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Revision 1.0
IPJ 1500
User Instructions: Operations, Maintenance
CLIENT NAME
EQUIPMENT LOCATION
SITE
PROJECT
MODEL
IPJ 1500
10 - 200
Volume (L)
1600
0 50
Concentrate (t/hr)
0.5 20
Tails (m /hr)
0 - 120
3
0 - 100
2 8 @ +350 kPa
50 250
0 - 20
2500 10000
Hydraulic Temperature ( C)
< 70
CLIENT NOTES
ii
Revision 1.0
IPJ 1500
User Instructions: Operations, Maintenance
CHANGE RECORD
iii
Revision
Date
Author
Sections/Pages
Affected
Remarks
0.1
25/02/11
S. Waters
All
1.0
13/04/12
S. Waters
All
Release
Revision 1.0
IPJ 1500
User Instructions: Operations, Maintenance
FOREWORD
Gekko Systems specialises in the design, development and distribution of innovative mineral processing equipment
and systems with a particular focus on gravity separation. Long-term relationships based on trust and mutual
benefit, as well as an emphasis on innovation are the cornerstones of our philosophy.
Gekko is the world leader in modular pre-concentration and gravity gold recovery circuits. Manufacture and
assembly of the modular components can be managed in-house utilizing both skilled engineering staff and our
network of key suppliers. Because of this, we have implemented a range of significant step-change lean mineral
processing systems, the most recent of which is an underground processing plant. The Python Underground
Processing System is a modular, transportable processing plant for use on the surface or in underground drifts with
little to no additional excavation. It provides miners with a flexible, robust, low cost, low energy pre-concentration
process for the recovery of gold and/or heavy minerals.
Gekko also offers a range of proprietary equipment including:
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Electrowinning cell
Revision 1.0
IPJ 1500
User Instructions: Operations, Maintenance
Table of Contents
1.0 GENERAL INFORMATION ..........................................................................................................................7
1.1 About this Manual ..............................................................................................................................8
1.1.1 Manual Purpose ...................................................................................................................8
1.1.2 Manual Scope ......................................................................................................................8
1.1.3 Manual Use and On-site Application ....................................................................................8
1.1.4 Disclaimer.............................................................................................................................9
1.1.5 Warnings, Cautions and Notes ............................................................................................9
1.2 Safe Work Procedures .....................................................................................................................10
1.2.1 General ...............................................................................................................................10
1.2.2 Guarding.............................................................................................................................10
1.2.3 Isolation Procedures ..........................................................................................................10
1.2.4 Stored Energy ....................................................................................................................11
1.2.5 Working at Heights .............................................................................................................12
1.2.6 Housekeeping Standards ...................................................................................................12
1.2.7 Personnel Qualification & Training .....................................................................................12
1.2.8 Noise Levels .......................................................................................................................13
1.2.9 Recycling and End of Product Life .....................................................................................13
2.0 EQUIPMENT INFORMATION ....................................................................................................................14
2.1 IPJ Key Features ..............................................................................................................................15
2.1.1 IPJ General Assembly ........................................................................................................15
2.1.2 Screen ................................................................................................................................17
2.1.3 Ragging ..............................................................................................................................18
2.1.4 Control System ...................................................................................................................19
2.1.5 Air Release Systems ..........................................................................................................21
2.1.6 Alarms, Indicators and Protective Devices (where fitted) ..................................................22
2.3 Handling, Transport and Storage .....................................................................................................23
2.3.1 Lifting ..................................................................................................................................23
2.3.2 Storage Short Term .........................................................................................................23
2.3.3 Storage Long Term .........................................................................................................23
3.0 OPERATIONAL GUIDELINES ...................................................................................................................24
3.1 Pre-start Checks ...............................................................................................................................25
3.2 Operational Requirements ...............................................................................................................25
3.2.1 Pressure Differentials .........................................................................................................25
3.2.2 Feed Preparation ...............................................................................................................26
3.2.3 Hose Sizes and Expected Flows........................................................................................26
3.2.4 Concentrate Transport .......................................................................................................27
3.2.5 Flushing Points ...................................................................................................................27
3.2.6 Power Requirements ..........................................................................................................28
3.2.7 Water Addition ....................................................................................................................28
3.2.8 Ragging ..............................................................................................................................30
3.2.9 Ram Stroke Ratio ...............................................................................................................30
3.3 Start-Up Procedure...........................................................................................................................31
3.4 Shut-Down Procedure ......................................................................................................................32
3.5 Influence of Key Variables on Output ...............................................................................................33
3.6 Operator Checklist ............................................................................................................................34
3.7 Hazard control ..................................................................................................................................35
3.8 Isolation ............................................................................................................................................35
3.9 Unscheduled stops ...........................................................................................................................35
3.10 Emergency .....................................................................................................................................35
4.0 MAINTENANCE ..........................................................................................................................................36
4.1 Maintenance Management System ..................................................................................................37
4.2 Maintenance Alert.............................................................................................................................37
4.3 InLine Pressure Jig (IPJ) Schedule ..................................................................................................38
4.3.1 Schedule ............................................................................................................................38
4.3.2 Lube Schedule ...................................................................................................................39
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Revision 1.0
IPJ 1500
User Instructions: Operations, Maintenance
Revision 1.0