BECHTEL CHILE LTDA.

HYDRAULIC
DESIGN CRITERIA

24617-150-3DR-M10L-00002

FOR

Southern Peru Copper Corporation

TOQUEPALA CONCENTRATOR EXPANSION PROJECT

0 Issued for Construction

B 4/April/ 01 Issued for Approval CG FG FG RH VV
A 19/Mar/01 Issued for Coordination CG FG FG
REV. DATE REASON FOR REVISION BY CHECK EGS PE CLIENT
JOB NO. 24617 SHEET 1 OF
BECHTEL CHILE LTDA. DESIGN CRITERIA N° REV. 0
24617 –150-3DR-M10L-00002

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TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 REFERENCES

3.0 DESIGN CRITERIA FOR SLURRY SYSTEM

4.0 DESIGN CRITERIA FOR AQUEOUS FLUIDS HANDLING

5.0 DESIGN CRITERIA FOR COMPRESSED AIR HANDLING

APPENDIX A: Mc Elvain & Cave Chart

APPENDIX B: Warman Chart for Solids Influence on Centrifugal Pump Performance

APPENDIX C: “A New Launder Design Procedure”, AIME – 1978

APPENDIX D: “Launders” by Harold A. Linke, A.I.M.E. Mining

Technology, September 1939.

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1.0 INTRODUCTION

This document contains design criteria for all slurry, water and air transport systems at
Toquepala Concentrator Expansion Project for Southern Peru Copper Corporation

2.0 REFERENCES

The Hydraulic Design Criteria is used in conjunction with the following:

 Project Scope and Procedures Manual

 General and Special Project Conditions
 Design Criteria for Process 24617-DB-001
 Design Criteria for Piping Design 24617-150-3DR-P30L-00001
 Design Criteria for Mechanical Design 24617-150-3DR-M10L-00001
 Process Flow Diagrams
 Process P & ID’s
 “A New Launder Design Procedure” by H.R. Green, D.M. Lamb, and A.D.Taylor,
Mining Engineering, 1978.
 “Launders” by Harold A. Linke, A.I.M.E. Mining Technology, September 1939.

3.0 DESIGN CRITERIA FOR SLURRY SYSTEMS

The Slurry System covers pipelines, transfer boxes, turn boxes and launders which will
transport tailings and concentrate or other slurry by gravity or pressure in the Process
Plant for Toquepala Concentrator Expansion Project.

3.1 DESIGN CRITERIA FOR GRAVITY SLURRY SYSTEM

This section summarizes the criteria applied in the dimensioning of slurry gravity
transport.

3.1.1 TYPE OF FLOW

Gravity transport systems shall avoid full flow through closed pipelines,
specially the formation of siphons. Gravitational transport systems shall be
used wherever possible.

3.1.2 FLOW FLUCTUATIONS

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Dimensioning of slurry transport systems shall consider the flow

fluctuation over the metallurgical balance, as indicated in the Process
Design Criteria and Process Flow Diagrams.

3.1.3 HYDRAULIC CALCULATIONS

Calculations will be carried out according with the method described in “A

New Launder Design Procedure” AIME – 1978, (see Appendix C), or
the following alternative method:

Alternative Method for Launder Calculation:

A.-Flow by Launders and Pipe Launders Settling Velocity

The settling velocity will be calculated according to the Durand’s

formula modified by JRI S.A. (Juan Rayo Ingeniería S.A.):

VL= 1.25 x FL x 2 x g x h x (S-1)0.25

Where:

VL = Settling Velocity (m/s)

FL = Function of size and concentration of solids (see Mc Elvain
& Cave Chart, Appendix A)
g = Gravitational acceleration (m/s2)
h = Flow height (m)
S = Relative density of the solid with respect to the conveying
fluid (non dimensional)

This modified equation has been widely used with good success in
several Chilean mining projects (Collahuasi, Los Pelambres, Escondida
Fase 3.5). Original Durand’s equation gives very conservative results
for homogeneous and pseudo-homogeneous slurries and is better when
using it with particles above 2 mm.

B.-Normal Height Of The Flow

The classic Manning’s formula has been used for calculating the
normal height of the flow:

Q x n = S x R2/3
i1/2

Where:

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Q = slurry flow (m3/s)

n = Manning roughness coefficient
i = launder slope (indicated in decimals)
S = slurry cross-sectional area (m2)
R= hydraulic radius = S (m)
P
P = wet perimeter (m)

The following values have been considered for the Manning

roughness coefficient (n), according to “k” values (effective
roughness) proposed by “A New Launder Design Procedure”

Material n

HDPE 0.011
RUBBER 0.013
STEEL 0.012
CONCRETE 0.013
3.1.3.1 Flow Velocity (Gravity Flow)

In order to avoid settlement in the pipeline, in formula under

paragraph 3.1.3 (A). For nominal flow, a minimum flow velocity
10% higher than the settling velocity shall be used, and to prevent
accelerated wear in the pipeline (critical where changes direction
occur), the maximum flow velocity shall be limited to 6 m/s.

3.1.3.2 Roughness Coefficient (k)

Material k (mm)

Steel 0.728
HDPE 0.146
Rubber 1.350
Concrete 1.350

Reference: “A New Launder Design Procedure”

3.1.3.3 Restrictions

The design of the slurry transport system in Launders or Pipeline in

Flume must preferably consider that the flow height be restricted
to the following:

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D= Pipe Diameter
h= Stream depth
w= Launder Width

The slurry flow rate must be multiplied by the froth factor (see
specification 24617-DB-001 for froth factor used numbers) to
determine the actual flow rate with the following restrictions:

h = 0.3 - 0.7
D

h = 0.3 - 0.7
w

The normal flow height shall be determined as far as possible from

the critical regime, 1.4 < Fr < 0.8
(Critical Flow Fr=1.0)
Where:

Fr = V/(gxS/L)1/2 : Froude’s number

V = Flow velocity (m/s)
g = gravitational acceleration (m/s2)
S = Slurry cross-sectional area (m2)
L = Stream Width (m)

3.1.3.4 Launder Height

Dimensioning criteria for launder height, namely the freeboard

between the edge of the launder and the height of the flow will be
as follows:

 In runs without fitting and elbows, the free board shall be

at least equal to 0.5 m.

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 In areas with fitting, elbows or restrictions (transfer boxes,

stations, etc.), the free board shall be equal to 0.7 m.

 Speed height calculations shall be done considering the

maximum volume of flow.

3.1.3.5 Other Considerations

FROTH FACTOR (for design of:)

PIPE LAUNDER F.F. OPEN LAUNDER F.F.
Grinding Cyclone O/F 1.0 Grinding Cyclone O/F 1.0
Regrind Discharge 1.0 Rougher Concentrate 2.0
Regrind Cyclone O/F 1.2 Cleaner Concentrate 2.0
Cleaner Concentrate 2.0 Scavenger concentrate 2.0
Rougher Concentrate 2.0 Thickener Concentrate UF 1.0
Thickener Concentrate UF 1.0 Final Tailing 1.0
Reg. Cyc. O/F vertical pipe 1.6

3.2 DESIGN CRITERIA FOR SLURRY PUMPING SYSTEM

This chapter summarizes the criteria applied in the dimensioning of slurry

pumping systems.

3.2.1 FLOW FLUCTUATIONS

Flow fluctuations over or under the metallurgical balances are as indicated

in the Process Design Criteria and Process Flow Diagrams.

3.2.2 HYDRAULIC CALCULATIONS

3.2.2.1 Settling Velocity (VL)

Will be calculated according to the Durand’s formula modified by

JRI S.A. (Juan Rayo Ingeniería S.A.):

VL = 1.25 x FL x [2 x g x D x (S-1)]0.25

Where:
VL = Settling Velocity (m/s).

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FL = Function of size and concentration of solids (see Mc Elvain

& Cave Chart, Appendix A).
g = Gravitational acceleration (m/s2).
D = Inside diameter of pipeline (m).
S = Relative density of the solid with respect to the conveying
fluid (dimensionless).

3.2.2.2 Flow Velocity (Vf)

For nominal flow, flow velocity shall exceed the settling velocity.

In order to prevent an excessive wear in the pipe, the maximum

flow velocity shall be less than or equal to 5 m/s.

3.2.2.3 Head Losses, Darcy’s Method

The slurry flow is transported on a pseudo-homogenous regime

and friction losses will be calculated according to the classical
Darcy’s formula for pure fluid considering the viscosity of the
transported slurry.

The Head Losses calculation shall be cross checked with Hazen

and Williams empirical formula with suggested design values of
friction factor “C” between the following ranges:

C steel : 100
C Rubber : 120
C HDPE : 140

Roughness Coefficient

The following roughness coefficients ( have been considered in

accordance with the nature of system and the pipeline material:

Pressurized Lines (Slurry)

Material  (mm)

Steel 0.15
HDPE 0.07
Rubber 0.30

3.2.4 SLURRY VISCOSITY

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Variable viscosity according to the percent solids by weight of the slurry

shall be as follows:

Cw VISCOSITY
(cSt) centistoke
<25 3
25 – 45 3-5
45 – 55 5-8
55 – 70 8 – 20

Remarks

1.- According to specific event and as much as possible it would be

necessary to confirm these values with laboratory’s measures.

2.- For design with “A New Launder Design Procedure”, apparent

viscosity – volume concentration curve shall be used. The curve is
part of this calculation’s method.

3.3 JUNCTION BOXES, SAMPLING BOXES AND DISTRIBUTORS

Junction boxes will be used to change direction of launders and for joining large
flows. A junction box that collects either the process stream for sampling or the
sample reject will be called a sampling box.

A distributor will be used where it is necessary to divide a process slurry stream

into two or more streams of specified proportions having the same solids
concentration, size distribution and composition as the original stream.
Cylindrical distributors will be designed so that all outlet compartments are
symmetrical about the vertical centerline. Distributors normally will be fed
vertically from either the top or bottom. A two or 3-way split of the flow stream
may be done with rectangular distributor with a stilling compartment ahead of the
discharge compartment.

A splitter box may be used to divide the slurry flow two ways where closer
control of the flow rate and maintaining slurry composition is not demanded by
the process.

Overflow weir outlets, wherever used, will be sized in accordance with the
Francis Formula, as modified by Linke:

Q = K ( L-0.2H)H 3/2
Where:

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Q= flow, m3/s
K= Constant
= 1.84 (Weir discharge to free air)
= 1.56 (Weir discharge to a launder)
L= length of weir, m
H= level in box above weir invert, m

Junction boxes will be designed so that the entering stream will fall on a body of
slurry and not on the bottom or walls of the box. The volume will be sufficient to
absorb and dissipate the excessive kinetic energy of the entering stream but not
excessive to cause solid deposition and particle segregation. The boxes generally
will be designed by using the guidelines recommended by Linke in AIME Mining
Technology, September 1939. (see Appendix D).

3.4 DIMENSIONING OF TRANSFER BOXES

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Transfer boxes must be dimensioned so as to avoid slurry overflow and spattering.

For this purpose, the following conditions must be simultaneously applied to any
flow range defined by balance (see figure No 1).

Lp R >
0.5m

Hn
H  5 D

 0.5
m
1.2Bc
E=H
D

A 
0.3 m
Lc>2
Lp

Figure N° 1

 The width of the transfer box must be at least 2.0 times the width of the
feeding or discharge section of the box. The nearest side wall to be 400
mm from the edge of pipe.

 The vertical clearance of the outlet must be at least 20% more than the
critical Bernoulli (Bc) defined for maximum flow.

 Slurry transfer must be made ensuring the hydraulic independence between

the incoming and outgoing flow of the transfer box. For this purpose, it is
recommended to consider a vertical clearance between the level defined by
the critical Bernoulli of the discharge section and the mat of the feeding
section of 0.5 meters.

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 The length of the transfer box LC must be equal to or more than 2 times
the horizontal distance LP of the path described by the calculated drop
parabola of the feeding slurry into an empty box (maximum flow).

 The discharge piece must ensure that the flow runs in the flume,
accelerating toward normal height conditions. If possible, normal
conditions must be reached at the end of the special piece.

 In case the exit conduit is a pipe, there must be vent tubes located no
farther than 5 diameters from the outlet.

 According to flow characteristics and design feasibility, transfer boxes

must be designed with a stone bed or buffering cushion, bottom drainage’s
(quick opening and full flow) and lids to prevent the foam from
overflowing. For boxes below ground level, the bottom of the box shall be
sloped to a pit in one corner of the box so that the box may be empty.

3.4.1 SPECIAL DIMENSIONING OF TRANSFER BOXES

All slurry outlets in the box must consider a special transition piece with a
flat bottom or a transition area with a variable section. Additionally, the
use of expansion nozzles must be considered in the design of some inlets
to the transference boxes in order to reduce drop speed.

3.4.2 HEAD LOSS DART VALVES

The loss of head in dart valves will be estimated according to the

following formula:

HL=[Q/(C x S)]2
2g

Where:

HL= Loss of head in the dart valves (m)

Q= Slurry flow (m3/s)
S= Orifice cross-section (m2)
C= Coefficient of discharge flow, for dart valves C = 0.61

3.5 DIMENSIONING OF PUMP BOXES

Dimensioning of pump boxes should avoid overflow, splashes, and sharp

variations in static pressure of slurry at the pump shaft.

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Process pump box should be sized for not less than 45 seconds retention time of
slurry at design flow rates, if possible. Retention time will be based on the volume
of the sump between 300 mm above the top of the pump suction nozzle and the
lip of the sump overflow weir. For froth slurry, the flow rate must be increased by
the froth factor, see table in 3.7

Slurry level in respect to pump shaft level should be as high enough as to guaranty
continuos pump operation at a NPSH higher than pump requirement, in order to
avoid cavitation.
Freeboard will be no less than 300 mm above the top of the overflow. The
overflow will be not less than one pipe size larger than the pump suction opening.

The sump discharges nozzles shall house a sacrificial flanged spool.

3.6 SELECTION OF SLURRY PUMPS

 Hard metal will be used for process pumps handling very coarse solids
(Primary Grinding). All other process pump will be lined with rubber,
polyurethane or similar lining, as applicable.

 The slurry pumps will be rated at a speed, which is at least 10 percent

below the maximum recommended, and to the left of the BEP of the pump
curve.

 Pump operation conditions must be defined according to nominal flow rate

and capable of operation at the design flow rate. However, the pump
sizing shall be selected considering the new flow rate as result of
multiplying the design flow rate by the froth factor.

 The Net Positive Suction Head available (NPSHa) in meters of slurry

column will be calculated according to the following formula:

NPSHa = Ha-Hv + Zs –Hf

Sm
Where:
Ha = Absolute (Barometric) pressure of the liquid supply level (m.w.c.)
Hv = Vapor pressure of liquid at pumping temperature and elevation of
service (m.w.c.)
Zs = Static pressure developed by column of fluid above (+) or below (-)
the centerline of the suction manifold (m.f.c.)

Hf = Suction line losses including entrance loss, friction loss, pressure

droop across valves, etc (m.f.c.)

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Sm = Slurry Specific Gravity (Ton/m3)

The NPSH available shall be greater than the NPSH required by the pump.

 Warman Chart will be used to calculate the correction in the performance

of centrifugal pumps on slurry (see Appendix B).

 The power will be calculated using correction factors for the solids effect
(Warman Chart).

 The motor nominal power shall be, as a minimum, the calculated power
increased by 10%, or next higher size motor.

 The motor power shall consider a transmission loss factor of 6% for gear
reducers and 10% loss for belt drive reducers.

 The maximun impeller tip speed for rubber lined impeller will be below 24
m/s to avoid wearing out the impeller and casing. Higher peripheral speeds
may be considered in some specific cases.
The maximun impeller tip speed for hard metal impeller will be below 26
m/s.

 All slurry pumps will have gland shaft seals flushed with pressurized seal
water. Milk of lime pumps should have mechanical seals if possible,
otherwise minimum water flow gland seals may be utilized.

3.7 OTHER CONSIDERATION

FROTH FACTOR (for design of)

DISTRIBUTOR F.F. PUMP BOX
Rougher Feed 1.0 Primary Cyclone Feed 1.0
Cleaner Concentrate 2.0 Concentrate Cyclone Feed 2.0
Rougher Concentrate 2.0 Cleaner Concentrate 2.0
Concentrate Thickener UF 1.0 Rougher Concentrate 2.0
Tail thick 1.0 Concentrate Thickener UF 1.0
Tail thick 1.0

4.0 DESIGN CRITERIA FOR AQUEOUS FLUIDS HANDLING

This chapter summarizes the criteria applied in the dimensioning of Fresh Water, Potable
Water, Fire Water, Seal and Cooling Water, Process Water and Solutions storage and
distribution systems.

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4.1 TYPE OF FLOW

Wherever possible, all transport and distribution for water and solutions systems
will be designed for full pipe flow.

4.2 FLOW FLUCTUATIONS

Fresh water, such as water for dust suppression, water pump seal water and
cooling water are sized according to the flow and the pressure recommended by
the equipment manufacturer, plus a 30% safety factor.

4.3 FLOW VELOCITY

Generally water services and solution systems will be sized using following
velocity criteria:

Type of Service Velocity, m/s

General service 2.5 – 3.0

Pump suction and drains lines 2.0 – 2.5

The velocity criteria above are intended as a general guideline. Velocities outside
the range specified above may be acceptable and should be evaluated on a case by
case basis. Velocities up to 4.6 m/s are acceptable for large size piping (greater
than 24” diameter)

4.4 HEAD LOSSES

Friction losses will be calculated by using the Darcy-Weisbach equation and the
Colebrook equation (or Moody chart)

The following roughness coefficients ( have been considered in accordance

with the nature of system and the pipeline material:

Roughness Coefficient

Pressurized Lines
(Water)
Material  (mm)

Steel 0.20
HDPE 0.009
Rubber 0.10

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The Head Losses calculation shall be cross checked with Hazen and Williams
empirical formula, with suggested design values of friction factor “C” between the
following ranges:

C steel : 100
C Rubber : 120
C HDPE : 140

4.5 STORAGE

Water storage tanks will be designed in accordance with API 650. In addition to
the inlet and outlet nozzles, tanks will be provided with overflow and vent (for
enclosed tank) nozzles. The sizing of the overflow nozzle will be based on the
maximum design inflow to the tank using the flow formula for orifices or nozzles
and taking into consideration the minimum available freeboard. The vent nozzle
will be sized using the requirements of API 2000.

Tanks will be provided with drain nozzles. The drain nozzles will be located such
that the complete contents of the tank can be emptied. Butterfly valves are not
acceptable for use as tank drain valve.

5.0 DESIGN CRITERIA FOR COMPRESSED AIR HANDLING

This chapter summarizes the criteria applied in the dimensioning of Air Plant Systems and
Instrument Air Supply in the Process Plant Facilities.

 A thorough investigation of all known, as well as anticipated air users will be

performed in order to establish the necessary compressed air system capacity. The
plant wide air demand will be tabulated in a utility summary showing the
individual maximum air requirements in standard m3/h. The standard conditions
are 101.352 kPa (14.7 psia) and 15.56 °C. Average air demand will be obtained
affecting the maximum air demand by utilization factors obtained from air systems
suppliers such as Ingersoll-Rand, Atlas Copco or others.

 Air systems will be designed to provide 621 to 862 kPa (90 to 125 psi) of air at
the furthest point from the plant air source while supplying air for as many tools
which may be in use at any one time. The main air supply line will be sized to
carry the average air demand of all users with a pressure drop through the main
line (including all fittings) not exceeding 21 kPa (3.0 psi). Branch lines from the
main header will be sized to carry the maximum air demand of the number of
outlets in use at any one time for a particular branch line with a pressure drop
through the branch line not exceeding 21 kPa (3.0 psi). Feeder lines from the
branch lines will be sized to carry the maximum air demand for as many tools,

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which may be connected at any one time with a pressure drop through the feeder
lines not exceeding 7 kPa (1.0 psi).
 Branch lines will be taken from the top of the main lines and feeder lines will be
taken from the top of branch lines. The main lines and branches will be sloped
toward low points. All low points will be drained with drip legs using automatic
moisture traps. Strainers and lubricators will be incorporated in the piping to for
IA (Instrumentation Air) or specific devices.

 Instrument air will be in accordance with ISA-S7.3, Quality Standard for

Instrument Air and will be provided from the existing facilities.

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APPENDIX A:

Mc Elvain & Cave Chart

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APPENDIX B:

Warman Chart for Solid Influence on Centrifugal Pump Performance

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APPENDIX C:

A New Launder Design Procedure AIME – 1978

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APPENDIX D:

“Launders” by Harold A. Linke, A.I.M.E. Mining Technology, September 1939.

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 Design Criteria for
Hydraulic
24617-3DR-M10L-00002 Rev. 0

\\IW\Job24617\DesignCriteria\Mechanical
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 Design Criteria for
Hydraulic
24617-3DR-M10L-00002 Rev. 0

\\IW\Job24617\DesignCriteria\Mechanical
03/07/19
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