PUMPS AND PIPELINES
no competitor offers , and adds value for the customer through reduced maintenance , spare parts and greater mining uptime .”
And , in Chile ’ s Atacama , it is encapsulated borehole pumps and cantilevered Etanorm pumps that help meet the region ’ s challenges .
Patricio Araya , Mining Head of KSB Chile , explained : “ Our customers require high-pressure pumps in a modular configuration that can be moved with the expansion of the open pit . The solution is to use horizontally positioned borehole pumps with a special configuration for sand filters encased in a pressurised shroud . This gives the customer flexibility and versatility because the equipment is compact , develops high pressures and is easy to move around the site .”
To accommodate increasing flows and discharge pressure , pumps are configured in series and in parallel specifically for the client ’ s requirements . Being coupled with diesel engines allows continuous , autonomous operation in places without electricity for 12-24 hours without refuelling , KSB claims .
Vertical Etanorm pumps and cantilever-type UPA pumps installed on a raft enable these pumps to handle the accumulation of water inside the mine , eliminating factors such as negative suction head at high altitudes .
Development of dewatering and dredge pump sets ( DnD ) as a solution for mining applications , especially for open-pit mine sites , is one example of KSB ’ s commitment to continuous product improvement and development .
To date , more than 260 DnD pumps with GIW ® LCC and LSA pumps have been installed in mines across Indonesia and Southeast Asia . In 2013 , KSB Indonesia launched a new model , the DnD Cruiser , based on enhancements requested by customers . KSB builds the entire diesel-driven pump unit on a barge , complete with fuel tank , vacuum pump , control panel , etc and ships them on trailers for easy commissioning at site .
Water management foundations
With a poll of mining operators carried out by water solutions company Xylem revealing that 63 % agree the growing cost of water and sustainable water management is their most pressing water-related issue on site , the company has come up with several steps to efficiently manage mine water on site .
“ From powerful and reliable pumping systems to smart technologies that automate processes , there is a wide range of support available ,” Jessy Parmar , Business Development Manager for the Industrial Marketing team at Xylem , explained .
The first step Xylem always advises is an audit of a mine ’ s total water management system . This five-stage process ensures a solid water management foundation is in place , according to the company .
For isolated or inaccessible mine sites or operations where manpower is limited , remote monitoring and control provides visibility of assets , and peace of mind , 24 / 7 , Xylem ’ s Jessy Parmar says
The steps are as follows : 1 . Perform a pumping system audit How are pumps operating relative to their best efficiency point ( BEP )? Are pumps sized properly ? Would a different type of pump perform more effectively for the application ? How are piping , valves and controls performing on site ?
All these questions and more should be asked and answered during such an audit .
2 . Optimise pump energy consumption for enhanced BEP performance “ Prime candidates are pumps that move large volumes of water over long distances or to much higher elevations ,” Parmar says . “ Ensure that air releases are installed to prevent the trapping of air at high points in the line . Non-return valves ensure the same water is not pumped repeatedly while also preventing backflow which is catastrophic to a pump ’ s resilience – based on the velocity of the backflow , an impeller can be stripped from the pump shaft . It is also important to ensure pumps are not ‘ snoring ’.”
3 . Optimise total cost of ownership Sizing your pump to operate as close to the BEP in conjunction with optimising the design of the hydraulic parts will reduce wear and energy consumption , which is directly related to cost savings , according to Parmar . Having the appropriate equipment in place with an effective maintenance schedule allows operators to achieve long service life with a low cost of ownership . Standardisation with the aid of devices such as variable frequency drives ( VFDs )
can also help control costs .
4 . Optimise the system Technology – such as VFDs , PLC controls and SCADA systems – can be a major enabler for ensuring the entire pumping system performs at the highest efficiency level , delivering the performance required at low energy and maintenance costs , and with the bare minimum of unplanned downtime . “ Such technologies with remote monitoring capabilities also support effective use of resources – staff and time ,” Parmar said .
5 . Contingency planning / emergency response Finally , an optimised system includes built-in protection against downtime caused by equipment failure . The first line of defence is effective monitoring and maintenance . However , the most critical equipment requires contingency planning and emergency backup such as redundant or replacement pumps .
A phased approach to smart tech “ Once you are confident you have the right pumping solutions in place , and each system is optimised , layering in smart technology can bring site efficiency , reliability and productivity to the next level ,” Parmar said . “ But how should you embark on introducing smart tech to your operation ?”
Bearing in mind a customised approach delivers maximum benefit , it can be helpful to look at a hypothetical scenario : an open-pit mining operator looking for an efficient dewatering solution , in this case .
The first step is to develop a customised solution using the most efficient dewatering pump to meet the head / flow requirements of the application . The pump should be paired with a VFD to ensure optimal performance .
As the mine expands and dewatering requirements increase , additional pumps may be needed . This second phase of integrating smart technologies could involve a PLC intelligent controller , such as the Flygt Multismart , being incorporated into the system . This enables the customer to easily control multiple pumps via the PLC or intelligent controller , according to Parmar .
A third phase would involve enhancing the dewatering system further by adding a remote monitoring and control ( M & C ) solution . Xylem ’ s Flygt cloud-based SCADA system connects to the Multismart control and allows the customer to monitor and control activity remotely . For isolated or inaccessible mine sites or operations where manpower is limited , remote M & C provides visibility of assets , and peace of mind , 24 / 7 , Parmar said .
52 International Mining | JUNE 2021