Brassengineeringinternational 151112220903 Lva1 App6891

Toromocho Tailings Pipelines
Tailings Pipelines Project Overview

The Tailings Pipelines were designed in two phases:
Initial Phase
Design to Startup:
Nominal Capacity:
Design Capacity:
2009 to 2014
124,000 dry t/d
155,000 dry t/d
Expansion Phase
Design Completed:
Nominal Capacity:
Design Capacity:
2015
54,000 dry t/d
70,000 dry t/d
11/11/2015
Slide 2
Tailings Pipelines Project Overview

Initial System Design
Located in the District of Morococha, Yauli Province, Junin Region,

Peru.
The Toromocho project mines copper, molybdenum, and silver with
respective grades of 0.48%, 0.019%, and 6.88 grams per ton
Ore Reserve is estimated to 1526 million metric tons
Pump Station elevation is 4523 masl and terminates 4.7 km
distance at 4777 masl (up hill).
Due to pressure requirements the pump station uses 10 of the
largest positive displacement pumps (8 + 2 mode) operating in
parallel
Due to number of pumps it is the largest pump station of its kind
Estimated Annual production:
One million metric tons of copper,
Ten thousand metric tons of molybdenum
Four million ounces of silver
And ~ 44 million metric tons of tailings
Expansion System Design

~26 million metric tons annually of tailings
Stand alone system adding four additional pumps operating in

parallel
11/11/2015
Slide 3
Initial Tailings Pipeline

Process Design Criteria:
Scope: from flange on P/S suction headers
Capacity:
Nominal = 5176 t/h
Design = 6470 t/h
Pump Station Elevation: 4,520 masl
Highest Discharge Elevation:
Phase I: 4,777 masl
Phase II: 4,890 masl
Pipeline length:
Phase I: 4,707 m
Phase II: 5,400m
Tailings Slurry Concentration:
Minimum = 69%
Maximum = 71%
Actual experience tailings thickened to 65%
Design Life:
30 years
11/11/2015
Slide 4
Initial Tailings Pipeline
Slurry Characteristics:
Sample taken from Pilot Testing
Solids SG:Sample 1 and 2 = 2.77 (used for
design) to 2.92
Handling Tests: Shutdown / Restart ability
are good, no serious problems are
foreseen
11/11/2015
Slide 5
Initial System Operating Range

Initital Toromocho Tailings System - Sample 2
7000
Contingency
Design Tonnage
6500
62.0%
63.0%
Limiting Velocity
6000
Q 5.8 pumps
Throughput, dry t/h
61.0%
5500
5000
64.0%
65.0%
Nominal Tonnage
66.0%
67.0%
4500
68.0%
Operating Range
69.0%
70.0%
4000
Nominal
Q 10 pumps
3500Limiting Velocity
Design Tonnage
Q 8 pumps
3000
2500
60.0%
3000
3500
4000
4500
Flow,
11/11/2015
5000
5500
6000
m3/h
Slide 6
Initial System 10 Pumps Operating @ 100 %

Diameter
34.000
NPS
Cw
68.80% %
Capacity
158,939 dry t/d
Sfac
1.100
10.000
7000
Contingency
Design Tonnage
6500
62.0%
63.0%
Limiting Velocity
6000
Q 5.8 pumps
61.0%
He = 0
Throughput, dry t/h
1.000
5500
5000
64.0%
65.0%
Nominal Tonnage
66.0%
67.0%
4500
68.0%
Operating Range
69.0%
70.0%
4000
Nominal
3500Limiting VelocityRec
0.100
Q 10 pumps
Design Tonnage
Q 8 pumps
3000
2500
60.0%
3000
3500
4000
4500
Flow,
5000
5500
m3/h
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 5400.0
Q 5400.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Initial
11/11/2015
2.792
2.792
Cw, %
68.8%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
6,622 dry t/h
6,622 dry t/h
24.369
18.660
#Pumps
m/km
m/km
10
1000000
w-dot
w-dot
10000000
158,939 dry t/d
158,939 dry t/d
-dH/dX, NWT
-dH/dX, NWT
11.437
10.528
Speed, %
100%
m/km
m/km
Slide 7
6000

Diameter
34.000
NPS
Cw
67.50% %
Capacity
153,653 dry t/d
Sfac
1.100
10.000
7000
Contingency
Design Tonnage
6500
62.0%
63.0%
Limiting Velocity
6000
Q 5.8 pumps
61.0%
He = 0
Throughput, dry t/h
1.000
5500
5000
64.0%
65.0%
Nominal Tonnage
66.0%
67.0%
4500
68.0%
Operating Range
69.0%
70.0%
4000
Nominal
0.100
Q 10 pumps
Design Tonnage
Q 8 pumps
3000
2500
60.0%
3000
3500
4000
4500
Flow,
5000
5500
m3/h
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 5400.0
Q 5400.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Initial
11/11/2015
2.792
2.792
Cw, %
67.5%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
6,402 dry t/h
6,402 dry t/h
18.209
15.319
#Pumps
m/km
m/km
10
1000000
w-dot
w-dot
10000000
153,653 dry t/d
153,653 dry t/d
-dH/dX, NWT
-dH/dX, NWT
10.849
10.054
Speed, %
100%
m/km
m/km
Slide 8
6000

Diameter
34.000
NPS
Cw
60.00% %
Capacity
125,946 dry t/d
Sfac
1.100
10.000
7000
Contingency
Design Tonnage
6500
62.0%
63.0%
Limiting Velocity
6000
Q 5.8 pumps
61.0%
He = 0
Throughput, dry t/h
1.000
5500
5000
64.0%
65.0%
Nominal Tonnage
66.0%
67.0%
4500
68.0%
Operating Range
69.0%
70.0%
4000
Nominal
Rec
0.100
Q 10 pumps
Design Tonnage
Q 8 pumps
3000
2500
60.0%
3000
3500
4000
4500
Flow,
5000
5500
m3/h
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 5400.0
Q 5400.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Initial
11/11/2015
2.792
2.792
Cw, %
60.0%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
5,248 dry t/h
5,248 dry t/h
8.877
8.584
#Pumps
m/km
m/km
10
1000000
w-dot
w-dot
10000000
125,946 dry t/d
125,946 dry t/d
-dH/dX, NWT
-dH/dX, NWT
8.747
8.351
Speed, %
100%
m/km
m/km
Slide 9
6000
Initial System 8 Pumps Operating @ 72.5 %

Diameter
34.000
NPS
Cw
60.00% %
Capacity
73,049 dry t/d
Sfac
1.100
10.000
7000
Contingency
Design Tonnage
6500
62.0%
63.0%
Limiting Velocity
6000
Q 5.8 pumps
61.0%
He = 0
Throughput, dry t/h
1.000
5500
5000
64.0%
65.0%
Nominal Tonnage
66.0%
67.0%
4500
68.0%
Operating Range
69.0%
70.0%
4000
Nominal
Rec
0.100
Q 10 pumps
Design Tonnage
Q 8 pumps
3000
2500
60.0%
3000
3500
4000
4500
Flow,
5000
5500
m3/h
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 3132.0
Q 3132.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Initial
11/11/2015
1.619
1.619
Cw, %
60.0%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
3,044 dry t/h
3,044 dry t/h
3.633
3.731
#Pumps
1000000
w-dot
w-dot
m/km
m/km
10000000
73,049 dry t/d
73,049 dry t/d
-dH/dX, NWT
-dH/dX, NWT
3.257
3.095
Speed, %
73%
m/km
m/km
Slide 10
6000
Initial System 8 Pumps Operating @ 72.5 %

Diameter
34.000
NPS
Cw
67.00% %
Capacity
87,964 dry t/d
Sfac
1.100
10.000
7000
Contingency
Design Tonnage
6500
62.0%
63.0%
Limiting Velocity
6000
Q 5.8 pumps
61.0%
He = 0
Throughput, dry t/h
1.000
5500
5000
64.0%
65.0%
Nominal Tonnage
66.0%
67.0%
4500
68.0%
Operating Range
69.0%
70.0%
4000
Nominal
Rec
0.100
Q 10 pumps
Design Tonnage
Q 8 pumps
3000
2500
60.0%
3000
3500
4000
4500
Flow,
5000
5500
m3/h
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 3132.0
Q 3132.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Initial
11/11/2015
1.619
1.619
Cw, %
67.0%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
3,665 dry t/h
3,665 dry t/h
13.402
10.830
#Pumps
1000000
w-dot
w-dot
m/km
m/km
10000000
87,964 dry t/d
87,964 dry t/d
-dH/dX, NWT
-dH/dX, NWT
4.018
3.722
Speed, %
73%
m/km
m/km
Slide 11
6000

Diameter
34.000
NPS
Cw
68.80% %
Capacity
127,151 dry t/d
Sfac
1.100
10.000
7000
Contingency
Design Tonnage
6500
62.0%
63.0%
Limiting Velocity
6000
Q 5.8 pumps
61.0%
He = 0
Throughput, dry t/h
1.000
5500
5000
64.0%
65.0%
Nominal Tonnage
66.0%
67.0%
4500
68.0%
Operating Range
69.0%
70.0%
4000
Nominal
0.100
Q 10 pumps
Design Tonnage
Q 8 pumps
3000
2500
60.0%
3000
3500
4000
4500
Flow,
5000
5500
m3/h
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 4320.0
Q 4320.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Initial
11/11/2015
2.234
2.234
Cw, %
68.8%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
5,298 dry t/h
5,298 dry t/h
23.053
16.932
#Pumps
1000000
w-dot
w-dot
m/km
m/km
10000000
127,151 dry t/d
127,151 dry t/d
-dH/dX, NWT
-dH/dX, NWT
7.672
7.060
Speed, %
100%
m/km
m/km
Slide 12
6000
Pipeline Routing and Impoundment
11/11/2015
Slide 13
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Slide 14
Impoundment and Tailings Dam
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Slide 15
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Slide 16
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Slide 17
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Slide 18
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Slide 19
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Slide 20
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Slide 21
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Slide 22
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Slide 23
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Slide 24
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Slide 25
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Slide 26
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Slide 27
Discharge Points
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Slide 28
Discharge Points
11/11/2015
Slide 29
Discharge Points
11/11/2015
Slide 30
Discharge Points
11/11/2015
Slide 31
System Hydraulics
11/11/2015
Slide 32
Initial System SS Hydraulics

Conventional Slurry
11/11/2015
Slide 33
Initial System SS Hydraulics

Bingham Plastic Slurry
Conventional Slurry
11/11/2015
Slide 34
Pump Duty
Geho: TZPM 2000 (largest PD pump)

Continuous Service
Flow Capability: 655 m3/h each
Initial System used 540 m3/h each
Expansion System used 650 m3/h each
Pressure Capability:
Normal:
8,100 kPa
w/ GLORES modification: 11,000 kPa
11/11/2015
Slide 35
Pump Station Design
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Slide 36
Pump Station Design
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Slide 37
Pump Station Design
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Slide 38
Pump Station Design
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Slide 39
Pump Station Design
11/11/2015
Slide 40
Pipe Stress Analysis
11/11/2015
Slide 41

Several unique difficulties in Mechanical Design of Toromocho Tailings
Pump Station
Tailings pump station is situated on an earthwork bench and the space
available for piping was not sufficient to accommodate the preferred
pump station design
Pump station is located in harsh, mountainous conditions 4,520m above
sea level
Pump station will experience high pressures and flows and the
possibility of large pressure fluctuations
11/11/2015
Slide 42

Preferred Pump Discharge Arrangement

11/11/2015
Slide 43

Preferred pump station layout
Pump discharge will incorporate bends to take the pipe from the pump
discharge nozzle to the station floor. Once on the floor the piping will
connect to the anchored discharge manifold
Piping is much easier to restrain because pipe supports can be mounted
directly to platforms on the floor
Pipe bends between the discharge nozzle and the discharge manifold
create flexibility in the piping
11/11/2015
Slide 44

The Toromocho Tailings Pump Station is located on an bench only about
40m wide
BRASS developed a station arrangement in which the discharge manifold
is at the same elevation as the discharge nozzle
Eliminated the space between the pump discharge and manifold taken
up by the two pipe bends
Reduced piping flexibility to absorb temperature expansion and
contraction
11/11/2015
Slide 45

Straight Discharge Pipe
11/11/2015
Slide 46

The mine owners elected to save material and construction costs by leaving
the tailings pump station exposed to the elements without any protective
structure.
Toromocho mine site sees large temperature changes both between day
and night and between seasons. The mine site can experience
temperatures as low as -4C and as high as 25C with an average
temperature of 7C
Such a large change in temperatures will result in significant pipe
expansion and contraction
11/11/2015
Slide 47

Pipe Expansion
Simplified calculation for the expansion and contraction of pipe

For a 5.5m, 12in NPS piece of pipe (same diameter and approximate
length as the pump discharge pipe) and an ambient temperature of 7C,
expansion almost 2 mm
=
=
=
=
11/11/2015
Slide 48

This is a seemingly small change in length. When the Elastic

Modulus of the pipe is considered the force that can be
developed is easily enough to overstress piping and pump
nozzles if the system is too rigid.
11/11/2015
Slide 49

The stiffness and location of pipe supports were carefully analyzed and
many iterations of the design were considered before a final solution was
reached
Caesar II simulations were run to analyze the pipe stresses
Two main over stress issues needed to be solved. Both issues were most
severe when low temperature pipe contraction was considered
straight pump discharge lines pull the discharge manifold laterally
large S-bend located after the discharge manifold stretched by the
contracting manifold
11/11/2015
Slide 50

S-Bend
11/11/2015
Slide 51

To reduce stress on the manifold and pump nozzles, BRASS used flexible
supports which allow the manifold piping to move laterally as the pipe
contracts
Over stress issue at the S-bend not as easy to fix
Possible solution: fix the manifold piping with very rigid supports
Prevent the manifold piping from pulling on the S-bend as
strongly
Has the effect of increasing the pump nozzle loads to

unacceptable levels
11/11/2015
Slide 52

After a number of design iteration BRASS discovered that a special support
needed to be designed
Support must be very rigid in the axial direction of the piping and
simultaneously flexible in the lateral direction
Developed large plate oriented in the direction of the pipe axis
Reinforcing ribs were added to achieve the required lateral and vertical
stiffness.
Support is located near the middle of the discharge manifold
11/11/2015
Slide 53

BRASS engineers needed to complete a vibrational or harmonic analysis of
the pump station. PD pumps and other oscillating equipment cause
harmonic excitations in piping
Excitation is in the form of pressure pulsations
BRASS coordinated vibrational analysis with GEHO engineers specializing
in pressure pulsation
With a combination of pump phase synchronization and properly
charged dampers the total pressure pulsation is less than 2% of the
maximum pressure for the GEHO TZPM2000 pumps
11/11/2015
Slide 54

Even small pressure pulsations can cause large deflection in piping if the
excitation frequency of the pump is close to the natural frequency of the
piping
The first mode of vibration of the piping should be signifigantly greater
than the pumps nominal frequency of excitation and must be greater
than the pumps maximum excitation to ensure no resonant vibration
will take place
11/11/2015
Slide 55

Frequency of Excitation Calculation

i(rpm)n
fe
60
f e : Frequency of Excitation (Hz)
i
: Numbers of pistons
rpm : Rotations per minute

n
11/11/2015
: Fundamental frequency, n=1,2,3..
Slide 56

The pumps nominal frequency of excitation is 4Hz and maximum
frequency of excitation is 5 Hz
Upon first analysis BRASS found that the piping natural frequency was
too low, due to the flexible supports
A number of iterations were made to adjust the stiffness and location of
supports to increase the piping natural frequency
The piping natural frequency was increased to approximately 6Hz. This is
high enough to prevent resonant vibration.
11/11/2015
Slide 57

The stress and flexibility analysis of the Toromocho

Tailings Pump Station presented numerous unique
engineering challenges. BRASS Engineering
International was able to develop a design which
overcame the space limitations, harsh environment,
and possible harmonic resonance of the pipe caused
by pressure pulsation.
11/11/2015
Slide 58
Pre-com, Com, Startup
11/11/2015
Slide 59
Low, Medium, and High Pressure Pre-charge
Nitrogen charged Pulsation dampeners
11/11/2015
Slide 60

Early pre-commissioning problems
Urethane lined pipe was welded on causing the lining to be compromised
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Slide 61
Photo shows field constructed Y on pump discharge line
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Slide 62
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Slide 63

Process Design Criteria:
Scope: from bottom of thickeners
Capacity:
Nominal = 2250 t/h
Design = 2916 t/h
Pump Station Elevation: 4,520 masl
Highest Discharge Elevation: 4,777 masl
Pipeline length: 4707 m
Tailings Slurry Concentration:
Minimum = 60.0%
Maximum = 68.8%
Based upon existing system the actual
experience tailings thickened to 65%
Design Life: 5 years
11/11/2015
Slide 64
Slurry Characteristics:
Sample taken from existing operation
Solids SG:
Sample 1: 2.89
Sample 2: 2.84
Handling Tests: Shutdown / Restart ability
are good, no serious problems are
foreseen
11/11/2015
Slide 65
Expansion System Operating Range
11/11/2015
Slide 66

Operating Range
Toromocho Tailings System Expansion - Sample 2

3500
Contingency
Q 2.4 pumps
62.0%
3000
Design Tonnage
63.0%
Limiting Velocity
Throughput, dry t/h
61.0%
64.0%
2500
65.0%
Nominal Tonnage
66.0%
67.0%
2000
Operating Range
68.0%
69.0%
70.0%
Nominal
1500
Q 4 pumps
Limiting Velocity
Design Tonnage
Q 3 pumps
1000
1300
60.0%
1500
1700
1900
2100
Flow,
11/11/2015
2300
2500
2700
m3/h
Slide 67
Expansion System 4 Pumps Operating @ 100 %

Diameter
24.000
NPS
Cw
68.80% %
Capacity
77,370 dry t/d
Sfac
1.100
10.000
3500
Contingency
Q 2.4 pumps
62.0%
3000
Design Tonnage
63.0%
Limiting Velocity
61.0%
Throughput, dry t/h
1.000
He = 0
64.0%
2500
65.0%
Nominal Tonnage
66.0%
67.0%
2000
Operating Range
68.0%
69.0%
70.0%
Nominal
1500
Q 4 pumps
Limiting Velocity
Rec
Design Tonnage
0.100
Q 3 pumps
1000
1300
60.0%
1500
1700
2100
1900
2500
2700
m3/h
Flow,
2300
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 2600.0
Q 2600.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Expansion
11/11/2015
2.800
2.800
Cw, %
68.8%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
3,248 dry t/h
3,224 dry t/h
34.202
46.561
#Pumps
m/km
m/km
1000000
w-dot
w-dot
10000000
77,959 dry t/d
77,370 dry t/d
-dH/dX, NWT
-dH/dX, NWT
15.713
17.960
Speed, %
100%
m/km
m/km
Slide 68

Diameter
24.000
NPS
Cw
65.00% %
Capacity
69,982 dry t/d
Sfac
1.100
10.000
3500
Contingency
Q 2.4 pumps
62.0%
3000
Design Tonnage
63.0%
Limiting Velocity
61.0%
Throughput, dry t/h
1.000
He = 0
64.0%
2500
65.0%
Nominal Tonnage
66.0%
67.0%
2000
Operating Range
68.0%
69.0%
70.0%
Nominal
1500
Q 4 pumps
Limiting Velocity
Rec
Design Tonnage
0.100
Q 3 pumps
1000
1300
60.0%
1500
1700
2100
1900
2500
2700
m3/h
Flow,
2300
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 2600.0
Q 2600.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Expansion
11/11/2015
2.800
2.800
Cw, %
65.0%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
2,936 dry t/h
2,916 dry t/h
20.244
30.402
#Pumps
m/km
m/km
1000000
w-dot
w-dot
10000000
70,464 dry t/d
69,982 dry t/d
-dH/dX, NWT
-dH/dX, NWT
14.036
15.560
Speed, %
100%
m/km
m/km
Slide 69

Diameter
24.000
NPS
Cw
60.00% %
Capacity
61,170 dry t/d
Sfac
1.100
10.000
3500
Contingency
Q 2.4 pumps
62.0%
3000
Design Tonnage
63.0%
Limiting Velocity
61.0%
Throughput, dry t/h
1.000
He = 0
64.0%
2500
65.0%
Nominal Tonnage
66.0%
67.0%
2000
Operating Range
68.0%
69.0%
70.0%
Nominal
1500
Q 4 pumps
Limiting Velocity
Rec
Design Tonnage
0.100
Q 3 pumps
1000
1300
60.0%
1500
1700
2100
1900
2500
2700
m3/h
Flow,
2300
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 2600.0
Q 2600.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Expansion
11/11/2015
2.800
2.800
Cw, %
60.0%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
2,564 dry t/h
2,549 dry t/h
13.744
19.498
#Pumps
m/km
m/km
1000000
w-dot
w-dot
10000000
61,537 dry t/d
61,170 dry t/d
-dH/dX, NWT
-dH/dX, NWT
12.670
13.644
Speed, %
100%
m/km
m/km
Slide 70

Diameter
24.000
NPS
Cw
60.00% %
Capacity
36,702 dry t/d
Sfac
1.100
10.000
3500
Contingency
Q 2.4 pumps
62.0%
3000
Design Tonnage
63.0%
Limiting Velocity
61.0%
Throughput, dry t/h
1.000
He = 0
64.0%
2500
65.0%
Nominal Tonnage
66.0%
67.0%
2000
Operating Range
68.0%
69.0%
70.0%
Nominal
1500
Q 4 pumps
Limiting Velocity
Rec
Design Tonnage
0.100
Q 3 pumps
1000
1300
60.0%
1500
1700
2100
1900
2500
2700
m3/h
Flow,
2300
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 1560.0
Q 1560.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Expansion
11/11/2015
1.680
1.680
Cw, %
60.0%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
1,538 dry t/h
1,529 dry t/h
7.272
14.555
#Pumps
m/km
m/km
1000000
w-dot
w-dot
10000000
36,922 dry t/d
36,702 dry t/d
-dH/dX, NWT
-dH/dX, NWT
4.991
5.416
Speed, %
60%
m/km
m/km
Slide 71

Diameter
24.000
NPS
Cw
64.00% %
Capacity
40,885 dry t/d
Sfac
1.100
10.000
3500
Contingency
Q 2.4 pumps
62.0%
3000
Design Tonnage
63.0%
Limiting Velocity
61.0%
Throughput, dry t/h
1.000
He = 0
64.0%
2500
65.0%
Nominal Tonnage
66.0%
67.0%
2000
Operating Range
68.0%
69.0%
70.0%
Nominal
1500
Q 4 pumps
Limiting Velocity
Rec
Design Tonnage
0.100
Q 3 pumps
1000
1300
60.0%
1500
1700
2100
1900
2500
2700
m3/h
Flow,
2300
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 1560.0
Q 1560.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Expansion
11/11/2015
1.680
1.680
Cw, %
64.0%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
1,715 dry t/h
1,704 dry t/h
12.884
23.753
#Pumps
m/km
m/km
1000000
w-dot
w-dot
10000000
41,159 dry t/d
40,885 dry t/d
-dH/dX, NWT
-dH/dX, NWT
5.442
6.042
Speed, %
60%
m/km
m/km
Slide 72

Diameter
24.000
NPS
Cw
68.80% %
Capacity
77,370 dry t/d
Sfac
1.100
10.000
3500
Contingency
Q 2.4 pumps
62.0%
3000
Design Tonnage
63.0%
Limiting Velocity
61.0%
Throughput, dry t/h
1.000
He = 0
64.0%
2500
65.0%
Nominal Tonnage
66.0%
67.0%
2000
Operating Range
68.0%
69.0%
70.0%
Nominal
1500
Q 4 pumps
Limiting Velocity
Rec
Design Tonnage
0.100
Q 3 pumps
1000
1300
60.0%
1500
2100
1900
1700
2500
2700
m3/h
Flow,
2300
0.010
0.001
10
100
1000
Sample #
Sample #
1
2
Q 2600.0
Q 2600.0
m3/h
m3/h
Sample #
Sample #
1
2
V
V
m/s
m/s
Expansion
11/11/2015
2.800
2.800
Cw, %
68.8%
Re
w-dot
w-dot
-dH/dX, BP
-dH/dX, BP
10000
100000
3,248 dry t/h
3,224 dry t/h
34.202
46.561
#Pumps
1000000
w-dot
w-dot
m/km
m/km
10000000
77,959 dry t/d
77,370 dry t/d
-dH/dX, NWT
-dH/dX, NWT
15.713
17.960
Speed, %
100%
m/km
m/km
Slide 73
Operating Ranges:
Initital Toromocho Tailings Systems - Comparison
7000
Design Tonnage
6000
62.0%
63.0%
Limiting Velocity
Q 5.8 pumps
Nominal Tonnage
61.0%
5000
64.0%
Throughput, dry t/h
65.0%
66.0%
67.0%
4000
68.0%
Limiting Velocity
69.0%
70.0%
Operating Range
3000
Nominal
Q 10 pumps
Design Tonnage
Design Tonnage
Q 8 pumps
60.0%
Nominal Tonnage
Limiting Velocity
2000
Nominal
Design Tonnage
Q 4 pumps
Limiting Velocity
1000
1300
1800
2300
2800
3300
3800
4300
4800
5300
5800
Flow, m3/h
11/11/2015
Slide 74
Operating Ranges:
Toromocho Tailings Systems - Complete Operating Range
12000
62.0%
63.0%
10000
Limiting Velocity
Both @ Design Tonnage
Q 5.8 pumps
61.0%
64.0%
8000
65.0%
Both @ Nominal Tonnages
66.0%
Throughput, dry t/h
67.0%
68.0%
Initial Design Tonnage
69.0%
6000
70.0%
Initial Nominal
Initial Nominal Tonnage
Q 10 pumps
Operating Ranges
Initial Limiting Velocity
Initial Design Tonnage

Q 8 pumps
4000
60.0%
Limiting Velocity
Expan Design
Tonnage
Exansion Nominal
Expansion Design
Expan Nominal Tonnage
2000
Q 4 pumps
w-14 pump
Expan Limiting Velocity
Total NominalTonnage
Total Design Tonnage
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
Flow, m3/h
11/11/2015
Slide 75
Expansion System Hydraulics
11/11/2015
Slide 76
Expansion System SS Hydraulics

Conventional Slurry
11/11/2015
Slide 77
Expansion System SS Hydraulics

Bingham Plastic Slurry
Conventional Slurry
11/11/2015
Slide 78
Expansion System Mechanical Design
11/11/2015
Slide 79
11/11/2015
Slide 80
11/11/2015
Slide 81
Available space for the new discharge pipe

11/11/2015
Slide 82

P/S West Side feed and discharge
11/11/2015
Slide 83

11/11/2015
Slide 84

P/S East Side feed and discharge
11/11/2015
Slide 85

P/S East Side feed and discharge
11/11/2015
Slide 86
Expansion System Pipe Stress Analysis
11/11/2015
Slide 87

Expansion Pipe Stress Analysis
The expansion system pipe stress analysis was more straight forward than
the work done for the original system
4 pumps spaced far apart allow the discharge manifold to be more
flexible
Elevated piping still required to avoid existing piping and structures
under the platform
Only one discharge manifold
More lateral space
Pipe bends used to bring discharge to station floor for East side
pumps increasing piping flexability
11/11/2015
Slide 88

Expansion System, Plant Discharge
11/11/2015
Slide 89
Acknowledgements
Brian Peer:
Brian Peer is a Mechanical Engineer specializing

in mechanical piping design and pipe stress
analysis.
Brian Peer was responsible for the Toromocho
Tailings Pipeline Pump Station Stress and
Flexibility Analysis.
Leroy Worthen:
Mr. Worthen served as commissioning and
start-up engineer for the project.
11/11/2015
Slide 90
Acknowledgements
Dr. George Shou (presentation reviewer):
VP and Chief engineer, BRASS Engineering
International, USA
Dr. Shou has over 30 years experience in slurry
pipeline engineering.
He was the project manager for basic
engineering, detailed engineering, construction
support and commissioning. Wushan Copper
tailings paste pipeline, 6km, 450 and 330mm
OD, in China. The pipeline was successfully
commissioned in September 2009.
11/11/2015
Slide 91
The End
&
Thank you
11/11/2015
Slide 92

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Toromocho Tailings Pipelines

Tailings Pipelines Project Overview

Toromocho Tailings Pipelines

Tailings Pipelines Project Overview

Located in the District of Morococha, Yauli Province, Junin Region,

Expansion System Design

Stand alone system adding four additional pumps operating in

Toromocho Tailings Pipelines

Initial Tailings Pipeline

Toromocho Tailings Pipelines

Initial Tailings Pipeline

Toromocho Tailings Pipelines

Initial System Operating Range

Throughput, dry t/h

Toromocho Tailings Pipelines

Initial System 10 Pumps Operating @ 100 %

158,939 dry t/d

Throughput, dry t/h

Toromocho Tailings Pipelines

Initial System 10 Pumps Operating @ 100 %

153,653 dry t/d

Throughput, dry t/h

Toromocho Tailings Pipelines

Initial System 10 Pumps Operating @ 100 %

125,946 dry t/d

Throughput, dry t/h

Toromocho Tailings Pipelines

Initial System 8 Pumps Operating @ 72.5 %

73,049 dry t/d

Throughput, dry t/h

Toromocho Tailings Pipelines

Initial System 8 Pumps Operating @ 72.5 %

87,964 dry t/d

Throughput, dry t/h

Toromocho Tailings Pipelines

Initial System 8 Pumps Operating @ 100 %

127,151 dry t/d

Throughput, dry t/h

Toromocho Tailings Pipelines

Pipeline Routing and Impoundment

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Impoundment and Tailings Dam

Toromocho Tailings Pipelines

Impoundment and Tailings Dam

Toromocho Tailings Pipelines

Impoundment and Tailings Dam

Toromocho Tailings Pipelines

Impoundment and Tailings Dam

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines

Toromocho Tailings Pipelines