A Total Solution For Your Concentrator: Thickener Commissioning Report

Thickener Commissioning Report
Outotec Large & Mega-lift Rakelift

Multi Pinion Drive (SBD)
Report Reference thk_ext_yymmdd_cse_thickener tcr @ 070514.doc
Customer Contact Details Outotec Representative

Customer
CSE Name
Contact Customer Support Engineer
Tel: +61 2 9984 2500
Telephone Fax: +61 2 9984 2501
Mobile: +61 XXX XXX XXX
Email xxxx.xxxx@outotec.com
www.outotec.com
Purchase Order No
Project Number Not Applicable
Equipment
Visit Type Rakelift Operation Report
Rakelift Operation Report No
Date of Service From dd mmm yyyy To dd mmm yyyy
Model Thickener Serial No.
A total solution for your concentrator
Form 305b Rev 0

Outotec Pty Ltd Australian Service Centre
ABN 74 003 491 165 Email: service.australia@outotec.com
1/25 Frenchs Forest Road, Frenchs Forest NSW 2086 Page 1 of 13
Level 2, 1 Walker Street, West Perth WA 6005 www.outotec.com
Equipment to be tested and

means of test (power/crane)
Fabricator/Location
Site Contact
Client - Present
1. PRE TEST CHECKS – these are to be performed prior to the rakelift operating
Item Description Comments Signature

and Date
1.1. Guide Blocks Shimmed/greased/nipples
Securely fastened
Fitted in correct
position/height
1.2. Rakelift Cylinders Clevis pins and clips fitted
Fittings accessible/tight
Hosed as per Hyd. Circuit
Rod orientation correct
Correct length
1.3. Hydraulic Hoses All fittings tight/no damage
Secured correctly
Sufficient length for lift
1.4. Rakelift Limits Set at correct position
Bracket/bolts fitted
Striker tabs work correctly
1.5. Rakelift Guards Complete and sound
Fits correctly in position
1.6. Gearbox/Motor Hold down bolts tight
All plugs fitted/tight
Oil filled (nominate ~L)
Correct size oil canister
Canister at correct height
Low oil switch fitted
Gasket fitted to motor
Case drain hose fitted
1.7. Hydraulic Oil filled (nominate ~L)
Powerpack Drive shut off valve fitted
Motor wired up correctly
Motor direction correct
OK/arrow
QA Form 307 for running
checks
1.8. Slewing Bearing Grease line(s) fitted
Greased
Form 305b Rev 0


and Date
1.9. Drive Pinion Level indicator fitted
Oil filled (nominate ~L)
Inspected for water ingress
Fill oil if funning >10 mins
All inspection hatches
fitted
1.10. Drive Coupling Bolts correct Spec/Config.
Bolts tight and recorded
Clears all items during lift
cycle
Rake position indicators on
1.11. Bridge Beam Pre- Measure left beam
camber mm
Measure right beam
mm
Compiles with drawings
1.12. Rakes Complete and fitted
Tie rods and struts fitted
Hydro test ports plugged
Underflow scraper fitted
Bed mass snout clear
Rakes will scrape to center
(clockwise looking from top)
1.13. Steady Bearing or Centralised – no preload
Guide Pin Bearing components fitted
Bearing post correct height
Underflow cone area clean
Has correct grade bolts
Correct material
1.14. Tank/Structure Orientation of
bridge/overflow/exits
Bolts all fitted to tension
Splice joint complete and
tensioned
Tank welds inspected
All bay bracing complete
Inner floor gore/cone infill
plates
Monorails have SWL and
end plates
Internal lining to Spec.
External lining to Spec.
Form 305b Rev 0


and Date
1.15. Feedwell Correct RL
Feedpipe Deflector cone gap to
Spec.
Baffles correct number and
place
Feedpipe supported OK
Autodils at correct height
Correct number and size of
Autodils
Lining to Spec
1.16. Bed Level Probe Bed level probe cable long
enough to remove probe
Bed mass fitted/calibrated
1.17. Turbodil Turbodil fitted correctly
Correct unit in correct
place
1.18. Rake Height Unit fitted
Target plate fitted/area
clear
1.19. Froth Removal Beach at correct level
Side of boom clears beach
Auto flash activates/timing
Run by hand prior to
power-up
Boom OK when there is no
water
1.20. Automatic Flocc Correctly fitted/complete
Addition Discharge not blocked
Isolation valves
1.21. Frothbuster Correctly fitted/complete
Ports not blocked
Isolation valves fitted
1.22. Roof All panels fitted
Access hatches fitted
Vent stacks fitted/secure
All bolts/seals fitted
Driveshaft seal fitted
Form 305b Rev 0

2. RUNNING CHECKS – These are to be performed during the initial operation of the
unit

and Date
2.1. Pre-Start Safety Bridge/Tank entry
restricted
Check all oil levels
Inside of tank clear
Rakes clear
internals/ladder
Bump motor/check
direction
Check e-stop works
2.2. System Prime Start motor/check for hose
leaks
Run DCVs to identify
lift/lower/forward/reverse
Run DCVs to bleed system
air
2.3. Start Rakelift Test Operate DCV for lift
– Lift Adjust flow control for
lifting speed
Monitor rakes/feedwell
clearances during lift cycle
2.4. Start Rakelift Test Operate DCV for lower
– Lower Adjust flow control valve
for lowering speed
At fully lowered clears floor
and cone
2.5. Start Rake Drive Operate DCV for drive
forward
Rakes clear wall, feedwell
deflector cone during
rotation and raise/lower
2.6. Slew Ring Slew ring rotates smoothly
2.7. Guide Blocks Operate smoothly

Do no jam or shudder
2.8. Guide Pin (if fitted) Snug fit in bearing
Travels full height
2.9. Rakelift Cylinders No leaks at full load
Circuit operates correctly
Smooth/free Travel
Lifts evenly
2.10. Hydraulic Hoses Any leaks under load
Free during full lift
Form 305b Rev 0


and Date
2.11. Rakelift Limits Trigger at upper limit
Trigger at lower limit
No false triggers
Holding bolts tight
Hoses crushed under base
at full lower
2.12. Rakelift Guard Rakelift clears guard
Hoses do not foul guard
2.13. Gearbox/Motor Runs smoothly

Flange rotates OK
Clears all items at full lift
2.14. Hydraulic Refer to check sheet
Powerpack DCVs operate OK
Pressure relief set/record
R/L lower speed set
Rake speed set/record
Check pressure switch set
2.15. Instruments/ Refer to check sheet
Electrical Check limit switches
trigger
Fill out site sheet on next
page
Access to bed level probe
2.16. General Items Froth boom clears beach
(where fitted) during operation
Form 305b Rev 0

3. POST TEST CHECKS – These items to be checked/completed a the end of the test
and before final handover

and Date
3.1. Rakelift Cylinders Fully lowered at end of test
Clean up leaks
3.2. Hydraulic Hoses Tied/fixed off
Clean up leaks
3.3. Rakelift Limits Seal cable gland holes
3.4. Rakelift Guard Left in position
3.5. Gearbox/Motor Breather fitted

Clean any leaks/spills
3.6. Hydraulic Leave shut off valve open
Powerpack Close motor terminal box
Clean up spills
Drain oil (shipping if
applicable)
3.7. Instruments All instruments and valves
fitted as per P&ID
3.8. Oil Fills Check Gearboxes/Pinions

Levels Turbodils
Powerpack
3.9. General Items Nameplate fitted on rakelift
Nameplate on tank
Do not weld stencils on
tank if required
Correct equipment
ID/labeling as per Spec.
Form 305b Rev 0

4. SITE ELECTRICAL AND LUBRICATION CHECKS
4.1. Field Devices:

Item Thickener Type or Input DCS Output Thk. Field indication or Signal
Signals not in to DCS control from Control control signal
use room DCS panel
Normal Panel Indicator Off
Level Switch – Gearbox Low Oil
4.2.
Gearbox oil Alarm On

Level Switch – Hydraulic Low Oil
4.3.
hydraulic oil
Alarm On
Temperature Sw Hydraulic Temp.
4.4.
– hydraulic oil
Alarm On

Pressure Switch
High Torque Alarm
4.5. – High Torque
(PP) Alarm On
Lifted Shuts off solenoid On

rakes raise + light
Limit Switch –
4.6. rakes fully raised
Rakes Raised
Free Off
Low’red Shuts off solenoid On

Limit Switch – rakes lower + light
4.7. rakes fully lowered
rakes lowered
Free Off
Pressure Switch Alarm Stops fill solenoid On

4.8. – Accumulator
Normal Off
High
Alarm Actuates fill On
Pressure Switch
4.9. – Accumulator solenoid
Low Normal Off
Healthy Allows drive to start On

Healthy Signal Light on panel
4.10.
from MCC Fault Prevents drive start On
Alarm light on panel
Pressure 0-100% Panel indicator
4.11. Transmtr Rake Rake Torque
Torque
Pressure 0-100% Panel Indicator
4.12. Transmtr Bed Bed Mass
Mass
Level Transmtr 0-100% Panel Indicator
4.13.
Bed Level Bed Level
0-100% Panel Indicator
Level Transmtr
4.14. Rake Height
Rake Height U/S
Form 305b Rev 0

5. Local Control Panel:

Item Thickener Type or Input DCS control Output Thk. Field indication Signal
Signals not in to DCS room from Control or control signal
use DCS panel
Forward Solenoid rakes
forward
Panel Switch Neutral
5.1.
Rake direction
Reverse Solenoid rakes
reverse
Auto Allows DCS On
Panel Switch control
5.2.
Rakelift Manual Disables DCS On
control
Remote Allows DCS
control
Hydraulic Off
5.3.
Powerpack motor
Local Disables DCS
control
PB Energizes Hyd On
Push Button
5.4. pump motor
Hydraulic Start
starter
PB De-energizes Hyd On
Push Button
5.5. pump motor
Hydraulic Stop
starter
PB Energizes On
Push Button
5.6. solenoid rake
Rakes Raise
raise
PB Energizes On
Push Button
5.7. solenoid rake
Rakes Lower
lower
Push Button High PB Releases latch On
5.8.
Torque Reset high torque
PB Energizes power On
Push Button Lamp
5.9. to all lights on
Test
panel
Alarm siren and Energized by
5.10.
beacon alarm signals
Form 305b Rev 0

6. LUBRICATION – Fill Record

Item Location Type Qty Fill Date By Level Comments Oil Test
ISO Check
Mode
6.1. Pinion Drive
6.2. Gearbox 1 Sightglass
6.3. Gearbox 2
6.4. Gearbox 3
6.5. Gearbox 4
6.6. Powerpack Sightglass
6.7. TurboDil 1
6.8. Turbol Dil 2
6.9. Rake Slides Visual
6.10. Guide Pin
6.11. Drive base seal
6.12. TurboDil Brg x2
6.13. Pinion Brg 1
6.14. Pinion Brg 2
6.15. Pinion Brg 3
6.16. Pinion Brg 4
6.17. Electric motor

Powerpack
6.18. Powerpack
Cooler Motor
Form 305b Rev 0

RAKE SURVEY
1............. mm .........mm
2............. mm .........mm
3............. mm .........mm
4............. mm .........mm
A ............ mm
B............. mm
C............. mm
D ............ mm
E............. mm
Project Name: Checked By:

Project Number: Date:
Form 305b Rev 0

7. COMMENTS ON MECHANICAL CONDITION
8. ACTION REQUIRED
Item Description Action By Due Date

Outotec
a.
b.
c.
d.
e.
Installer
f.
g.
h.
i.
j.
Customer
k.
l.
m.
n.
o.
List any improvements related to Drawings, Assembly, Fabrication and Commissioning:
CSE NAME
Customer Support Engineer
Tel: +61 X XXXX XXXX
Fax: +61 X XXXX XXXX
Mobile: +61 XXX XXX XXX
xxxx.xxxx@outotec.com
www.outotec.com
Form 305b Rev 0

Thickener Site Commissioning Report
PROJECT HANDOVER PUNCH LIST
Project Name & Project
Number: Manager: Date:
Item Noted by: Description, Priority Due Date Action by: Status Operational
Client Actions Required Low (dd mm yyyy) Responsible Completed Status
Outotec or Outstanding Med Party Pending (see Legend)
Works High
ACKNOWLEDGED BY:
Customer Support Customer
Engineer: Contact: Date:
LEGEND:
1. Inoperable 2. Water Fill Only 3. Run In Water 4. Compromised Run (refer Full Report) 5. Fully Operational
Form 305b Rev 0


A Total Solution For Your Concentrator: Thickener Commissioning Report

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A Total Solution For Your Concentrator: Thickener Commissioning Report

Încărcat de

Drepturi de autor:

Formate disponibile

Thickener Commissioning Report

Outotec Large & Mega-lift Rakelift

Report Reference thk_ext_yymmdd_cse_thickener tcr @ 070514.doc

Customer Contact Details Outotec Representative

A total solution for your concentrator

Form 305b Rev 0

Equipment to be tested and

Item Description Comments Signature

Form 305b Rev 0

Item Description Comments Signature

Form 305b Rev 0

Item Description Comments Signature

Form 305b Rev 0

Item Description Comments Signature

2.7. Guide Blocks Operate smoothly

Form 305b Rev 0

Item Description Comments Signature

2.13. Gearbox/Motor Runs smoothly

Form 305b Rev 0

Item Description Comments Signature

3.4. Rakelift Guard Left in position

3.5. Gearbox/Motor Breather fitted

3.8. Oil Fills Check Gearboxes/Pinions

Form 305b Rev 0

4. SITE ELECTRICAL AND LUBRICATION CHECKS

4.1. Field Devices:

Normal Panel Indicator Off

Normal Panel Indicator Off

Lifted Shuts off solenoid On

Low’red Shuts off solenoid On

Pressure Switch Alarm Stops fill solenoid On

Healthy Allows drive to start On

Form 305b Rev 0

5. Local Control Panel:

Form 305b Rev 0

6. LUBRICATION – Fill Record

6.2. Gearbox 1 Sightglass

6.6. Powerpack Sightglass

6.8. Turbol Dil 2

6.9. Rake Slides Visual

6.10. Guide Pin

6.11. Drive base seal

6.12. TurboDil Brg x2

6.13. Pinion Brg 1

6.14. Pinion Brg 2

6.15. Pinion Brg 3

6.16. Pinion Brg 4

6.17. Electric motor

Form 305b Rev 0

Project Name: Checked By:

Form 305b Rev 0

7. COMMENTS ON MECHANICAL CONDITION

Item Description Action By Due Date

Form 305b Rev 0

Form 305b Rev 0

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