low Level )

X

LUBE OIL RESERVOIR TEMPERATURE NOT LOW (below the Lube Oil Reservoir

Low Temperature

X

STANDBY LUBE OIL SUPPLY PUMP

MAIN LUBE OIL SUPPLY PUMP NOT

RUN-NING

X

LUBE OIL COOLER OUTLET TEMPERA-TURE MOVING AVERAGE NOT LOW (below

the Lube Oil Cooler Main Fan Off )

X

LUBE OIL

COOLER FAN A

MAIN OR STANDBY LUBE OIL PUMP

RUN-NING

X

LUBE OIL COOLER OUTLET TEMPERA-TURE MOVING AVERAGE NOT LOW (below

the Lube Oil Cooler Standby Fan Off )

X

LUBE OIL

COOLER FAN B

MAIN OR STANDBY LUBE OIL PUMP

RUN-NING

X

ANY ONE (1) OIL LUBE PUMPS RUNNING

(CLOSE VALVE)

X

LUBE OIL COOLER DRAIN

VALVE

BOTH OIL LUBE PUMPS NOT RUNNING

(47)

H. Interlocks (cont’d)

Interlock Type Equipment or

Control System Permissive

Signals _Safety _Start _Process

LUBE RESERVOIR OIL LEVEL NOT LOW

(below the Lube Oil Reservoir Low Level )

X

COUNTERSHAFT BEARINGS OIL FLOW

NOT LOW (below the Countershaft Bearings

Lube Oil Low Flow )

X

INNER ECCENTRIC BUSHING OIL FLOW

NOT LOW (below the Inner Eccentric Bush-

ing Lube Oil Low Flow )

X

OUTER ECCENTRIC BUSHING OIL FLOW

NOT LOW (below the Outer Eccentric Bush-

X

LUBE OIL RETURN LINE TEMPERATURE

NOT HIGH (below the Lube Oil High Return

Line Temperature )

X

COUNTERSHAFT INBOARD BEARING

TEM-PERATURE NOT HIGH (below the Counter-

shaft Inboard Bearing High Temperature )

X

LUBE OIL START

PERMISSIVE FOR THE CRUSHER MAIN DRIVE

MO-TOR C1LBSTART (SEE CHAPTER 7,

SECTION H)

COUNTERSHAFT OUTBOARD BEARING TEMPERATURE NOT HIGH (below the Countershaft Outboard Bearing High Tem- perature )

(48)

H. Interlocks (cont’d)

COUNTERSHAFT INBOARD BEARING TEM-PERATURES NOT HIGH-HIGH (below the Countershaft Inboard Bearing High-High Temperature )

X

COUNTERSHAFT OUTBOARD BEARING TEMPERATURES NOT HIGH-HIGH (below the Countershaft Outboard Bearing High- High Temperature )

X

COUNTERSHAFT BEARING OIL FLOW NOT LOW (below the Countershaft Bearings

Lube Oil Low Flow )

X

OUTER ECCENTRIC BUSHING OIL FLOW

NOT LOW (below the Outer Eccentric Bush-

X

LUBE RESERVOIR OIL LEVEL NOT LOW

(below the Lube Oil Reservoir Low Level )

X

RETURN LINE OIL TEMPERATURE NOT

HIGH-HIGH (below the Lube Oil Reservoir

High-High Temperature )

X

LUBE OIL

30-SECOND DE-LAYED STOP IN-TERLOCKS FOR THE CRUSHER MAIN DRIVE

MO-TOR C1LBSTOP (SEE CHAPTER 7,

SECTION H)

INNER ECCENTRIC BUSHING OIL FLOW NOT LOW (below the Inner Eccentric Bush-

(49)

The Crusher Hydraulic Adjustment Group provides high pressure oil to lift the

Crusher main shaft (mantle) to maintain it at a certain vertical elevation.

The Crusher mantle is supported by a volume of oil between the piston and the

cylinder cover. This volume of oil supports the mantle and all crushing loads.

The volume of this oil is intentionally varied, in order to change the vertical

posi-tion of the shaft and to thereby adjust the Crusher open-side setting (material

discharge size setting).

Refer to FFE Minerals Control and Instrumentation Diagrams 8.500980 Sheets 4

and 5 for details.

A. Equipment

This group consists of the following equipment, which is monitored and controlled

by the Control system:

A1. Crusher Hydraulic Oil Reservoir

A2. Crusher Hydraulic Oil Supply Circuit

A3. Crusher Hydraulic Adjustment Mechanisms

A1. Crusher Hydraulic Oil Reservoir

The Crusher Hydraulic System and Crusher Lubrication System share one

common reservoir with an internal sealed partition. The Crusher Hydraulic Oil

Reservoir has the following devices associated with it:

1. Level Switches

There are two (2) oil level switches 31-LSL-6511 & 31-LSLL-6511 located in

the oil reservoir. The level switches share a common housing. The level

switch contacts for Hydraulic Oil Reservoir Low Level and Hydraulic Oil

Reservoir Low-Low Level

are wired to the Control system for alarming and

interlocking.

4

Crusher Hydraulic

(50)

2. Other Local Instruments

Other local instruments, such as temperature gauges and level indicators etc.

are identified on the Control and Instrumentation Diagrams and the Field

In-strument List.

A2. Crusher Hydraulic Oil Supply Circuit

The Crusher Hydraulic Oil Supply Circuit has the following devices associated

with it:

1. Hydraulic Oil Pump

There are two (2) high pressure hydraulic oil pumps. In normal operation only

one of the pumps is running and the other is standby. Each pump has an inlet

and an outlet isolation valve for maintenance.

2. Hydraulic Oil Pump Pressure Relief Valve and Gauge

The Hydraulic Oil Pumps are protected by a pressure relief valve at the

discharge piping. The relief valve outlet is piped back to the Hydraulic Oil

Reservoir. A local pressure gauge is also provided.

3. Oil Filter with Differential Pressure Switch

There is a hydraulic oil filter with a differential pressure switch

31-PDSH-6506. If the filter in service is dirty, as indicated by an input to the control

system from its differential pressure switch, when the pressure exceeds the

Hydraulic Oil Filter High Differential Pressure

set point listed, the control

system generates an alarm 31-PDAH-6506. The dirty filter should then be

manually taken out of service and cleaned or replaced.

4. Dual Solenoid Directional Control Valve

A four way, solenoid operated, spring return directional control valve is

pro-vided and is used to control the direction of high pressure oil flow. The

sole-noids of the directional control valve are wired to the Control system. The

function of the directional control valve is described in Section C of this

chap-ter.

(51)

A3. Crusher Hydraulic Adjustment Mechanisms

The Hydraulic Adjustment Mechanisms include the following devices:

1. Hydraulic Accumulator

The hydraulic accumulator receives pressurized fluid from the pumping

sys-tem and provides local pressure accumulation. The accumulator is of the

hy-dro-pneumatic type, with an integral gas bladder. Before operating the

Crusher, the customer must pre-charge the gas bladder as stated in the

FFEM Installation, Operation and Maintenance Manual for the Gyrator

Crush-ers (see the Contract Instruction Manual).

2. Hydraulic Oil Supply Pressure Relief Valve

One (1) pressure relief valve 31-PSV-0103 is provided to protect the

accumu-lator and other hydraulic adjustment group components from excessive

pres-sure. The relief valve outlet is piped back to the hydraulic oil reservoir

3. Hydraulic Oil Supply Pressure Gauge

One (1) pressure gauge 31-PI-6504 is provided to monitor the hydraulic oil

supply pressure.

4. Crusher Hydraulic Cylinder

The hydraulic cylinder contains a volume of fluid. As the volume of fluid

be-low the piston is varied, the vertical position of the Crusher mantle is

changed.

5. Crusher Mantle Position Transmitter

Crusher Mantle Position

is monitored by a position transmitter. Vertical

movement of the mantle positively displaces the core of a differential

trans-former. Flux change is converted to a signal proportional to the position

31-ZY-0118, which is wired to a local position-indicating transmitter 31-ZIT-0118.

The transmitter then converts this signal to a 4-20mADC Crusher Mantle

Po-sition signal, which is wired to the Control system, where it is used to derive

the Crusher Mantle Low Position 31-ZAL-0118 and Crusher Mantle High

Position 31-ZAH-0118 set points for alarming and interlocking.

(52)

B. Normal Startup Sequence

Prior to starting the Crusher Hydraulic Adjustment Group, the operator should

first perform the following actions:

1. Verify that the Crusher Hydraulic Oil Reservoir is not at the Hydraulic Oil

Reservoir Low Level

31-LAL-6511.

2. Verify that the hydraulic oil pump's inlet and outlet isolation valves are fully

open.

After the operator has performed the actions listed above, the normal order of

starting the Crusher Hydraulic Adjustment Group is as follows:

Place the hydraulic oil supply pump in “AUTO”.

C. Normal Operation

Once the Crusher Hydraulic Adjustment Group is operating, normal operation

simply requires periodic adjustment of the volume of oil in the hydraulic cylinder,

in order to maintain the mantle elevation (position) at the desired point for

crush-ing operations. Also, normal operation ensures that the required function group

interlocks (listed in Section H of this chapter) are satisfied.

When the operator presses the “MANTLE RAISE” button 31-HS-6507A, the

hy-draulic oil supply pump automatically starts (if it is not already running), the

LOWER solenoid S2 remains de-energized and the RAISE solenoid S1 is

ener-gized. Oil is then ported towards the hydraulic cylinder. Simultaneously, a thirty

(30) minute run timer begins timing out. When the run timer expires, the

hydrau-lic oil supply pump is automatically stopped. The function of the run timer is to

allow the hydraulic oil to circulate through the filter.

When the operator presses the “MANTLE LOWER” button 31-HS-6507B, the

hy-draulic oil supply pump automatically stops (if it is running), the RAISE S1

solenoid remains de-energized and the LOWER solenoid S2 is energized.

Hydraulic oil from the main piston then drains back to the reservoir.

When the RAISE and LOWER solenoids are both de-energized, hydraulic oil in

the main piston is blocked off at the solenoid valve port to maintain mantle

posi-tion. Oil from the hydraulic oil supply pump is ported back to the reservoir.

(53)

dur-D. Normal Shutdown Sequence

The normal order for short-term shutdown of the Crusher Hydraulic Adjustment

Group is as follows:

After the Crusher has come to a complete stop, the hydraulic oil supply pump (if

operating) will automatically stop. If the run timer is still timing, the pump will

automatically stop after the timer times out.

Operate the LOWER push button 31-HS-6507B, to lower the mantle elevation to

the zero point (“fully-lowered” point of travel).

E. Abnormal and Emergency Shutdowns

1. Hydraulic Oil Pump Trip

If the Crusher is operating and the operating hydraulic oil pump trips, the

Con-trol system will provide an alarm to the operator. The Crusher will continue to

operate until shutdown by the operator.

2. Emergency Shutdowns

If the emergency stop push button(s) (by others) is depressed while the

Crusher Hydraulic Adjustment Group is running all function group motors

must be immediately and simultaneously stopped. Furthermore, all motors

associated with the Crusher Hydraulic Adjustment Group are prohibited from

restarting until the emergency stop push button(s) is reset.

F. HMI Control Summary

The following signals are displayed on the operator control stations:

1. Status of the Hydraulic Oil Reservoir level (within normal limits or alarm states

31-LAL-6511, 31-LALL-6511.

2. Status of Hydraulic Pump Motor ready, running, stopped (31-XL-6505 or

tripped 31-XA-6505)

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G. Alarms

Debounced Alarms

Alarm Tag Alarm Text LAL-6511 CRUSHER HYDRAULIC TANK LOW LEVEL LALL-6511 CRUSHER HYDRAULIC TANK LOW-LOW LEVEL PDAH-6506 CRUSHER HYDRAULIC OIL FILTER DIRTY

ZAL-0118 CRUSHER MANTLE LOW POSITION

(*low alarm to be set at or below the lowest normal recommended operating point. This point shall be field set at 50mm above the zero point of travel)

ZAH-0118 CRUSHER MANTLE HIGH POSITION

(*high alarm to be set at or above the highest normal recommended operating point. This point shall be field set at 25mm below the maximum point of travel)

Non-debounced Alarms

Alarm Tag Alarm Text 31-XA-6505 CRUSHER HYDRAULIC MAIN OIL PUMP TRIP

(If trips on run command)

31-XA-6510 CRUSHER HYDRAULIC STANDBY OIL PUMP TRIP (If trips on run command)

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H. Interlocks

Interlock Type Equipment or Control System permissive Signals

Safety Start Process HYDRAULIC RESERVOIR OIL LEVEL NOT

LOW (below the Hydraulic Oil Reservoir Low

Level )

X

HYDRAULIC OIL PUMP

HYDRAULIC RESERVOIR OIL LEVEL NOT LOW-LOW (below the Hydraulic Oil Reservoir

Low-Low Level )

X

MANTLE LOWER

SOLENOID VALVE

CRUSHER MANTLE POSITION NOT LOW

(below the Crusher Mantle Low Position )

_X

MANTLE RAISE

SOLENOID VALVE

CRUSHER MANTLE POSITION NOT HIGH

(below the Crusher Mantle High Position )

X

HYDRAULIC RESERVOIR OIL LEVEL NOT

LOW-LOW (below the Hydraulic Oil Reservoir

Low-Low Level )

X

MANTLE POSITION NOT LOW (BELOW

MINI-MUM NORMAL RECOMMENDED OPERATING

POINT)

X

HYDRAULIC START

PERMIS-SIVE FOR THE CRUSHER MAIN

DRIVE MOTOR C1HYSTART (SEE CHAPTER 7,

SECTION H) MANTLE POSITION NOT HIGH (ABOVE_{MAXIMUM NORMAL RECOMMENDED}

OPER-ATING POINT)

X

HYDRAULIC DE-LAYED STOP IN-TERLOCKS FOR THE CRUSHER MAIN DRIVE

MO-TOR C1HYSTOP (SEE CHAPTER 7,

SECTION H)

HYDRAULIC RESERVOIR OIL LEVEL NOT LOW-LOW (below the Hydraulic Oil Reservoir Low-Low Level )

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